Note: Descriptions are shown in the official language in which they were submitted.
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This invention relates to a method of installing a sheet
of surface covering material on a substrate surface such as a
floor surface. More particularly, this invention relates to
a method for installing a surface covering material on a floor
surface or the like using a foamed adhesive.
BACKGROUND AND OBJECTS
The prior art has suggested many methods for installing
a surface covering material on a surface such as a floor sur-
face, wall surface, counter top, ceiling, upholstery substrates
or the like. Many types of adhesives or adhesive products have
been used, but the type of adhesive used depends to a large
extent upon the use to which the surface covering will be sub-
jected, as well as the nature of the surface covering material
and the surface being covered. For example, the adhesive used
for laying vinyl sheet goods on a concrete floor is substan-
~ tially different than the adhesive used for applying wall paper
`` to a gypsum-board wall.
Surface covering materials have increased tremendously
in popularity in recent years, and the large variety of surface
covering materials on the market as well as the many decorative
~ patterns and textures available has added to the popularity of
-~ such materials.
One disadvantage of prior art methods for installing
surface covering materials has been the skill and craftsmanship
required of the installer. This skill is required because
frequently the surface covering material is applied to a sub-
strate having an uneven surface contour, and the adhesive must
be used to at least partially compensate for the irregularities
in the surface of the substrate.
Thus taking floor coverings as an example, the most
commonly used method of laying floor covering such as poly-
vinyl chloride sheet goods and the like has been to meter a
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` suitable mastic to the substrate using a notched trowel to
leave a rib or corrugated coating of mastic on the substrate
surface. The mastic is allowed to dry for approximately one
half-one hour to a tacky condition before the surface covering
is applied thereto. A notched trowel is used primarily as a
metering device to control the amount of adhesive spread on
the substrate. This type of installation requires a skilled
worker to lay down an even coating of the mastic.
The surface coverings of the type formed from a polyvinyl
halide layer with or without a felt backing layer such as of
cellulose or asbestos fibers or of a natural or synthetic foam
or sponge layer will transmit any irregularities in the surface
to which it is applied to its wear surface. Therefore any
irregularities in the sub-floor will appear as such in the
finished floor unless the mastic is skillfully applied and
rolled so as to even out the irregularities of the adhesive.
In the case of carpeting, much carpeting uses a foam
rubber backing sheet laminated to the carpeting to provide a
resilient feel as well as to help in eliminating the effects
of any sub-floor irregularities. This type of surface covering
is most commonly applied by means of a double-faced adhesive
tape for bonding the carpeting to the sub-floor. -
Another method for installing surface covering which
has become quite popular both for carpeting and vi~yl surface
- covering is the use of adhesive-backed tiles which are sold
with an adhesive coating on the back and a cover sheet pro-
tecting the adhesive backing. For use, the cover sheet is
removed and the adhesive coated tiles are pressed into place
on the sub-floor
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~ Another type of system used for installing surface
coverings is found both in the floor covering and wall covering
fleld. This consists of a solvent-activatable adhesive-coated
sheet of surface covering. Thus, wallpaper having a water
activatable adhesive on the back is a common product, and the
floor tile having an adhesive which may be activated by an alcohol
is also a common product,
In the surface covering industry, any steps of applying
an adhesive to the back of the surface covering results in
lncreased cost of the product, thus making it somewhat less
tesirable, commercially. On the other hand, the use of a mastic
which is applied to the sub-floor by skilled workers also
increases the installed cost of the surface covering, even though
the initial cost of the material may be less.
Accordingly, a primary ob~ect of the present invention
is to provide a method for installing a surface covering material ~
without requiring costly additional processing of the material. -
` In one aspect the present invention provides a method
for installing a flexible sheet of surface covering material on
a floor surface comprising: a) depositing at least one bead of
a foamed athesive from a pressurized receptacle upon portions of
sait floor surface; b) laying said sheet on said foamed adhesive
while said adhesive is wet; c) applying pressure to said sheet for -
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substantially completely collapsing the foam and spreading said
.! athesive to cover substantially the entire area of contact of
sait surface covering ant said floor surface and thereby causing
sait adhesive to conform to any irregularities of said floor
surface; and d) allowing said adhesive to dry, thereby uniformly
bonding said sheet to said floor surface.
In another aspect the invention provides a method for
installing a flexible sheet of surface covering material on a
floor surface comprising: a) depositing at least one bead of
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foamed vinyl acrylic copolymer emulsion adhesive composition
from a pressurized receptacle upon portions of said floor surface,
b) laying said sheet on said foamed composition while said
composition is wet, c) applying pressure to said sheet so as to
substantially completely collapse the foam and spread sald
adhesive to an even layer; and d) drying said adhesive composition
thereby adhesively bonding said sheet to said floor surface.
In a further aspect the present invention provides a
method for in~talling a flexible sheet of surface covering
material on a floor surface comprising: a) depositing at least
one bead of a foamed adhesive composition from an aerosol type
receptacle upon portions of said floor surface, b) laying said
sheet on said foamed adhesive while said adhesive is wet, c)
applying pressure to said sheet while said adhesive is wet so as -
to substantially completely collapse said foam and spread said
adhesive to a uniform layer and cause said adhesive to conform to
any irregularities of said floor surface and establish a uniform
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layer of adhesive, and d) allowing said adhesive to dry, thereby
uniformly bonding said sheet to said floor surface.
In yet a further particular aspect the present invention :
provides a packaged adhesive for use in installing a flexible ~ :
sheet of surface covering material on a floor surface by a method
comprising: a) depositing at least one bead of a foamed adhesive
from a pressurized receptacle upon portions of said floor surface;
b) laylng said sheet on said foamed adhesive while said adhesive
is wet; c) applying pressure to said sheet for substantially
`~ completely collapsing the foam and spreading said adhesive to -
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cover substantially the entire area of contact of said surface
covering and said floor surface and thereby causing said adhesive
to conform to any irregularities of said floor surface; and d)
allowing said adhesive to dry, thereby uniformly bonding said
sheet to said floor surface; said packaged adhesive comprising:
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1) a receptacle having a discharge nozzle and a discharge valve;
2) a foamable adhesive composition in said receptacle; 3) a
pressurized gaseous propellant in said receptacle for said foamable
adhesive composition; 4) said propellant serving to expell said
foamable adhesive composition from said receptacle upon opeDing
said valve and simultaneously foam said foamable adhesive
composltion.
DESCRIPTION OF THE_DRAWINGS
These and other ob~ects and advantages of this invention
will become apparent when considered in light of the following ~ -
descriptlon and claims when taken together with the accompanying
drawings in which: -
FIGURE 1 is a perspective view showing the manner of
laying down the adhesive according to the method of this
invention; and
FIGURE 2 is a sectional view along line 2-2 of FIGURE 1
and viewed in the tirection of the arrows.
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DESCRIPTION OF T~E INVENTION
The method of the present invention may be used in
installing sheet goods such as large widths or tiles of floor
coverings of vinyl, vinyl-asbestos, vinyl-foamed vinyl-asbestos,
cellulose backed vinyl, ~ute or foam backed carpeting, and the
like; wall ccverings such as fabric-backed polyvinyl halide,
polyvinyl halide coated paper, and the like.
When used in this specification, the term "vinyl" refers
to conventional vinyl resins used in the surface covering indus-
try such as polyvinyl chloride, polyvinyl fluoride, or poly-
vinyl acetate homopolymers or copolymers of vinyl halides with
vinyl acetate, styrene, etc.
Taking floor covering as a typical example of the method
of the present invention, the installer uses according to this
method an aerosol can of a foamable adhesive. The foamable
adhesive when discharged from the can under the pressure of a
conventional pressurized propellant becomes a foam upon dis-
charge. Thus, as seen in FIGURE 1, the installer may apply a
continuous, discontinuous, or other suitable bead 10 of foamed
, 20 adhesive to the sub-surface 12 from the aerosol can 14. The
`~ bead 10 as laid down is comparatively thick in relation to its
width and to its ultimate thickness after the surface covering
is installed. The adhesive may be applied at a rate of about
20 ounces per 80 square feet.
After the area to be covered at a given time is coated
with the bead of foamed adhesive 10, the surface covering
.;
! material 16 is laid down over the foam adhesive. Pressure is
~5 applied, either as the weight of the surface covering material r
or with an additional pressure source such as a roller or a
broom, to the surface covering material 16. The pressure causes
the foam bead 10, which was initially comparatively thick, to
spread so as to substantially completely cover the sub-surface
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12 beneath the surface covering 16. Additionally, the foam is
preferably at least partially collapsed by the pressure appli-
cation so as to bed the surface covering material in the
adhesive foam.
Because of the nature of the adhesive foam, it does not
tend to flow as a liquid, but does spread readily under the
pressure of the surface covering material applied to it. The
foam in being spread provides a smooth even finished surface.
The adhesive used is a resinous material which comprises
a major proportion of a synthetic resin. Particularly suitable
synthetic resins are the acrylic resins, polyvinyl halides, and
polyvinyl acetate. Polyvinyl acetate homopolymers, and copoly-
mers of polyvinyl acetate with polyvinyl halides such as poly-
vinyl chloride or polyvinyl fluoride are particularly suitable.
Additionally, arylic resins ~sh-as methyl methacrylate and
~ ethyl acrylate and vinyl acrylic copolymers may be used as the
j adhesive component of the composition. A particularly suitable
resin is a vinyl acetate butyl acrylate copolymer latex having
a glass transition temperature in the range of + 5 to + 15 C.
~ 20 This particulax latex is 55~ resin solids and has a pH of 4.5
- and Brookfield viscosity of 700 cps. The particles are
generally anionic in the aqueous latex emulsion and have a size
of approximately 0.35 microns. This resin has a density of 9.1
pounds per gallon.
, The adhesive composition, also includes a filler and
clay fillers are particularly suitable because of their low
cost and good properties as fillers. Huber 35 clay has been
i found suitable in this regard and has a particle size distri-
bution of 30-40% finer than 2 micron and 35-45~ coarser than
5 micron. This clay has a Brookfield viscosity at a 70~
solids slurry in water of 100-150 centipoise at 20 rpm using
a #l spindle at 25 C. In an aqueous slurry, the clay has a
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pH of about 4.5-5.5. With the filler in the adhesive composi-
tion, it is desirable to use a dispersant therefor, since the
resin is present in aqueous emulsion. A suitable dispersant
is potassium tripolyphosphate.
Also as is conventional in latex emulsions, a small
amount of a defoaming agent is preferably included.
The adhesive preferably contains a plasticizer which
may also serve as a tackifier for the adhesive. Such plasti-
cizers are well known in the art and include materials such
as dibutyl phthalate, dioctyl phthalate, and similar ester-type
plasticizers. An additional tackifier may also be included in
the adhesive composition, such as for example toluol.
It is also desirable when using a metal aerosol can for
the adhesive to include a rust inhibitor in the adhesive com-
position. Similarly, bactericides for both gram negative and
gram positive bacteria may be included in the composition.
Typical formulations of adhesive compositions which may
, be utilized in accordance with this invention are given in the
j following examples:
EXAMPLE 1
Weight %
water 17.5
Dispersant
(potassium tripolyphosphate - KTPPl < 0.1
filler (Huber 35 clay) 29.0
;~1 vinyl acetate butyl acrylate copolymerl 42.0
plasticizer (dibutyl phthalate) 6.5
;~ tackifier (toluol) 2.5
defoaming agent (Deefo 97-2) < 1.0
~ rust inhibitor (Raybo 60) < 1.0
,, 30
~ bacteriocide (Cotin 234) 1.0
$ bacteriocide (Cosan 1850) < 1.0
_ _ .
Aqueous latex emulsion, 55~ solids
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EXAMPLE 2
Parts by weight
water 600.0
KTPP 3.2
Huber 35 llO0.0
Colloid 691 ~defoamer) 8.0
Cosan 1850 lO.0
vinyl acetate butyl acrylate copolymerl 1600.0
dibutyl phthalate 240.0
3561.2
EXAMPLE 3
Parts by weight
water 500-0
PMA 30 (bacteriocide) 7.0
KTPP 3. 2
Huber 35 llO0.0
~ Raybo 60 36.0
- . Colloid 691 8.0
, vinyl acetate butyl acrylate copolymerl 1600.0
3 toluol lO0.0
~ dibutyl phthalate 24-0.0
i 3594.2
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EXAMPLE 4
Parts by weight
water 130.0
KTPP .96
Huber 35 330~
10% PMA 30 22.0
Raybo 60 10.8
Colloid 691 2.4
vinyl acetate butyl acrylate copolymerl 480.0
toluol 30.0
; dibutyl phthalate 72.0
1078.16
:'~
EXAMPLE 5
~, Parts by weight
j 20 water 1500.0
~ KTPP 9.6
Huber 35 3300-0
Cotin 234 90.0
Raybo 60 108.0
Colloid 691 24.0
~3 vinyl acetate butyl acrylate copolymerl 4800.0
toluol 300.0
j dibutyl phthalate 720.0
Cosan 1850 99.7
~: 30
10,951.3
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EXAMPLE 6
Parts by wei~ht
water 1500.0
KTPP 9.6
PMA 30 21.0
Huber 35
Raybo 60 108.0
Colloid 691 24.0
vinyl acetate butyl acrylate copolymerl 4800.0
toluol 300.0
dibutyl phthalate. 720.0
10,782.6 ::.
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EXAMPLE 7 ~:
I Parts by weight
20 water 150.0
1 KTPP .96 :
- Huber 35 330,0 ~
¦ Raybo 60 10.8
Colloid 691 2.4
~ vinyl acetate butyl acrylate copolymerl 480.0
¦ Cotin 234 4.5
toluol 30~0
d~ utyl phthalate 72.0
Cosan 1850 9,97
1090.63
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EXAMPLE 8
Parts by weight
water 1500.0
KTPP 9.6
Huber 35 3300 0
Cotin 234 go,o
Raybo 60 108.0
Colloid 691 24.0
- vinyl acetate butyl acrylate copolymerl 4800.0
toluol 300.0
dibutyl phthalate 720.0
Cosan 1850 99.7
10,951.3
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EXAMPLE 9
Parts by weight ~
water 1975.6
KTPP 9.6
Huber 35 3300.0
Cotin 234 92.0
Raybo 60 108.0
Deefo 97.2 24.0
vinyl acetate butyl acrylate copolymerl 4800.0
toluol 300.0
dibutyl phthalate 720.0
~i Cosan 1850 99.7
11,428.9
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The propellant utilized in the aerosol cans is one or
a combination of several of the propellants sold under the
trademar~ ~EON. These propellants are halogenated hydro-
carbons. Freon 12 has been found to be a particularly suitable
propellant as has a combination of Freon 12 (dichlorodifluoro-
methane) and ~reon 114 (1,2 dichloro - 1,1, 2,2 - tetrafluoro-
ethane) in a ratio of 10:90 parts to 60:40 parts, and preferably
30:70 parts.
The nozzle used on the aerosol can is designed so as to
emit a comparatively narrow bead of adhesive composition and
to thereby prevent overspray of adhesive onto the surrounding
area. The foam adhesive beads are preferably laid down at a
depth of about 1/2 - 1 inch, and about 6 inches to 1 foot apart~
When the surface covering is applied over these beads, the foam
; flattens out and at least partially and preferably completely
collapses as seen in Figure 2 thus substantially filling the
space between the surface covering material and the substrate.
The adhesive layer then has a thickness of about 2 - 5 mils.
If the adhesive is laid down in strips about 1" high and 1~" ;wide with strips about 6" apart, the adhesive spreads when the - -
sheet material is applied so as to almost completely eliminate
' any void in the adhesive layer.
; The presence of the filler in the adhesive composition
æerves to give the composition sufficient body so as to prevent
running of the a& esive as well as provide support for the
~ surface covering~ Of course the filler, as well as the particles
--~ of the resin, must be very finely divided so as to prevent
i formation of lumps which would create unevenness in the finished ~ -
`~ surface. The filler is added in accordance with the viscosity
~¦ 30 of the material so that the adhesive foam as applied does not
run. The adhesive composition is a thixotropic gel which
readily converts to a liquid having a viscosity in the approximate
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range of 1500 - 3500 cps, and preferably in the range of
1600 - 2000 cps. The viscosity and thixotropy may of course
be controlled according to viscosity improved additives.
The viscosity of the composition of Examples 1 - 9 as measured
by a Brookfield viscometer with a number 4 spindle at 20 rpm
is given in the following table, both after insertion of the
spindle and after five minutes stirring.
TABLE
Viscosity after Viscosity after #4
breaking down gel spindle has turned
structure with at 20 RPM for 5
Example spatula mixing (cps.) minutes (cps.)
1 1950 1950
2 3900 3000
3 2250 2400
- 4 2300 2300 -
2800 2500
6 2800 2550
? 7 2700 2200
8 2500 2450
9 1850 1800
` 20
The adhesive composition according to this invention
has been tested in applying foam backed and felt backed vinyl
flooring to wood floor and masonite with very good bond strength
and even coating ability. There appears to be no decline in the
' adhesive bond between the surface covering and the substrate
with aging, and the shelf life of the aerosol adhesive can is
~ in excess of one year.
j The use of the foam according to the method of this
¦ invention greatly extends the "open time" of the adhesive. The
open time of prlor art adhesives or mastics has generally been
approximately 1/2 - 3/4 hour, while the adhesive composition
~-~ used in the present invention may have an open time of several
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hours.
The propellant used in the aerosol can of the foamable
composition not only serves to propel the adhesive composition
but also foams the composition as it is discharged from the can.
Although the examples indicate a number of components
in the adhesive composition, the primary and essential com-
ponents are the water, filler, resinous adhesive, plasticizer,
and tackifier. As indicated previously, the filler is prefer-
ably a clay-type filler, and as such r may consist of any of the
conventional clays such as talc, bentonite, kaolin, calcium car-
bonate, etc. The tackifier is generally a solvent such as
~ toluol, isopropyl alcohol, or ethylene glycol. The plasticizer
E ~ which may also function as a tackifier may be any one of a
` large number of typical plasticizers used in conjunction with
acrylic homopolymers and copolymers of the thermoplastic type.
` The adhesive agent which is preferably a vinyl acrylic
. copolymer must of course be compatible with both the substrate
and the portion of the surface covering material with which it
is in contact. A particularly useful adhesive agent is poly-
vinyl acetate either as a homopolymer or a copolymer with poly-
vinyl chloride, methyl methacrylate, ethyl acrylate or butyl
acrylate.
` While this invention has been described, it will be
understood that it is capable of further modification, and the
application is intended to cover any variations, uses and/or
adaptations of the invention following in general, the principle
of the invention and including such departures from the present
disclosure as come within known or customary practice in the
art to which the invention pertains, and as may be applied to
the essential features hereinbefore set forth, as fall within
the scope of the invention or the limits of the appended claims.
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