Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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COATING FOR INHIBITING STAIN FORMATION IN FLOOR COVERING
This application is divided from Canadian Patent Application Serial
Number 2,281,267 filed August 31, 1999
Field of the Invention
This invention relates to liquid formulations that can be applied to the
surface of a wood-based flooring panel and dried to form a coated product that
is suitable for use as a substrate for decorative floor covering. The coating
on
the panel dramatically inhibits the staining action that occurs when a
decorative
vinyl floor covering is installed directly over a wooden substrate. The
coating
system described inhibits the staining action that occurs when oriented
strandboard (OSB) underlayment is used in conjunction with vinyl floor
sheathing, while simultaneously providing a substrate surface that has
exceptional compatibility with the adhesives and patching materials that are
commonly used during the process of installing vinyl floor coverings. The
coating formulations are stable and resistant to phase separation and settling
over storage periods in excess of two months, and they can be used in high-
volume commercial coating operations in compliance with current U.S.
environmental regulations.
Background of the Invention
Decorative vinyl floor coverings are commonly installed in residential
dwellings in North America. Manufacturers of vinyl floor coverings include
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Armstrong World Industries (Lancaster, Pa.), Mannington (Salem, N.J.),
Congoleum Corporation (Mercerville, N.J.), and Tarkett Incorporated
(Whitehall,
Pa.). Contemporary floor covering materials are described in U.S. Patent No.
5,308,694. Although there are a number of elaborate vinyl floor covering
construction designs, most are comprised of a three-layered structure. The
bottom layer generally consists of a plasticized polymeric film, felt or
paper. The
middle layer is the decorative portion and it often consists of polyvinyl
chloride
along with plasticizing agents, dyes and/or pigments, stabilizers and/or other
components. In many cases this decorative layer has a cellular structure,
which
is achieved by decomposing a blowing agent, most commonly
azodicarbonamide, during the manufacturing process. In some cases a colored
design is gravure-printed on the topside of the middle layer. A discontinuous
pattern of foam inhibitor can also be deposited on the topside of the middle
layer in order to yield a highly textured floor covering. The upper layer is
known
as the "wear layer" and it often consists of a plasticized polyvinyl chloride
or
polyurethane film.
Most types of vinyl floor covering are thin and very conformable. Thus,
they must be installed directly over a smooth, flat substrate. Residential sub-
floors consisting of 3/4" OSB or plywood sub-floor panels mounted over 2"x 10"
joists are frequently abused during the home building process, and have
surfaces which are often too rough and irregular to be used as a vinyl floor
covering substrate. It is common practice to install a thin, smooth panel,
known
as an "underlayment panel", over the rough sub-floor just prior to
installation of
the vinyl floor covering. FIGURE 1 shows a representative floor construction
(10) in which a layer of vinyl floor covering (20) is adhered to a layer of
underlayment panels (30), which are stapled or nailed to 3/4" thick sub-floor
panels (40), which span and are nailed to 2" x 10" supporting joists (50).
Typical underlayment panels are sanded and comprised of plywood,
particleboard, oriented strand board (OSB), or cement/fiber board. Plywood
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underlayments that are commonly used in North America include those derived
from lauan veneer and manufactured in Indonesia and Malaysia. A plywood
underlayment, known as MULTIPLYTM, is composed of aspen veneer and is
manufactured by MacMillan Bloedel Ltd. (Vancouver, BC). Another plywood
underlayment, known as TECHPLYTM, is composed of Russian birch veneer
and is distributed in North America by the Plywood & Doors Mfrs. Corporation
(Union, N.J.). A sanded 3/8" thick fiberboard, known as FIBERFLORTM, is
manufactured by MacMillan Bloedel Ltd. (Vancouver, BC). A coated 1/4" thick
OSB underlayment panel known as THE INSTALLER'S EDGE TM is
manufactured and sold by the Weyerhaeuser Co. (Tacoma, Wash.). A 3/8"
thick cement/fiber board, known as FIBERBONDTM, is sold as underlayment by
the Louisiana-Pacific Corporation (Portland, OR).
All of these commercial underlayment panels have structural properties
that are sufficient for an underlayment application. The panels must also have
a
smooth, flat, dimensionally stable, hard surface for the duration of their use
in a
floor system. The typical installation practice includes fastening the
underlayment panels to the sub-floor by use of staples or nails; patching the
seams; removing any debris from the surface of the panels; and adhering the
vinyl floor covering to the underlayment by use of aqueous latex adhesives.
Thus, the panels should have a solid, uniform color and appearance in order to
aid in the visualization of fastener placement and surface debris when
cleaning
the panels. The panels must not corrode or degrade metallic fasteners. The
panels must be fully compatible with conventional patching compounds and
adhesives that are used during the floor covering installation process. The
panels must not stain or otherwise adversely interact with the vinyl floor
covering that is placed directly on top of them. Underlayment panel attributes
that are particularly important and relevant to this invention include 1)
compatibility with the commonly used aqueous latex adhesives and patching
compounds and 2) an ability to resist staining vinyl floor coverings.
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Compatibility with aqueous latex adhesives. The surface of the installed,
underlayment must be receptive and functionally compatible with a large
number of water-based adhesives that are used to attach the vinyl floor
covering to the underlayment. Most of the adhesives are primarily comprised of
aqueous acrylic or styrene-butadiene lattices, which are designed to absorb
into the underlayment. Thus, the underlayment must have a surface, which will
allow some penetration of a water-based adhesive.
One type of vinyl floor covering, known as "fully-adhered", requires the
application of adhesive across the entire underlayment surface. In this case
the
adhesive must be spread by use of a trowel with repeated stroking actions.
Applied adhesive on one part of a floor must remain in a liquid state for a
period
of time sufficient for the installer to spread the adhesive across the entire
floor.
Thus, the adhesive must interact with the underlayment panels in a manner that
results in a sufficiently long "open-time". Interactions between the adhesive
and
the underlayment surface must not cause the adhesive to prematurely solidify.
Simultaneously, bond strength must develop between the vinyl floor covering
and the underlayment panel within a reasonably short time period after the
vinyl
floor covering has been placed in intimate contact with the adhesive on top of
the underlayment. This bond strength must increase to a level that secures the
vinyl floor covering to the underlayment subsequent to installation.
Therefore,
interactions between the applied adhesive and the underlayment surface must
not impede or interfere with bond strength development.
A second type of vinyl floor covering, known as "perimeter-attached",
requires application of an adhesive only at the perimeter of the floor. The
perimeter-attached vinyl floor covering is laid onto the floor and positioned
into
the applied adhesive. In this application it is important that a strong bond
quickly develop between the vinyl floor covering and the underlayment along
the perimeter of the floor. Immediately after installation a volatile
component in
the vinyl floor covering will begin to evaporate and the floor covering will
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simultaneously shrink. As shrinkage occurs a strong shear stress is developed
along the perimeter bond. It is vital that the bond strength along the
perimeter
of the floor-to-vinyl interface be sufficiently high to prevent delamination
during
this shrinking process.
5 Ability to bond with aqueous patching compounds. Patching compounds
are often applied along the seams between the underlayment panels. Most
patching compounds are prepared by mixing either Portland cement or gypsum
with either water or an acrylic latex. Examples of commercial patching
compounds that are utilized with underlayment panels and vinyl floor covering
are MAPEI PLANI/PATCHTM from Mapei Inc. (Montreal, PQ, Canada), S-184
from Armstrong World Industries (Lancaster, Pa.) and DEPENDABLE
SKIMCOATTM from the Dependable Chemical Company, Incorporated (Rocky
River, Ohio). It is important that these patching compounds bond to the
underlayment. In general this requires that the water-based, patching
compound be capable of penetrating or absorbing into the underlayment.
Ability to resist fastener corrosion. Underlayment panels are generally
installed directly over structural subfloor panels and are fastened to the
subfloor
by use of metallic nails or staples. These metallic fasteners must not be
corroded by the underlayment panel.
Ability to resist staining vinyl floor covering. Most underlayment panels
for vinyl floor covering are comprised of wood laminates or composites. Wood
is known to contain an array of extractives. Under conditions of elevated
temperatures and high humidity some of these extractives appear to be able to
migrate out of the wood and absorb into the vinyl floor covering where they
can
cause a stain. Underlayment composed of aspen wood appears to be
particularly prone to staining vinyl floor covering. OSB underlayment, which
contains aspen bark or wood isolated from the cambium layer of an aspen log
is most prone to staining. Woods isolated from pine, maple, black poplar,
cottonwood, walnut, hickory, elm and other species also contain extractives
that
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are capable of staining vinyl floor coverings. Homeowners cannot remove this
type of stain. Resolution generally requires replacement of the vinyl floor
covering.
Some vinyl floor coverings are very susceptible to stain formation, while
others are quite resistant to "bottom-up" staining even when they are placed
in
contact with an aspen substrate in an environment of high temperature and
high relative humidity. In general we have found that thin, perimeter-attached
type vinyl floor coverings are more prone to develop stains from contact with
floor underlayment than are fully-adhered vinyl floor coverings. Also the
stains
observed in perimeter-attached vinyl floor covering tend to develop more
rapidly and they are more intense than stains that develop in most fully-
adhered
vinyl floor coverings. Additionally, we have found that vinyl floor coverings
with
cellular decorative layers have a greater propensity to stain than do vinyl
floor
coverings with no cellular layer. It is suspected that plasticizing agents in
the
vinyl floor covering help to facilitate the transfer of extractives into the
vinyl. It is
further suspected that residual azodicarbonamide or its decomposition products
in the cellular layer of the vinyl floor covering reacts with some wood
extractives
to form intensely dark products, which manifest themselves as stains.
Potential solutions to the staining problem. The vinyl floor covering
manufacturers are aware of the "bottom-up" staining problem and they have
diligently searched for a practical, cost-effective solution. The
aforementioned
U.S. patent 5,308,694 assigned to Tarkett describes a vinyl floor covering in
which a barrier layer of plastisol and water glass are incorporated into a
layer
that is positioned on the bottom side of the vinyl floor covering or somewhere
between the bottom side and the decorative layer. This "barrier" layer
reportedly prevents wooden underlayments from causing a top-side stain in the
vinyl floor covering. The inventors suggest that organic stainants from the
underlying floor are unable to migrate or diffuse through the barrier layer.
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U.S. Patent No. 5,891,294, assigned to Mannington, describes a vinyl
floor covering in which a barrier layer consisting of a polyurethane or a
polyamide is preferably positioned between the backing layer and the middle
layer of the vinyl floor covering.
The inventions described is U.S. Patent Nos. 5,308,694 and 5,891,294
appear to be too expensive to practice and these technologies have not been
implemented by Tarkett, Mannington, or any of the other floor covering
manufacturers.
It should also be noted that there are complications associated with
applying these vinyl stain-blocking technologies to wooden underlayment
products. For instance, when water glass is applied to a wooden underlayment
as a coating, it forms a surface, which is not compatible with many of the
conventional adhesives that are used to secure the vinyl floor sheathing
during
the installation process. More specifically, many latex adhesives will
prematurely solidify or coagulate when applied to the water-glass coating. In
fact, application of many alkaline coating systems to wooden underlayment
panels generally makes the surface of the coated panel incompatible with at
least some of the conventional adhesives that are used to secure the vinyl.
Thus, water-glass is not suitable for use as a stain-blocking coating on a
wood-
based underlayment panel.
Several years ago it became known that placement of a continuous
sheet of aluminum foil between a wooden substrate and the vinyl floor covering
completely prevented the wood from staining the floor covering. Unfortunately,
the water-based adhesives and patching compounds that are used to attach
the vinyl floor covering to the wooden underlayment will not bond to the
aluminum. Furthermore, the aluminum foil is expensive and susceptible to small
tears or punctures. Wood extractives are capable of diffusing into the vinyl
floor
covering at locations in the aluminum barrier where it has been torn or
perforated. Consequently, neither the vinyl floor covering manufacturers nor
the
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underlayment manufacturers have incorporated aluminum foil barriers into their
products to prevent the staining problem. Additionally, installers generally
do
not position a layer of aluminum foil between the underlayment and the vinyl
floor covering.
There are a number of Portland cement patching compounds that are
effective stain-blocking materials when they are applied to the wooden
underlayment as a top surface coating at a spread rate of about 16 wet g/ft2
or
greater. Examples of such patching compounds are the previously mentioned
MAPEI PLANI/PATCHTM by Mapei Inc. (Montreal, PQ, Canada) and ARDEX
FEATHER-FINISH CEMENTTM produced by Ardex, Inc. (Coraopolis, Pa.). A
small number of installers will apply the patching compound over the entire
underlayment surface prior to vinyl floor covering installment in order to
prevent
the wood from staining the floor covering. Unfortunately, this practice is
labor
intensive and is not widely utilized. Although a Portland cement can be
manufactured that could be mixed with water or an aqueous latex and then
applied to the wooden underlayment by use of a roll-coating machine, the
limited pot-life and high viscosity of the cement mixture makes the roll-
coating
machine very susceptible to fouling when the operation is conducted on a
continuous, long-term basis. Also, it should be noted that the Portland cement
based patching materials are highly alkaline in nature. After a 1-2 week
equilibration period the cement coating becomes incompatible with a number of
the conventional adhesives used to secure the vinyl to the underlayment. Thus,
a Portland cement based coating appears not to be a suitable material for
preparing a factory-coated underlayment panel.
Formulations that have been designed for use as primer coats over
redwood, cedar or pine boards do not appear to be suitable for use as a
coating
over a wood-based floor underlayment panel. Such formulations are designed
to be applied directly onto solid wood articles that have high concentrations
of
tannin, tocopherol or other intensely colored extractives. The primer
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formulations contain stain-blocking components, which will selectively react
with and immobilize the colored extractives in the wood. Subsequent to
application and drying of the primer coat, the board can be coated without
discoloring the paint by transfer of the colored extractives into the paint.
Although some of these "paint primers" do have some ability to prevent OSB
underlayment from staining vinyl floor sheathing, they generally yield a
coated
surface that is not compatible with many of the adhesives and patching
compounds that are used in the floor installation process. Thus, the stain-
blocking technologies that have been developed for paint primers are not
generally suitable for application to a floor underlayment panel that is used
in
conjunction with vinyl floor sheathing.
One example of a paint primer formulation is that described by
Thomassen in U.S. Patent No. 5,460,644. The formulation described in this
patent preferably contains a soluble zinc ammonium complex, which prevents
wood extractives from staining freshly applied paint. Unfortunately, stain-
blocking compounds for underlayment based on water-soluble salts are
notorious for coagulating water-based vinyl adhesives immediately upon
application to the underlayment.
Another example of a paint primer formulation is that described by
Gilman et al. in U.S. Patent Nos. 3,900,620 and 4,021,398. The formulation
described in these patents preferably contains an aluminum hydroxychloride
complex, which reportedly prevents wood extractives from staining freshly
applied paint. OSB underlayment panels coated with aqueous solutions of
aluminum hydroxychloride demonstrate gross incompatibility with many
aqueous adhesives that are used to secure vinyl floor coverings. Aluminum
hydroxychloride has little or no stain-blocking efficacy when applied to OSB
panels that are used as underlayment panels for vinyl floor covering.
Yet another example of a paint primer formulation is that described by
Meyer et al, in U.S. Patent No. 4,218,516. The formulation described in this
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patent preferably contains magnesium hydroxide at a 1-10% level, which
prevents wood extractives from staining freshly applied paint. Unfortunately,
formulations that contain magnesium hydroxide at a loading level of 1-10% do
not yield effective stain-blocking coatings at spread rates of 15 g/ft2 or
less,
5 which is a level that can be reasonably achieved in a commercial operation.
Formulations with magnesium hydroxide concentrations of 25-30% solidify in
less than one day of storage, which makes them difficult to utilize in a
commercial coating operation. Stable formulations based on U.S. Patent No.
4,218,516 are limited to magnesium hydroxide concentrations of 5% or less.
10 Unfortunately, stain-blocking formulations that contain only 5% magnesium
hydroxide must be applied at spread rates of approximately 50 g/ft2 on OSB
panels in order to prevent vinyl discoloration. Such a high spread rate is not
commercially feasible. An additional complication with the magnesium
hydroxide-based coatings relates to the fact that aqueous suspensions of
magnesium hydroxide are alkaline. Wooden panels treated with these
suspensions and equilibrated for at least 1 week are incompatible with a
number of the water-based adhesives that are used to secure vinyl floor
sheathing.
A further example of a paint primer formulation is that described by Van
Rheenen et al. in U.S. Patent No. 5,312,863. The formulation described in this
patent contains a latex with amine functionality, which prevents wood
extractives from staining freshly applied paint. Application of non-complexed
amines to OSB panels does not prevent the discoloration that generally occurs
when the OSB is placed in contact with vinyl floor coverings.
As previously noted, the paint primer formulations were designed for an
application pertaining to the wood/paint interface, which is distinctly
different
than that of a stain-blocker for the interface between vinyl floor sheathing
and
wooden OSB underlayment.
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SUMMARY OF THE INVENTION
The present invention provides a formulation comprising a copper
amine complex and a binder material, wherein the copper amine complex is
present in an amount from about 5 to about 20 percent weight based on the
total weight of the formulation, and wherein the binder material is present in
an amount from about 20 to about 80 percent by weight of the total
formulation; wherein the copper amine complex comprises an amine
selected from the group consisting of morpholine, triethanolamine,
diethanolamine, ammonia, dimethylamine, and m-phenylenediamine.
The present invention allows for the convenient conversion of
wooden underlayment panels, especially OSB panels, that are prone to
staining vinyl floor covering into coated panels that will not stain vinyl
floor
covering. Furthermore, this is accomplished without adversely impacting the
compatibility of the underlayment panel with aqueous latex adhesives,
patching compounds, metallic fasteners or vinyl floor coverings. The safe,
single-component, liquid formulations are stable under typical storage
conditions (5-40 C) for at least 6-8 weeks and have rheological properties
that are appropriate for commercial roll-coating and curtain-coating
equipment.
Wooden underlayment panels that are prone to staining vinyl floor
sheathing under conditions of elevated temperatures and high relative
humidity are sequentially coated with two distinct formulations. The first
formulation is applied directly on top of the virgin underlayment panel to
form a coat. The formulation includes an aqueous dispersion of a
copper/amine complex. Typically, this first coating is dried on the panel to
form a basal (or bottom) layer (or stratum) and a second coating formulation
is applied on top of the basal layer. The second formulation is predominantly
comprised of water, calcium carbonate and an inert, non-ionic latex or other
binder material. The applied second formulation is then dried on top of the
basal layer to form a supra (or top) layer (or stratum). The coated panel is
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highly resistant to staining vinyl floor coverings and it is fully compatible
with
commonly used aqueous latex adhesives, patching compounds, metallic
fasteners and vinyl floor coverings.
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Brief Description of the Drawings
The foregoing aspects and many of the attendant advantages of this
invention will become more readily appreciated as the same become better
understood by reference to the following detailed description, when taken in
conjunction with the accompanying drawings, wherein:
FIGURE 1 is a perspective view of a typical floor including a subfloor,
underlayment, and floor covering
FIGURES 2A-2D are cross-sectional views of representative coated
panels formed in accordance with the present invention;
FIGURE 3 is a graph comparing the development of latex adhesive bond
strength for an uncoated underlayment and a coated underlayment formed in
accordance with the present invention; and
FIGURE 4 is a graph comparing patching compound bond strength for
uncoated underlayments and coated underlayments formed in accordance with
the present invention.
Detailed Description of the Preferred Embodiment
The present invention relates to a set of coating formulations that can be
applied to a wooden underlayment panel and dried to yield a product that is
fully compatible with aqueous latex adhesives that are typically used to
adhere
vinyl floor sheathing to wooden underlayment panels. The coated panel is also
substantially resistant to staining vinyl floor covering even when the floor
is
exposed to an environment of elevated temperature and high relative humidity.
As used herein, the term "vinyl floor covering" refers to polyvinyl chloride-
based
floor covering, and the term "covering" is used interchangeably with the term
"sheathing".
Wooden underlayment panels that are suitable for this invention include
those composed of oriented strandboard, particleboard, medium density
fiberboard, plywood or any other wooden panel or board material that is
utilized
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in a flooring system and is positioned just beneath decorative vinyl floor
covering. Panels or boards, which are only partially composed of wood can also
be used in this invention. The dimensions of the underlayment panel or board
are not critical to this invention, but thickness values between 1/8" and 1-
1/4"
will most generally be utilized. Width and length dimensions will most
commonly be 4' x 8', but other dimensions could be used.
The coating comprises a basal stratum (bottom layer) formed from a first
formulation and a supra stratum (upper layer) formed from a second
formulation. Referring to FIGURE 2A, coated panel 32 includes underlayment
34, basal stratum 36, and supra stratum 38.
The basal stratum includes a copper/amine complex and a binding
agent. The concentration of the copper/amine complex is sufficient to provide
the desired level of stain prevention in the coated underlayment panel.
Typical
levels of the copper/amine complex in the basal stratum are 5-20%.
The copper/amine complex is generally formed in situ as the basal
stratum formulation is being prepared. It is most convenient to sequentially
charge a blending vessel with water, binder agent, and any other desired
formulation additives. The contents of the vessel are homogenized subsequent
to each addition. A water-soluble copper salt is then added to the vessel and
the formulation is stirred until the copper salt is dissolved. Appropriate
copper
salts include copper (II) chloride and copper (II) nitrate, among others.
Alternatively, an aqueous solution of a copper salt can be added to the
formulation. After the copper has been solubilized and homogeneously
incorporated into the formulation, an amine is added to the formulation with
continuous stirring to form the copper/amine complex. The amount of amine
should most preferably be in the range of 1-4 moles of amine per 1 mole of
copper. Suitable amines for the basal strata formulation include morpholine,
triethanolamine, diethanolamine, ethanolamine, ammonia, m-phenylenediamine
and dimethylamine. Morpholine is a preferred amine for this formulation. A
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highly preferred basal strata is based on a ratio of 1 mole of copper salt to
1.3-4
moles of morpholine. Preferably, the copper/morpholine complex is present in
the basal stratum at a level of about 14-18%.
The binding agent is preferably an aqueous, non-ionic latex, but
solutions of other polymers or resins can also be used. Suitable binding
agents
could include acrylic latex, styrene-butadiene latex, and polyvinyl acetate
latex.
Aqueous solutions of polymers are suitable as binding agents, especially if
they
are combined with a cross-linking agent that is activated upon drying.
Examples
of such polymers include starch, carboxymethyl cellulose, hydroxyethyl
cellulose, guar gum and xanthan gum. Suitable crosslinking agents include
formaldehyde or glutaraldehyde. Alternatively, aminoplast resins, such as
urea/formaldehyde or melamine/formaldehyde resins are suitable as binding
agents. Anionic lattices and anionic binding agents should be avoided because
they have detrimental effects on the adhesive compatibility properties of the
coated underlayment panel. The binding agent is preferably a stable solute or
homogeneously dispersed phase during the storage life of the basal
formulation. The binding agent preferably secures all of the solid, suspended
particles in the coating formulation to the underlayment substrate subsequent
to
application and drying. A preferred binding agent is a carboxylated styrene-
butadiene latex with a surfactant system that is mostly nonionic. Generally
the
binding agent is present in the basal stratum formulation at a level of 20-80
percent by weight, more preferably, 35-45 percent by weight based on the total
weight of the formulation.
Other additives that can be incorporated into the basal stratum
formulation include viscosifying agents, fillers, surfactants, pigments or
other
types of colorants, opacifying agents, preservatives, defoaming agents and/or
any additive that improves the shelf-life or rheology of the formulation for
the
intended method of application to the underlayment substrate. Small amounts
of metal ion complexing agents such as, for example, melamine can be added
CA 02632436 2008-06-17
to the basal stratum formulation in order to improve the adhesive
compatibility
properties of the coated underlayment panel. A preferred basal stratum
formulation includes water (15-50%), a viscosifying agent (1-10%), colorant (0-
5%), opacifying agent (0-20%), a binding agent (20-50%), copper/amine
5 complex (5-20%), and a metal ion scavenger (1-10%). A more preferred basal
stratum formulation includes water (18-25%), a polysaccharide-based
viscosifying agent (1-2%), aqueous pigment dispersion (2-8%), a nonionic
surfactant (0.1-2.0%), a nonionic latex (35-45%), a copper/morpholine complex
(7-18%), a fumed silica viscosifying agent (1-2%), an opacifying agent (10-
10 20%), and melamine (1-5%).
The supra stratum formulation preferably dries into a coating that has a
pH value that is close to neutral (i.e., pH=6-8). The dry supra stratum
coating
preferably strongly bonds to the basal stratum coating, and includes
concentration of water-soluble salts that is sufficiently small to allow it to
15 interact with aqueous latex adhesives without significantly increasing the
ionic
strength of the adhesive and causing coagulation. The supra stratum
formulation includes water, an aqueous nonionic binder material and an inert
solid filler. A preferred inert binder material suitable for the supra stratum
is a
nonionic, self-crosslinking latex. Another preferred inert solid filler is
calcium
carbonate. Calcium sulfate, clay or any dispersible inert, insoluble particle
can
be used. Other additives such as surfactants, viscosifying agents,
preservatives, colorants, opacifying agents, defoaming agents, stabilizing
agents, or processing aids can be included. A preferred supra strata
formulation consists of water (15-35%), a viscosifying agent (1-3%), a
surfactant (0.1-2%), a preservative (0.1-1.0%), an aqueous nonionic self-
crosslinking latex (35-55%), and inert, insoluble fine filler particles (25-
50%).
The basal and supra strata formulations can be applied to the wooden
underlayment panel by use of a spray gun, a roll-coating machine including
direct roll coating and reverse roll filling machines, a curtain-coater, a
slot-
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coater, or any other liquid application equipment. It is advantageous to
adjust
the viscosity of each coating formulation to a level that is convenient for
the
specified application equipment and technique. For instance, relatively high
viscosity values are helpful when a formulation is being applied to a
substrate
by use of a roll-coating machine. In contrast, relatively low viscosity values
are
desired when a formulation is being applied by use of a spray gun or a curtain-
coating machine. When a formula is being applied with a curtain-coating
machine, the surface tension properties are particularly important. Surface
tension values are generally manipulated by use of surfactants. In order to
maximize favorable interactions between the coating system and the aqueous
latex adhesives, it is best to use nonionic surfactants in both the basal and
supra strata formulations.
The basal stratum formulation will most commonly be applied directly to
the wooden underlayment (see, e.g., FIGURE 2A), although it is conceivable
that some other material or layer, such as a resin impregnated paper, can be
attached to the wooden underlayment directly to provide a panel having a layer
intermediate the wood panel and basal stratum. Referring to FIGURE 2B,
coated panel 132 includes underlayment 134, intermediate layer 133, basal
stratum 136, and supra stratum 138. When the wooden underlayment is
pretreated with some other coating material or laminated with a resin
impregnated paper, the basal stratum formulation is applied to the exposed
side of the primary coating material or paper laminate. The required amount of
basal stratum formulation to be applied to each unit area of wooden
underlayment is dependent upon the concentration and type of stain blocking
agent(s) in the formulation; the amount and type of extractives in the wooden
underlayment; the type of vinyl floor covering used on top of it; and the
environmental conditions (temperature and relative humidity) of the finished
floor over the duration of its use. General spread rate values for the basal
stratum formulation are about 1 -15 g/ft2. More typical spread rate values for
the
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basal stratum formulation are about 2-6 g/ft2 The applied basal stratum
formulation should preferably completely cover the top major face of the
underlayment panel.
The supra stratum is placed on top of the basal strata so that the basal
stratum coating is positioned between the wooden underlayment and the
applied supra stratum coating. The basal stratum formulation can be directly
applied to the wooden underlayment followed by attachment of a resin
impregnated paper or some other coating material directly over the basal
strata
coating layer. The supra stratum formulation can then be applied directly onto
the impregnated paper or other coating material. The coated panel can include
a layer intermediate the basal and supra strata. Referring to FIGURE 2C,
coated panel 232 includes underlayment 234, basal stratum 236, intermediate
layer 237, and supra stratum 238. The coated panel can also include layers
intermediate the wood panel and basal stratum and intermediate the basal and
supra strata. Referring to FIGURE 2D, coated panel 332 includes underlayment
334, first intermediate layer 333, basal stratum 336, second intermediate
layer
337, and supra stratum 338. Other coating layer configurations will be
apparent
to those skilled in the art and are considered to be within the scope of the
present invention. The required amount of the supra stratum formulation is
essentially that which will eliminate any incompatible interactions between an
aqueous latex adhesive and the coated panel which would normally occur if the
underlayment was coated with only the basal strata formulation. Typical supra
stratum formulation spread rates are 2-12 g/ft2. Preferred supra stratum
formulation spread rates are 4-6 g/ft2.
In another aspect, the present invention provides a coated panel. The
panel includes a wood-based panel having a wood member with a major
surface coated with the coating described above.
CA 02632436 2008-06-17
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In a further aspect of the invention, a floor assembly is provided. The
floor assembly includes a floor covering adhered to a wood-based panel having
a wood member with a major surface coated with the coating described above.
Example 1
The Preparation and Characteristics of Representative Basal and Supra Strata
Formulations and Coatings Prepared Therefrom
In this example, the preparation and characteristics of representative
basal and supra strata formulations are described. Coatings prepared from
these formulations and their ability to inhibit stain formation in overlaying
vinyl
floor coverings is also described. For these representative coatings, the
copper
amine complex was a copper morpholine complex.
Basal stratum formulation. A basal stratum formulation that exhibits excellent
shelf-life during storage; and has a set of rheological properties that are
appropriate for application to an OSB underlayment panel with a reverse-roll-
filling-machine; dramatically inhibits a pine-based OSB panel from staining a
vinyl floor covering under conditions of elevated temperatures and high
relative
humidity values; and forms a coating layer that can be covered with the
aforementioned supra strata to yield a two strata coating that is perfectly
compatible with vinyl adhesives, patching compounds and metallic fasteners
was prepared according to the following procedure.
A 1-liter WaringTM blender was charged with water (250.0 parts by
weight) and RCN-30 AvicelTM (15.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation (Philadelphia,
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment dispersions from Sun Chemical Corporation (Amelia, Ohio), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (5.0 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.3 parts by weight), and
CA 02632436 2008-06-17
19
SunsperseTM LHD-9303 carbon black dispersion (0.4 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. A non-
ionic,
carboxylated styrene-butadiene resin (SBR) latex (400.0 parts by weight),
known as TylacTM 97422-20 from Reichhold Chemicals Inc. (Dover, Del.) was
then added to the blender and the contents were stirred for at least 30 s.
Copper (II) nitrate trihydrate (70.0 parts by weight) from Shepherd Chemical
Company (Cincinnati, Ohio) was added to the blender and the mixture was
stirred for at least 60 s. Cab-0-SilTM EH-5 (6.0 parts by weight), a porous,
precipitated silica powder from Cabot Corporation (Tuscola, III.), was added
to
the blender and the mixture was stirred for at least 60 s. Morpholine (70.0
parts
by weight) was added to the blender and the mixture was stirred for at least
60
s. Titanium dioxide powder (150.0 parts by weight), known as TronoxTM CR-
822, available from Kerr-McGee (Oklahoma City, Okla.), was added to the
blender and the mixture was stirred for at least 60 s. Superfine melamine
powder (33.3 parts by weight), available from Melamine Chemicals Inc.
(Donaldson, La.), was added to the blender and the mixture was stirred for at
least 120 s.
Supra stratum formulation. A supra stratum formulation that has
excellent shelf life during storage; has rheology and surface tension
properties
that are appropriate for application to an underlayment panel by use of a
curtain-coating machine; and provides a coated underlayment surface that is
highly compatible with the typical aqueous latex adhesives that are used to
adhere vinyl floor coverings to wooden underlayment panels was prepared
according to the following procedure.
A 1-liter WaringTM blender was charged with water (215.5 parts by
weight) and RCN-30 AviceITM (16.5 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation (Philadelphia, Pa.)
and the mixture was stirred for 2 minutes at the highest rate of shear. A non-
ionic surfactant, Surfyno!TM 104 PA (3.0 parts by weight) available from Air
CA 02632436 2008-06-17
Products and Chemicals, Inc. (Allentown, Pa.) was added to the blender and
the mixture was stirred for an additional 60 s. Ethylene glycol monobutylether
(10.0 parts by weight), available from Dow Chemical Inc. (Midland, Mich.), was
added to the blender and the mixture was stirred for an additional 60 s. A
5 preservative, known as DowicilTM 75 (1.0 parts by weight) available from Dow
Chemical Inc. (Midland, Mich.), was added to the blender and the mixture was
stirred for an additional 60 s. A fine calcium carbonate powder, OMYACARBTM
3 (304.0 parts by weight) available from Omya Inc. (Proctor, Vt.), was added
to
the blender and the mixture was stirred for an additional 60 s. A non-ionic,
10 carboxylated SBR latex (450.0 parts by weight), TylacTM 97422-21 from
Reichhold Chemicals Inc. (Dover, Del.), was added to the blender and the
contents were stirred for at least 90 s.
Basal and supra strata formulation gel strength. Replicate batches of the
basal and supra strata formulations were prepared and stored in closed
15 containers at a temperature of 20 C for an eight-week period. Neither
formulation demonstrated any phase separation or settling of suspended
material during this storage period. At weekly intervals each batch was
examined and then gently stirred and subjected to a viscosity measurement by
use of an Electronic Thomas StormerTM Viscometer by the Cannon Instrument
20 Co. (State College, Pa.). The basal stratum formulation had viscosity
values
that ranged from 71-89 Krebs units throughout the course of the experiment.
The viscosity value seemed to be highly dependent upon the amount of manual
stirring prior to each measurement. The supra stratum formulation had
viscosity
values that ranged between 55 and 58 Krebs Units throughout the eight-week
period. Similar basal and supra strata formulations were prepared, stored at
20 C, and subjected to a gel strength measurement at weekly intervals. For
this
experiment, the gel strength was measured by inserting a metal probe
(cylindrical shape and diameter of 1.0") into an aliquot of undisturbed sample
(500 g) at a constant rate of 1.0 inch/minute. The force exerted at a
penetration
CA 02632436 2008-06-17
21
depth of 0.75" is taken as the gel strength. Gel strength values provide an
indication of the difficulty in pumping a batch of stored formulation from a
storage tote to an application machine. Formulations that have gel strength
values in excess of about 3 lbf (pounds force) are not preferred for this
invention. The gel strength technique has the key advantage of not being
influenced by variations in the degree to which an operator stirs the sample
prior to the measurement. The gel strength values of the basal strata are
displayed in Table 1.
Table 1. Gel strength values of basal stratum formulation stored at 20 C
Storage Time (weeks) Gel Strength (Ibf)
1 0.09
2 0.15
3 0.16
4 0.25
5 0.20
6 0.19
7 0.18
8 0.18
Another set of the basal stratum and supra strata formulations were
prepared and stored at a constant temperature of 40 C. At the higher storage
temperature a significant decrease in the viscosity value of the supra stratum
formulation was observed within 2 weeks and some settling of the suspended
material was observed after 3 weeks. The higher storage temperature of the
basal stratum formulation was associated with gel strength values that were
initially high and then decreased (see Table 2). Thus, both the supra stratum
and basal strata formulations were less stable at the higher storage
temperature.
CA 02632436 2008-06-17
22
Table 2. Gel strength values of basal stratum formulation stored at 40 C
Storage Time (weeks) Gel Strength (Ibf)
1 0.44
2 0.61
3 0.24
4 0.25
0.26
6 0.17
7 0.15
8 0.13
Samples of both types of formulation were also subjected to freeze/thaw
cycles. The basal stratum formulation was able to withstand 1, but not 2,
freeze
5 thaw cycles before sediment formation and liquid/liquid phase separation
were
observed. The supra stratum formulation demonstrated sediment formation and
liquid/liquid phase separation after just one freeze/thaw cycle.
Basal and supra strata formulation settling resistance. Samples of both
formulations were also subjected to a settling resistance test in which
aliquots
of formulation were packaged in sealed containers and then agitated for three
days in a model RX-86 Sieve Shaker from W. S. Tyler Co. (Mentor, Ohio). The
test is designed to simulate the vibrational action that occurs when totes of
formulation are shipped long distances by trucks. Neither the supra nor the
basal strata formulations showed any liquid/liquid phase separation or
sediment
formation when the samples were examined at the end of the test.
The test results gathered during these shelf life tests show that the basal
and supra strata formulations retain their initial rheology properties and
other
characteristics sufficiently well during normal storage conditions to make
them
suitable for a commercial production operation. Although exceptionally cold or
hot storage conditions should be avoided, a storage life of at least two
months
CA 02632436 2008-06-17
23
can be expected when the formulations are stored at a temperature of about
20 C.
Basal and supra strata formulation coating. The basal stratum
formulation had rheological properties that made it particularly suitable for
application to the top major surface of an OSB underlayment panel by use of a
reverse roll-filling machine such as that manufactured by the Black Brothers
Co. (Mendota, III.). This machine was used to apply the basal stratum
formulation to the top major surface of OSB underlayment panels with
dimensions of 1/4" x 4' x 8' at a spread rate of 3 wet g/ft2. The strands in
the
OSB consisted primarily of southern yellow pine wood. The applied basal
stratum coating was partially dried by heating the treated panel for 10 s in a
forced-air oven that had an air temperature of 350 C. The upper major surface
of these same panels was then coated with the supra stratum formulation by
use of a curtain-coating machine. The curtain-coating machine consisted of a
formulation reservoir, a pump, an application head and a collection pan. Supra
stratum formulation was pumped up into the application head where it was
collected in a long trough, which spanned more than the width of the
underlayment panel. Excess formulation in the head accumulated and spilled
down a vertical, metal face, then fell a distance and into a collection system
for
recycling. Between the bottom of the metal face and the collection system the
falling formulation formed a sheet or a curtain, like a waterfall. Panels to
be
coated were transported through this curtain and were thus coated on the top
major surface at a spread rate of about 6 wet g/ft2. The applied supra strata
coating was partially dried by heating the treated panel for 20 s in a forced-
air
oven that had an air temperature of 350 C. The supra stratum coating dried
essentially clear and colorless, while the basal stratum coating was green and
opaque. The coating layers were intimately bound to each other as well as the
wooden underlayment.
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24
Adhesive Compatibility. Common, commercially available adhesives,
which are typically used to adhere vinyl floor sheathing to wood based
underlayment panels, were evaluated for their compatibility with the surface
of
the coated underlayment panels. The adhesives included Henry 'STM 270,
Henry 'STM 356, S-220, S-235, S-254, S-665 and S-670, which are (including
Henry 'STM) produced by Armstrong World Industries (Lancaster, Pa.); V-61 and
V-81, which are produced by Mannington (Salem, N.J.); FB-1, VINYLBONDTM
FB-600 and FB6-P, which are produced by Tarkett Inc. (Whitehall, Pa.); and
3044 and 3080, which are produced by the Congoleum Corp. (Mercerville,
N.J.). All of these adhesives were applied in aliquots of about 30 g to coated
and uncoated sections (1' x 1') of the OSB underlayment panel. During each
evaluation the adhesive was stroked across the board in both vertical and
horizontal directions by use of a trowel. One stroke was defined as the action
of
contacting the trowel on the sample surface at a location away from the
operator and dragging the trowel towards the operator's body. The trowel was
then lifted off of the board and carried back to the original starting point
in
preparation for the subsequent stroke. The stroke orientation was rotated 90
degrees after every four strokes. A total of 240 strokes were conducted for
the
ArmstrongTM and HenryTM adhesives, while 160 strokes were conducted for the
other adhesives. Each of the adhesives was evaluated for the following failure
modes:
"Coagulation" defined as the immediate solidification or gross phase
separation of the latex adhesive while it was being stroked across the sample
surface.
"Bubble-Gumming" defined as the conversion of the latex adhesive into
a rubbery, elastic, bubble-gum-like, material while it was being stroked
across
the sample surface.
"Coagulation on Trowel" defined as the accumulation of solidified latex
adhesive on the trowel during the stroking process. This may or may not have
CA 02632436 2008-06-17
been coincident with the "Coagulation" phenomenon, which pertained only to
the latex adhesive that resided on the surface of the panel sample.
"Color Transfer from Coating onto Trowel" defined as the accumulation
of abraded basal strata coating on the trowel during the stroking process.
5 "Premature Curing" defined as the act of solidification, hardening or the
loss of tack of the vinyl adhesive during the first 10 minutes subsequent to
application. An examination of the interface between the applied adhesive and
the board surface was conducted in order to determine whether or not the
applied adhesive was prematurely solidifying at that location.
10 None of the adhesives demonstrated any incompatibilities with the fully
coated underlayment panels based on these criteria. Uncoated underlayment
panels were also tested. The Henry'STM 270 and 356 demonstrated subtle
coagulation and coagulation on the trowel at 144 strokes and 112 strokes,
respectively, when they were tested on uncoated underlayment panels.
15 The test was also conducted on underlayment sections that were coated
with just the basal strata formulation and not the supra strata formulation.
Coagulation on the trowel was observed after 160 strokes with the ArmstrongTM
S235 and S670 adhesives. Color transfer was observed on all ArmstrongTM and
HenrysTM adhesives. Coagulation, coagulation on the trowel and bubble-
20 gumming were observed at only 120 strokes with the Henry'sTM adhesives.
Coagulation, coagulation on the trowel and bubble-gumming were observed at
only 112 strokes with the TarkettTM FB-1 adhesive. The other adhesives did not
develop problems during the evaluation.
The adhesive compatibility test was also conducted on underlayment
25 sections that were coated at a spread rate of 11 wet g/ft2 with a
formulation that
contained magnesium hydroxide at a 30% level. The ArmstrongTM S235 and
S254 and Henry'sTM 270 and 356 adhesives demonstrated coagulation,
coagulation on the trowel, and premature curing after only about 32 strokes.
The CongoleumTM 3044 adhesive showed coagulation on the trowel after 160
CA 02632436 2008-06-17
26
strokes. The TarkettTM FB-1 adhesive demonstrated coagulation, coagulation
on the trowel, and premature curing after only about 32 strokes.
An adhesive bond strength test was also conducted on panels that were
coated with both the basal and supra strata formulations as previously
described in this example. Uncoated panels were also tested. Sections (6" x
12") of a vinyl floor covering known as SUCCESSOR TM (produced by
Armstrong World Industries of Lancaster, Pa.) were glued to both types of the
underlayment by use of S670 adhesive from ArmstrongTM. The samples were
glued together according to the floor installation procedures specified by
ArmstrongTM. The adhesive was allowed to cure for either 1 or 7 days and the
samples were then tested for shear strength. Ten replicate laminates were
prepared and tested for each underlayment type and equilibration time. The
test results are displayed in FIGURE 3. The data generated indicate that the
rate of strength development for the adhesive bond was effected very little by
the coating system.
Patching compound bond strength. A patching compound bond strength
test was also conducted on OSB aspen underlayment panels that were coated
with both the basal and supra strata formulations as previously described in
this
example. Uncoated panels were also tested. Sections (3" x 12") of each
underlayment type were treated on the top major surface with either the MAPEI
PLANI/PATCHTM material from Mapei Inc. (Montreal, PQ, Canada) or the S-184
from Armstrong World Industries (Lancaster, Pa.). Both types of patching
materials were applied at a level of 40 wet g/ft2 and were allowed to dry for
60
minutes at a temperature of 20 C. Like samples were then glued together with
the patched faces contacting each other. The adhesive used was
Armstrong'STM S254 and the spread rate was 15-25 g/ft2. Immediately after
adhesive application the samples were mated with a contact pressure of only
about 5 psi, which was maintained over a 24 h period. After 7 additional days
of
equilibration at a temperature of 20 C the laminates were tested for shear
CA 02632436 2008-06-17
27
strength. Ten replicate laminates were prepared and tested for each
underlayment and patching compound type. The results of these tests are
displayed in FIGURE 4. The data generated indicate that this coating system
did not appear to significantly effect the bond strength between the
underlayment and two typical patching compounds.
Stain Testing. Vinyl staining tests were conducted in which sections (6" x
12") of vinyl floor covering were stapled to sections (6" x 12") of coated and
uncoated pine OSB underlayment. The coating system was comprised of both
the basal and supra strata formulations as previously described in this
example.
The assemblies were then placed in an environmental chamber for a period of
eight weeks with the relative humidity maintained at 90% and the temperature
maintained at 50 C. The vinyl sections in the assemblies were inspected for
stain formation at one week intervals. Replicates of 20 were used for all
tests
and the vinyl sections in each assembly were assigned a value during each
evaluation period that represented the degree of staining associated with it.
Types of vinyl floor covering evaluated included SUCCESSOR TM perimeter
attached and CAMBRAYTM fully adhered from Armstrong World Industries
(Lancaster, Pa.); OMNITM perimeter attached, ARGENT TM perimeter attached
and VEGA IITM fully adhered from Mannington (Salem, N.J.); HIGHLIGHT TM
perimeter attached from the Congoleum Corporation (Mercerville, N.J.); and
BRIGHT IMAGE TM fully adhered from Tarkett Incorporated (Whitehall, Pa.).
After 8 weeks of conditioning the vinyl floor covering sections that were
placed in contact with uncoated underlayment sections were generally
substantially stained on the side of the vinyl that contacted the wood. The
opposite side of the vinyl, which did not directly contact the wood, was
stained
to a lesser degree. In many cases these stains appeared to mirror specific
strands in the OSB underlayment.
CA 02632436 2008-06-17
28
No stains were observed on the topside of the vinyl floor covering that
was attached to the coated underlayment. Only minimal staining was observed
on the side of the vinyl floor covering that contacted the coated OSB
underlayment.
Example 2
The Preparations of Representative Basal and Supra Strata Formulations and
Coatings Prepared Therefrom
In this example, the preparation and characteristics of representative
basal and supra strata formulations are described. Coatings prepared from
these formulations and their ability to inhibit stain formation in overlaying
vinyl
floor coverings is also described. For these representative coatings, the
copper
amino complex was a copper morpholine complex.
Basal stratum formulation. A basal stratum formulation that exhibits
excellent shelf-life during storage; has a set of rheological properties that
are
appropriate for application to an OSB underlayment panel with a reverse-roll-
filling-machine; dramatically inhibits a pine-based OSB panel from staining a
vinyl floor covering under conditions of elevated temperatures and high
relative
humidity values; and forms a coating layer that can be covered with the
aforementioned supra stratum to yield a two strata coating that is perfectly
compatible with vinyl adhesives, patching compounds and metallic fasteners
was prepared according to the following procedure.
A 1-liter WaringTM blender was charged with water (250.0 parts by
weight) and RCN-30 AvicelTM (16.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation (Philadelphia,
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment dispersions from the Sun Chemical Corporation (Amelia, Ohio), known
as SunsperseTM YHD-6005 diarylide yellow dispersion (5.0 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.3 parts by weight), and
SunsperseTM LHD-9303 carbon black dispersion (0.4 parts by weight) were
CA 02632436 2008-06-17
29
added to the blender and the mixture was stirred for at least 60 s. A non-
ionic,
carboxylated SBR latex (400.0 parts by weight), known as Tylac TM 97422-20
from Reichhold Chemicals Inc. (Dover, Del.), was then added to the blender
and the contents were stirred for at least 30 s. Copper (II) nitrate
trihydrate
(35.0 parts by weight) from Shepherd Chemical Company (Cincinnati, Ohio)
was added to the blender and the mixture was stirred for at least 60 s. Cab-0-
Sil TM EH-5 (10.0 parts by weight), which is a porous, precipitated silica
powder
from Cabot Corporation (Tuscola, III.) was added to the blender and the
mixture
was stirred for at least 60 s. Morpholine (35.0 parts by weight) was added to
the
blender and the mixture was stirred for at least 60 s. Titanium dioxide powder
(50.0 parts by weight), known as TronoxTM CR-822, which was produced by
Kerr-McGee (Oklahoma City, Okla.), was added to the blender and the mixture
was stirred for at least 60 s. Superfine melamine powder (90.0 parts by
weight),
which was produced by Melamine Chemicals Inc. (Donaldson, La.), was added
to the blender and the mixture was stirred for at least 120 s. A calcium
carbonate powder (93.3 parts by weight) was added to the blender and the
mixture was stirred for at least 60 s. Cab-O-SilTM EH-5 (15.0 parts by
weight),
which is a porous, precipitated silica powder from Cabot Corporation (Tuscola,
III.) was added to the blender and the mixture was stirred for at least 60 s.
Supra stratum formulation. A supra stratum formulation that has
excellent shelf life during storage; has rheology and surface tension
properties
that are appropriate for application to an underlayment panel by use of a
curtain-coating machine; and provides a coated underlayment surface that is
highly compatible with the typical aqueous latex adhesives that are used to
adhere vinyl floor coverings to wooden underlayment panels was prepared
according to the following procedure.
A 1-liter WaringTM blender was charged with water (230.0 parts by
weight) and RCN-30 AviceITM (16.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation (Philadelphia,
CA 02632436 2008-06-17
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
A
fine calcium carbonate powder, known as OMYACARB 3TM (304.0 parts by
weight) produced by Omya Inc. (Proctorõ Vt.), was added to the blender and the
mixture was stirred for an additional 60 s. A non-ionic, carboxylated SBR
latex
5 (450.0 parts by weight), known as Tylac TM 97422-21 from Reichhold Chemicals
Inc. (Dover, Del.), was added to the blender and the contents were stirred for
at
least 90 s.
Basal and supra strata formulation coating. OSB panel sections (1/4" x
6" x 12"; 40 count) comprised primarily of pine strands were randomized and
10 then divided into 2 groups of 20 sections each. All of the sections in one
of
these groups were coated on the top surface with the basal stratum formulation
described in this example by use of a roll coater at a spread rate of 6 g/ft2.
The
supra stratum formulation described in this example was then sprayed on top of
the basal strata at a spread rate of 6 g/ft2. The coated samples were dried in
a
15 forced air oven at a temperature of 100 C for 3 minutes.
Stain testing. The coated and uncoated panels were then subjected to
an accelerated floor sheathing staining test. Sections of vinyl-backed floor
sheathing (6" x 12"), SUCCESSOR TM from Armstrong World Industries
(Lancaster, Pa.), were stapled to the coated side of the coated OSB samples.
20 Other floor sheathing sections were also attached to one side of the
uncoated
OSB samples. The staples were inserted into just one side of the laminate so
that the floor sheathing could be inspected on the backside by simply rolling
it
back on the nonstapled sides. The floor sheathing/OSB laminate samples were
then conditioned in an environmental chamber at a temperature of 50 C and a
25 relative humidity value of 90% for an 8 week period. The samples were
removed at weekly intervals and evaluated for stain formation. During these
evaluations the topside of each floor sheathing section was inspected for
stains. The backside of the floor sheathing, which was in direct contact with
either the OSB or the coating on the OSB, was also examined and assigned a
CA 02632436 2008-06-17
31
rating based on the degree of discoloration. Floor sheathing samples with no
discoloration on their back-side were assigned a perfect rating of 1Ø Floor
sheathing samples with the most severe degree of discoloration on their back-
side were given a rating of 6Ø Six standard samples with different degrees
of
back-side stain formation, which ranged from mild discoloration to severe,
were
used as a reference by the person who was conducting the evaluation. An
average degree of backside stain formation was calculated based on the twenty
samples in each group. These numbers were then converted to a percentage of
stain severity. A vinyl with a perfect 1.0 stain rating had 0% staining, while
a
vinyl with the most severe stain rating of 6.0 had 100% staining. Over 10,000
samples have been analyzed by this method and it has been found that this
test can yield reproducible results that can be used to successfully predict
the
rate of stain formation in the field. The results of this evaluation are
displayed in
Tables 3 and 4. The samples were conditioned at 50 C at 90 percent relative
humidity. In the tables, 0%=no backside staining; 100%=most severe back-side
discoloration. Stains were yellow in color. The 400 ft2 area represents the
approximate surface area of vinyl floor sheathing used in many homes.
25
CA 02632436 2008-06-17
32
Table 3. Backside Vinyl Staining Expressed as a Percentage of the Most
Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 6
14 2 14
21 4 20
28 6 26
35 6 26
42 8 30
49 14 38
56 16 48
Table 4. Number of Topside Stains Per 400 ft2
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 0
14 0 0
21 0 0
28 0 0
35 0 0
42 0 0
49 0 80
56 0 160
CA 02632436 2008-06-17
33
Although the discoloration on the backside of the floor sheathing is not
generally viewed by a homeowner, there appears to be a relationship between
the rate of backside stain formation in vinyl-backed floor sheathing and the
rate
of topside stain formation. This relationship is complex, but in general the
incidence of topside stain formation for vinyl-backed floor sheathing at a
given
point in time is proportional to the numerical summation of the product of the
backside stain formation and contact time squared. Thus, an assessment of
backside stain formation can be used to predict topside;stain formation in
vinyl-
backed floor sheathing. Use of this relationship greatly reduces test cycle
time.
Metal Fastener Corrosion. Samples of coated and uncoated OSB
underlayment that were similar to those described in this example were also
tested for their propensity to corrode metal fasteners. In this test metal
staples,
which are commonly used in the field to attach the underlayment to the
subfloor
were obtained. The staples were washed with acetone prior to testing in order
to remove any protective oils. A total of 120 washed staples were partitioned
into six groups of 20. Three coated OSB underlayment samples (12" x 12") and
three uncoated OSB underlayment samples (12" x 12") were obtained. The
initial mass of each set of washed staples was measured and recorded. Each
set of washed staples was then placed in intimate contact with the top surface
of each underlayment sample in an environmental chamber which was
conditioned to 50 C and 90% relative humidity for a period of 8 days. The
staples were then separated from the underlayment samples and measured for
mass. The percentage of mass lost was then calculated and is shown in Table
5.
CA 02632436 2008-06-17
34
Table 5. Percentage of Staple Mass Lost after Equilibration with OSB
Underlayment
Coated OSB Uncoated OSB
0.1% 0.2%
The results indicate that percent loss of staple mass was twice as
greater for the uncoated underlayment compared to the coated underlayment of
the invention.
Example 3
The Preparation of Representative Basal and Supra Strata Formulations and
Coatings Prepared Therefrom
In this example, the preparation and characteristics of representation
basal and supra strata formulations are described. Coatings prepared from
these formulations and their ability to inhibit stain formation in overlaying
vinyl
floor coverings is also described. For these representative coatings, the
copper
amino complex was a copper morpholine complex.
Basal stratum formulation. A basal stratum formulation that exhibits
excellent shelf-life during storage; has a set of rheological properties that
are
appropriate for application to an OSB underlayment panel with a reverse-roll-
filling-machine; dramatically inhibits either a pine-based or an aspen-based
OSB panel from staining vinyl floor covering under conditions of elevated
temperatures and high relative humidity values; and forms a coating layer that
can be covered with the aforementioned supra strata to yield a two strata
coating that is perfectly compatible with vinyl adhesives and patching
compounds was prepared according to the following procedure.
A 1-liter WaringTM blender was charged with water (218.3 parts by
weight) and RCN-30 AvicelTM (15.0 parts by weight), a blend of xanthan gum
CA 02632436 2008-06-17
and microcrystalline cellulose produced by FMC Corporation (Philadelphia,
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment dispersions from the Sun Chemical Corporation (Amelia, Ohio), known
as SunsperseTM YHD-6005 diarylide yellow dispersion (3.645 parts by weight),
5 SunsperseTM BHD-6000 phthalo blue dispersion (0.146 parts by weight), and
SunsperseTM LHD-9303 carbon black dispersion (0.109 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. An
ethoxylated nonyiphenol surfactant from Rhodia, Inc. (Cranbury, N.J.), known
as IGEPALTM CO-630 (3.0 parts by weight), was added to the blender and the
10 mixture was stirred for 30 s. Titanium dioxide powder (160.0 parts by
weight),
known as TronoxTM CR-822, which was produced by Kerr-McGee (Oklahoma
City, Okla.), was added to the blender and the mixture was stirred for at
least
60 s. A non-ionic, carboxylated SBR latex (385.0 parts by weight), known as
TylacTM 97422-00 from Reichhold Chemicals Inc. (Dover, DL.), was then added
15 to the blender and the contents were stirred for at least 30 s. Hydrated
copper
(II) nitrate (90.0 parts by weight) from Shepherd Chemical Company
(Cincinnati, Ohio) was added to the blender and the mixture was stirred for at
least 60 s. Cab-0-SiITM EH-5 (4.0 parts by weight), which is a porous,
precipitated powder from Cabot Corporation (Tuscola, III.) was added to the
20 blender and the mixture was stirred for at least 60 s. Morpholine (90.0
parts by
weight) was added to the blender and the mixture was stirred for at least 60
s.
Superfine melamine powder (23.3 parts by weight), which was produced by
Melamine Chemicals Inc. (Donaldson, La.), was added to the blender and the
mixture was stirred for at least 120 s. Cab-O-SiITM EH-5 (7.5 parts by
weight),
25 which is a porous, precipitated powder from Cabot Corporation (Tuscola,
III.)
was added to the blender and the mixture was stirred for at least 60 s.
The basal stratum formulation was particularly suitable for application to
the top major surface of an OSB underlayment panel by use of a reverse roll-
filling machine such as that manufactured by Black Brothers Co. (Mendota,
III.).
CA 02632436 2008-06-17
36
This machine was used to apply the basal stratum formulation to the top major
surface of OSB underlayment panels with dimensions of 1/4" x 4' x 8' at a
spread rate of 3-4 wet g/ft2. The basal stratum coating was at least partially
dried and then the supra stratum formulation, prepared as described in
Example 1, was applied on top of the basal stratum at a spread rate of 6 wet
g/ft2. The coated panel was then dried. The resulting coated underlayment
panel had virtually perfect adhesive and patching compound compatibility
properties. The staining potential of the coated panel was found to be
dramatically less than that of the corresponding uncoated panel.
Example 4
The Preparation of Representative Basal Stratum Formulations Having Variable
Copper:Amine Molar Ratios
In this example, basal stratum formulations having variable
copper:amine (morpholine) molar ratios are described. The ability of coatings
prepared from these formulations in inhibiting stain formation in overlaying
vinyl
coverings is also described.
Basal stratum formulations that exhibit excellent shelf-life during storage;
have rheological properties that are appropriate for application to an OSB
underlayment panel with a reverse-roll-filling-machine; dramatically inhibit a
pine-based or an aspen-based OSB panel from staining a vinyl floor covering
under conditions of elevated temperatures and high relative humidity values;
and forms a coating layer that can be covered with the aforementioned supra
stratum to yield a two strata coating that is highly compatible with vinyl
adhesives and patching compounds were prepared according to the following
procedures.
Basal stratum formulation having 1:2 molar ratio of copper:morpholine. A
1-liter WaringTM blender was charged with water (250.0 parts by weight) and
RCN-30 Avicel TM (15.0 parts by weight), a blend of xanthan gum and
microcrystalline cellulose produced by FMC Corporation (Philadelphia, Pa.),
CA 02632436 2008-06-17
37
and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment
dispersions from the Sun Chemical Corporation (Amelia, Ohio), known as
Sunsperse TM YHD-6005 diarylide yellow dispersion (5.0 parts by weight),
Sunsperse TM BHD-6000 phthalo blue dispersion (0.3 parts by weight), and the
Sunsperse TM LHD-9303 carbon black dispersion (0.4 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. A non-
ionic,
carboxylated SBR latex (400.0 parts by weight), known as Tylac TM 97422-20
from Reichhold Chemicals Inc. (Dover, Del.), was then added to the blender
and the contents were stirred for at least 30 s. Copper (II) nitrate
trihydrate
(80.6 parts by weight) from Shepherd Chemical Company (Cincinnati, Ohio)
was added to the blender and the mixture was stirred for at least 60 s. Cab-0-
Sil TM EH-5 (6.0 parts by weight), which is a porous, precipitated silica
powder
from the Cabot Corporation (Tuscola, III.) was added to the blender and the
mixture was stirred for at least 60 s. Morpholine (59.4 parts by weight) was
added to the blender and the mixture was stirred for at least 60 s. Titanium
dioxide powder (150.0 parts by weight), known as Tronox TM CR-822, which
was produced by Kerr-McGee (Oklahoma City, Okla.), was added to the
blender and the mixture was stirred for at least 60 s. Superfine melamine
powder (33.3 parts by weight), which was produced by Melamine Chemicals
Inc. (Donaldson, La.), was added to the blender and the mixture was stirred
for
at least 120 s.
Basal stratum formulation having 3:4 molar ratio of copper:morpholine. A
1-liter WaringTM blender was charged with water (250.0 parts by weight) and
RCN-30 AvicelTM (15.0 parts by weight), a blend of xanthan gum and
microcrystalline cellulose produced by FMC Corporation (Philadelphia, Pa.),
and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment
dispersions from Sun Chemical Corporation (Amelia, Ohio), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (5.0 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.3 parts by weight), and
CA 02632436 2008-06-17
38
SunsperseTM LHD-9303 carbon black dispersion (0.4 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. A non-
ionic,
carboxylated SBR latex (400.0 parts by weight), known as TylacTM 97422-20
from Reichhold Chemicals Inc. (Dover, Del.), was then added to the blender
and the contents were stirred for at least 30 s. Copper (II) nitrate
trihydrate
(93.9 parts by weight) from Shepherd Chemical Company (Cincinnati, Ohio)
was added to the blender and the mixture was stirred for at least 60 s. Cab-0-
SiITM EH-5 (6.0 parts by weight), which is a porous, precipitated silica
powder
from Cabot Corporation (Tuscola, III.) was added to the blender and the
mixture
was stirred for at least 60 s. Morpholine (46.1 parts by weight) was added to
the
blender and the mixture was stirred for at least 60 s. Titanium dioxide powder
(150.0 parts by weight), known as TronoxTM CR-822, which was produced by
Kerr-McGee (Oklahoma City, OK.), was added to the blender and the mixture
was stirred for at least 60 s. Superfine melamine powder (33.3 parts by
weight),
which was produced by Melamine Chemicals Inc. (Donaldson, La.), was added
to the blender and the mixture was stirred for at least 120 s.
Basal stratum formulation having 1:4 molar ratio of copper:morpholine. A
1-liter WaringTM blender was charged with water (250.0 parts by weight) and
RCN-30 AvicelTM (15.0 parts by weight), a blend of xanthan gum and
microcrystalline cellulose produced by FMC Corporation (Philadelphia, Pa.) and
the mixture was stirred for 2 minutes at the highest rate of shear. Pigment
dispersions from Sun Chemical Corporation (Amelia, OH), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (5.0 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.3 parts by weight), and
Sunsperse TM LHD-9303 carbon black dispersion (0.4 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. A non-
ionic,
carboxylated SBR latex (400.0 parts by weight), known as Tylac TM 97422-20
from Reichhold Chemicals Inc. (Dover, DL.), was then added to the blender and
the contents were stirred for at least 30 s. Copper (II) nitrate trihydrate
(56.6
CA 02632436 2008-06-17
39
parts by weight) from Shepherd Chemical Company (Cincinnati, OH) was
added to the blender and the mixture was stirred for at least 60 s. Cab-O-Si I
TM
EH-5 (6.0 parts by weight), which is a porous, precipitated silica powder from
Cabot Corporation (Tuscola, III.) was added to the blender and the mixture was
stirred for at least 60 s. Morpholine (83.4 parts by weight) was added to the
blender and the mixture was stirred for at least 60 s. Titanium dioxide powder
(150.0 parts by weight), known as Tronox TM CR-822, which was produced by
Kerr-McGee (Oklahoma City, Okla.), was added to the blender and the mixture
was stirred for at least 60 s. Superfine melamine powder (33.3 parts by
weight),
which was produced by Melamine Chemicals Inc. (Donaldson, La.), was added
to the blender and the mixture was stirred for at least 120 s.
Panel coating. OSB panel sections (1/4" x 6" x 12"; 40 count) comprised
primarily of aspen, maple and pine strands were randomized and then divided
into 4 groups of 10 sections each. One of the groups was coated on the top
surface with the 3:4 copper:morpholine molar ratio basal stratum formulation
described in this example by use of a roll coater at a spread rate of 3 g/ft2.
A
second group was coated on the top surface with the 1:4 copper:morpholine
molar ratio basal stratum formulation described in this example by use of a
roll
coater at a spread rate of 3 g/ft2. A third group was coated on the top
surface
with the 1:4 copper:morpholine molar ratio basal stratum formulation described
in this example by use of a roll coater at a spread rate of 3 g/ft2. The supra
stratum formulation described in Example 1 was then sprayed on top of the
basal stratum at a spread rate of 6 g/ft2 for all samples in these first three
groups. The coated samples were dried in a forced air oven at a temperature of
100 C for 3 minutes. The fourth group of OSB underlayment was not coated.
Stain testing. The panel samples were then subjected to an accelerated
floor sheathing staining test. Sections of vinyl-backed floor sheathing (6" x
12"),
known as SUCCESSOR TM from Armstrong World Industries (Lancaster, Pa.),
were stapled to the coated side of the coated OSB samples. Other floor
CA 02632436 2008-06-17
sheathing sections were also attached to one side of the uncoated OSB
samples. These laminates were subjected to the same staining test described
in Example 2 with the exception that the test was conducted for a 35 day
period. The results are shown in Tables 6 and 7. The samples were conditioned
5 at 50 C. at 90 percent relative humidity. In the tables, 0%=backside
staining;
100%=most severe backside discoloration. Stains were yellow in color. The
400 ft2 area represents the approximate surface area of vinyl floor sheathing
used in many homes. This type of OSB had a stronger staining action on the
floor sheathing than did the OSB described in Example 2.
Table 6. Backside Vinyl Staining Expressed as a Percentage of the Most
Intense Backside Stain Possible
1:4 1:2 3:4
Time (days) copper:morpholine copper:morpholine copper: morpholine Uncoated
molar ratio basal molar ratio basal molar ratio basal OSB
stratum stratum stratum
0 0 0 0 0
3 4 4 6 62
7 16 14 12 64
16 18 14 14 74
35 26 24 22 82
CA 02632436 2008-06-17
41
Table 7. Number of Topside Stains Per 400 ft2
1:4 1:2 3:4
copper:morpholine copper:morpholine copper: morpholine
molar ratio basal molar ratio basal molar ratio basal Uncoated
Time (days)
stratum stratum stratum OSB
0 0 0 0 0
3 0 0 0 80
7 0 0 0 80
16 0 0 0 240
35 160 0 80 240
The results indicate that all of the copper:morpholine complexes were
effective in significantly reducing staining in coated panels compared to
uncoated OSB panels.
Example 5
The Preparation of a Representative Basal Stratum Formulation
Including Copper Triethanolamine Complex and Coating Prepared Therefrom
In this example, the preparation of a basal stratum formulation including
a copper triethanolamine complex is described. The ability of a representative
coating formed from this formulation in inhibiting stain formation in
overlaying
vinyl floor coverings is also described.
Basal stratum formulation. A basal stratum formulation that inhibits an
aspen-based OSB panel from staining a vinyl floor covering under conditions of
elevated temperatures and high relative humidity values; and forms a coating
layer that can be covered with the aforementioned supra stratum to yield two
strata coating that is highly compatible with vinyl adhesives and patching
compounds was prepared according to the following procedure.
A 1-liter WaringTM blender was charged with water (209.4 parts by
weight) and RCN-30 AvicelTM (15.0 parts by weight), a blend of xanthan gum
CA 02632436 2008-06-17
42
and microcrystalline cellulose produced by FMC Corporation (Philadelphia,
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment dispersions from Sun Chemical Corporation (Amelia, OH), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (7.50 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.50 parts by weight), and
SunsperseTM LHD-9303 carbon black dispersion (0.60 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. Titanium
dioxide powder (190.0 parts by weight), known as Tronox TM CR-822, which
was produced by Kerr-McGee (Oklahoma City, OK.), was added to the blender
and the mixture was stirred for at least 60 s. An antimony trioxide powder
(15.0
parts by weight) was added to the blender and the mixture was stirred for
about
60 s. A non-ionic, carboxylated SBR latex (400.0 parts by weight), known as
TylacTM 97422-20 from Reichhold Chemicals Inc. (Dover, Del.), was then
added to the blender and the contents were stirred for at least 30 s. Copper
(II)
nitrate trihydrate (71.6 parts by weight) from Shepherd Chemical Company
(Cincinnati, OH) was added to the blender and the mixture was stirred for at
least 60 s. Cab-O-SilTM EH-5 (2.0 parts by weight), which is a porous,
precipitated silica powder from Cabot Corporation (Tuscola, IL.) was added to
the blender and the mixture was stirred for at least 60 s. Triethanolamine
(88.4
parts by weight) was added to the blender and the mixture was stirred for at
least 60 s.
Panel coating. OSB panel sections (1/4" x 6" x 12"; 20 count)
comprised primarily of aspen, maple and pine strands were randomized and
then divided into 2 groups of 10 sections each. All of the sections in one of
these groups were coated on the top surface with the basal stratum formulation
described in this example by use of a roll coater at a spread rate of 3 g/ft2.
The
supra stratum formulation described in Example 1 was then sprayed on top of
the basal stratum at a spread rate of 6 g/ft2. The coated samples were dried
in
a forced air oven at a temperature of 1 00 C for 3 minutes.
CA 02632436 2008-06-17
43
Stain testing. The coated and uncoated panels were then subjected to
an accelerated floor sheathing staining test. Sections of vinyl-backed floor
sheathing (6" x 12"), known as SUCCESSOR TM from Armstrong World
Industries (Lancaster, Pa.), were stapled to the coated side of the coated OSB
samples. Other floor sheathing sections were also attached to one side of the
uncoated OSB samples.
These laminates were subjected to the same staining test described in
Example 2 with the exception that the test was only conducted for a 1 week
period. The results are shown in Table 8. The samples were conditioned at
50 C at 90 percent relative humidity. In the tables, 0%=backside staining;
100%=most severe backside discoloration. Stains were yellow in color. The
400 ft2 area represents the approximate surface area of vinyl floor sheathing
used in many homes.
Table 8. Backside Vinyl Staining Expressed as a Percentage of the Most
Intense Backside Stain
Time (days) Coated OSB Uncoated OSB
0 0 0
7 38 60
The results demonstrate that the coating containing the
copper:triethanolamine complex is effective in significantly inhibiting stain
formation in vinyl floor covering.
Example 6
The Preparation of a Representative Basal Stratum Formulation Including
Copper Diethanolamine Complex and Coating Prepared Therefrom
In this example, the preparation of a basal stratum formulation including
a copper diethanolamine complex is described. The ability of a representative
CA 02632436 2008-06-17
44
coating prepared from this formulation in inhibiting stain formation in
overlaying
vinyl floor coverings is also described.
Basal stratum formulation stratum. A basal stratum formulation that
inhibits an aspen-based OSB panel from staining a vinyl floor covering under
conditions of elevated temperatures and high relative humidity values; and
forms a coating layer that can be covered with the aforementioned supra
stratum to yield a two strata coating that is perfectly compatible with vinyl
adhesives and patching compounds was prepared according to the following
procedure.
A 1-liter WaringTM blender was charged with water (209.4 parts by
weight) and RCN-30 Avicel TM (15.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation (Phi.ladelphia,
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment dispersions from Sun Chemical Corporation (Amelia, OH), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (7.50 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.50 parts by weight), and
SunsperseTM LHD-9303 carbon black dispersion (0.60 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. Titanium
dioxide powder (190.0 parts by weight), known as TronoxTM CR-822, which was
produced by Kerr-McGee (Oklahoma City, OK.), was added to the blender and
the mixture was stirred for at least 60 s. An antimony trioxide powder (15.0
parts by weight) was added to the blender and the mixture was stirred for
about
60 s. A non-ionic, carboxylated SBR latex (400.0 parts by weight), known as
TylacTM 97422-20 from Reichhold Chemicals Inc. (Dover, Del.), was then
added to the blender and the contents were stirred for at least 30 s. Copper
(II)
nitrate trihydrate (85.6 parts by weight) from Shepherd Chemical Company
(Cincinnati, OH) was added to the blender and the mixture was stirred for at
least 60 s. Cab-0-SilTM EH-5 (2.0 parts by weight), which is a porous,
CA 02632436 2008-06-17
precipitated silica powder from Cabot Corporation (Tuscola, IL.) was added to
the blender and the mixture was stirred for at least 60 s. Diethanolamine
(74.4
parts by weight) was added to the blender and the mixture was stirred for at
least 60 s.
5 Panel coating. OSB panel sections (1/4"x 6" x 12"; 20 count) comprised
primarily of aspen, maple and pine strands were randomized and then divided
into 2 groups of 10 sections each. All of the sections in one of these groups
were coated on the top surface with the basal stratum formulation described in
this example by use of a roll coater at a spread rate of 3 g/ft2. The supra
10 stratum formulation described in Example 1 was then sprayed on top of the
basal stratum at a spread rate of 6 g/ft2. The coated samples were dried in a
forced air oven at a temperature of 100 C for 3 minutes.
Stain testing. The coated and uncoated panels were then subjected to
an accelerated floor sheathing staining test. Sections of vinyl-backed floor
15 sheathing (6" x 12"), known as SUCCESSOR TM from Armstrong World
Industries (Lancaster, Pa.), were stapled to the coated side of the coated OSB
samples. Other floor sheathing sections were also attached to one side of the
uncoated OSB samples.
These laminates were subjected to the same staining test described in
20 Example 2 with the exception that the test was only conducted for a 1 week
period. The results are shown in Table 9. The samples were conditioned at
C at 90 percent relative humidity. In the tables, 0%=backside staining;
100%=most severe backside discoloration. Stains were yellow in color. The
400 ft2 area represents the approximate surface area of vinyl floor sheathing
25 used in many homes.
CA 02632436 2008-06-17
46
Table 9. Backside Vinyl Staining Expressed as a Percentage of the Most
Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 26 60
The results demonstrate that the coating containing the
copper:diethanolamine complex is effective in significantly inhibiting stain
formation in vinyl floor covering.
Example 7
The Preparation of a Representative Basal Stratum Formulation Including
Copper Ethanolamine Complex and Coating Prepared Therefrom
In this example, the preparation of a basal stratum formulation including a
copper ethanolamine complex is described. The ability of a representative
coating formed from this formulation in inhibiting stain formation in
overlaying
vinyl floor coverings is also described.
Basal stratum formulation stratum. A basal stratum formulation that
inhibits an aspen-based OSB panel from staining a vinyl floor covering under
conditions of elevated temperatures and high relative humidity values; and
forms a coating layer that can be covered with the aforementioned supra
stratum to yield a two strata coating that is perfectly compatible with vinyl
adhesives and patching compounds was prepared according to the following
procedure.
A 1-liter WaringTM blender was charged with water (209.4 parts by
weight) and RCN-30 AviceITM (15.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation Philadelphia, Pa.),
and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment
dispersions from Sun Chemical Corporation (Amelia, OH), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (7.50 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.50 parts by weight), and the
CA 02632436 2008-06-17
47
SunsperseTM LHD-9303 carbon black dispersion (0.60 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. Titanium
dioxide powder (190.0 parts by weight), known as TronoxTM CR-822, which was
produced by Kerr-McGee (Oklahoma City, OK.), was added to the blender and
the mixture was stirred for at least 60 s. An antimony trioxide powder (15.0
parts by weight) was added to the blender and the mixture was stirred for
about
60 s. A non-ionic, carboxylated SBR latex (400.0 parts by weight), known as
TylacTM 97422-20 from Reichhold Chemicals Inc. (Dover, DL.), was then added
to the blender and the contents were stirred for at least 30 s. Copper (II)
nitrate
trihydrate (104.1 parts by weight) from Shepherd Chemical Company
(Cincinnati, OH) was added to the blender and the mixture was stirred for at
least 60 s. Cab-O-SiITM EH-5 (2.0 parts by weight), which is a porous,
precipitated silica powder from Cabot Corporation (Tuscola, IL.) was added to
the blender and the mixture was stirred for at least 60 s. Ethanolamine (55.9
parts by weight) was added to the blender and the mixture was stirred for at
least 60 s.
Panel coating. OSB panel sections (1/4" x 6" x 12"; 20 count)
comprised primarily of aspen, maple and pine strands were randomized and
then divided into 2 groups of 10 sections each. All of the sections in one of
these groups were coated on the top surface with the basal stratum formulation
described in this example by use of a roll coater at a spread rate of 3 g/ft2.
The
supra stratum formulation described in Example 1 was then sprayed on top of
the basal stratum at a spread rate of 6 g/ft2. The coated samples were dried
in
a forced air oven at a temperature of 100 C for 3 minutes.
Stain testing. The coated and uncoated panels were then subjected to
an accelerated floor sheathing staining test. Sections of vinyl-backed floor
sheathing (6" x 12"), known as SUCCESSOR TM from Armstrong World
Industries (Lancaster, Pa.), were stapled to the coated side of the coated OSB
CA 02632436 2008-06-17
48
samples. Other floor sheathing sections were also attached to one side of the
uncoated OSB samples.
These laminates were subjected to the same staining test described in
example 2 with the exception that the test was only conducted for a 1 week
period. The results are shown in Table 10. The samples were conditioned at
50 C at 90 percent relative humidity. In the tables, 0%=backside staining;
100%=most severe backside discoloration. Stains were yellow in color. The
400 ft2 area represents the approximate surface area of vinyl floor sheathing
used in many homes.
Table 10. Backside Vinyl Staining Expressed as a Percentage of the Most
Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 26 60
The results demonstrate that the coating containing the
copper:ethanolamine complex is effective in significantly inhibiting stain
formation in vinyl floor covering.
Example 8
The Preparation of a Representative Basal Stratum Formulation Including
Copper Ammonia Complex and Coating Prepared Therefrom
In this example, the preparation of a basal stratum formulation including
a copper ammonia complex is described. The ability of a representative coating
formed from this formulation in inhibiting stain formation in overlaying vinyl
floor
coverings is also described.
Basal stratum formulation stratum. A basal stratum formulation that
inhibits an aspen-based OSB panel from staining a vinyl floor covering under
conditions of elevated temperatures and high relative humidity values; and
forms a coating layer that can be covered with the aforementioned supra
CA 02632436 2008-06-17
49
stratum to yield a two strata coating that is perfectly compatible with vinyl
adhesives and patching compounds was prepared according to the following
procedure.
A 1-liter WaringTM blender was charged with water (209.4 parts by
weight) and RCN-30 AvicelTM (15.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation (Philadelphia,
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment dispersions from Sun Chemical Corporation (Amelia, OH), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (7.50 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.50 parts by weight), and
SunsperseTM LHD-9303 carbon black dispersion (0.60 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. Titanium
dioxide powder (190.0 parts by weight), known as TronoxTM CR-822, which was
produced by Kerr-McGee (Oklahoma City, OK.), was added to the blender and
the mixture was stirred for at least 60 s. An antimony trioxide powder (15.0
parts by weight) was added to the blender and the mixture was stirred for
about
60 s. A non-ionic, carboxylated SBR latex (400.0 parts by weight), known as
TylacTM 97422-20 from Reichhold Chemicals Inc. (Dover, Del.), was then
added to the blender and the contents were stirred for at least 30 s. Copper
(II)
nitrate trihydrate (108.9 parts by weight) from Shepherd Chemical Company
(Cincinnati, OH) was added to the blender and the mixture was stirred for at
least 60 s. Cab-O-SilTM EH-5 (2.0 parts by weight), which is a porous,
precipitated silica powder from Cabot Corporation of (Tuscola, III.) was added
to the blender and the mixture was stirred for at least 60 s. A 30% ammonium
hydroxide (aq) solution (51.1 parts by weight) was added to the blender and
the
mixture was stirred for at least 60 S.
Panel coating. OSB panel sections (1/4" x 6" x 12"; 20 count) comprised
primarily of aspen, maple and pine strands were randomized and then divided
into 2 groups of 10 sections each. All of the sections in one of these groups
CA 02632436 2008-06-17
were coated on the top surface with the basal stratum formulation described in
this example by use of a roll coater at a spread rate of 3 g/ft2. The supra
stratum formulation described in Example 1 was then sprayed on top of the
basal stratum at a spread rate of 6 g/ft2. The coated samples were dried in a
5 forced air oven at a temperature of 1000 C for 3 minutes.
Stain testing. The coated and uncoated panels were then subjected to
an accelerated floor sheathing staining test. Sections of vinyl-backed floor
sheathing (6" x 12"), known as SUCCESSOR TM from Armstrong World
Industries (Lancaster, Pa.), were stapled to the coated side of the coated OSB
10 samples. Other floor sheathing sections were also attached to one side of
the
uncoated OSB samples.
These laminates were subjected to the same staining test described in
Example 2 with the exception that the test was only conducted for a 1 week
period. The results are shown in Table 11. The samples were conditioned at
15 50 C at 90 percent relative humidity. In the tables, 0%=backside staining;
100%=most severe backside discoloration. Stains were yellow in color. The
400 ft2 area represents the approximate surface area of vinyl floor sheathing
used in many homes.
Table 11. Backside Vinyl Staining Expressed as a Percentage of the Most
20 Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 20 60
The results demonstrate that the coating containing the copper:ammonia
complex is effective in significantly inhibiting stain formation in vinyl
floor
covering.
Example 9
25 The Preparation of a Representative Basal Stratum Formulation
Including Copper Dimethylamine Complex and Coating Prepared Therefrom
CA 02632436 2008-06-17
51
In this example, the preparation of a basal stratum formulation including
a copper dimethylamine complex is described. The ability of a representative
coating formed from this formulation in inhibiting stain formation in
overlaying
vinyl floor coverings is also described.
Basal stratum formulation stratum. A basal stratum formulation that
inhibits an aspen-based OSB panel from staining a vinyl floor covering under
conditions of elevated temperatures and high relative humidity values; and
forms a coating layer that can be covered with the aforementioned supra
stratum to yield a two strata coating that is perfectly compatible with vinyl
adhesives and patching compounds was prepared according to the following
procedure.
A 1-liter WaringTM blender was charged with water (209.4 parts by
weight) and RCN-30 AvicelTM (15.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation (Philadelphia,
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment dispersions from Sun Chemical Corporation (Amelia, OH), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (7.50 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.50 parts by weight) and
SunsperseTM LHD-9303 carbon black dispersion (0.60 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. Titanium
dioxide powder (190.0 parts by weight), known as TronoxTM CR-822, which was
produced by Kerr-McGee (Oklahoma City, Okla.), was added to the blender
and the mixture was stirred for at least 60 s. An antimony trioxide powder
(15.0
parts by weight) was added to the blender and the mixture was stirred for
about
60 s. A non-ionic, carboxylated SBR latex (400.0 parts by weight), known as
TylacTM 97422-20 from Reichhold Chemicals Inc. (Dover, Del.), was then
added to the blender and the contents were stirred for at least 30 s. Copper
(II)
nitrate trihydrate (79.4 parts by weight) from Shepherd Chemical Company
(Cincinnati, Ohio) was added to the blender and the mixture was stirred for at
CA 02632436 2008-06-17
52
least 60 s. Cab-O-SilTM EH-5 (2.0 parts by weight), which is a porous,
precipitated silica powder from Cabot Corporation (Tuscola, III.) was added to
the blender and the mixture was stirred for at least 60 s. A 40% dimethylamine
aqueous solution (80.6 parts by weight) was added to the blender and the
mixture was stirred for at least 60 s.
Panel coating. OSB panel sections (1/4" x 6" x 12"; 20 count) comprised
primarily of aspen, maple and pine strands were randomized and then divided
into 2 groups of 10 sections each. All of the sections in one of these groups
were coated on the top surface with the basal stratum formulation described in
this example by use of a roll coater at a spread rate of 3 g/ft2. The supra
stratum formulation described in Example 1 was then sprayed on top of the
basal stratum at a spread rate of 6 g/ft2. The coated samples were dried in a
forced air oven at a temperature of 100 C for 3 minutes.
Stain coating. The coated and uncoated panels were then subjected to
an accelerated floor sheathing staining test. Sections of vinyl-backed floor
sheathing (6" x 12"), known as SUCCESSOR TM from Armstrong World
Industries (Lancaster, Pa.), were stapled to the coated side of the coated OSB
samples. Other floor sheathing sections were also attached to one side of the
uncoated OSB samples.
These laminates were subjected to the same staining test described in
Example 2 with the exception that the test was only conducted for a 1 week
period. The results are shown in Table 12. The samples were conditioned at
50 C at 90 percent relative humidity. In the tables, 0%=backside staining;
100%=most severe backside discoloration. Stains were yellow in color. The
400 ft2 area represents the approximate surface area of vinyl floor sheathing
used in many homes.
CA 02632436 2008-06-17
53
Table 12. Backside Vinyl Staining Expressed as a Percentage of the
Most Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 24 60
The results demonstrate that the coating containing the
copper:dimethylamine complex is effective in significantly inhibiting stain
formation in vinyl floor covering.
Example 10
The Preparation of a Representative Basal Stratum Formulation and Coating
Prepared Therefrom
Basal stratum formulation stratum. A basal stratum formulation that
inhibits an aspen-based OSB panel from staining a vinyl floor covering under
conditions of elevated temperatures and high relative humidity values; and
forms a coating layer that can be covered with the aforementioned supra
stratum to yield a two strata coating that is perfectly compatible with vinyl
adhesives and patching compounds was prepared according to the following
procedure.
A 1-liter WaringTM blender was charged with water (256.0 parts by
weight) and RCN-30 AvicelTM (15.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation of (Philadelphia,
Pa.), and the mixture was stirred for 2 minutes at the highest rate of shear.
Pigment dispersions from Sun Chemical Corporation (Amelia, Ohio), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (2.50 parts by weight),
SunsperseTM BHD-6000 phthalo blue dispersion (0.15 parts by weight), and
SunsperseTM LHD-9303 carbon black dispersion (0.20 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. Titanium
dioxide powder (150.0 parts by weight), known as TronoxTM CR-822, which was
CA 02632436 2008-06-17
54
produced by Kerr-McGee (Oklahoma City, Okla.), was added to the blender
and the mixture was stirred for at least 60 s. A non-ionic, carboxylated SBR
latex (400.0 parts by weight), known as TylacTM 97422-20 from Reichhold
Chemicals Inc. (Dover, Del.), was then added to the blender and the contents
were stirred for at least 30 s. Copper (II) nitrate trihydrate (80.6 parts by
weight)
from Shepherd Chemical Company (Cincinnati, Ohio) was added to the blender
and the mixture was stirred for at least 60 s. Cab-O-SilTM EH-5 (2.85 parts by
weight), which is a porous, precipitated silica powder from Cabot Corporation
(Tuscola, III.) was added to the blender and the mixture was stirred for at
least
60 s. Morpholine (59.4 parts by weight) was added to the blender and the
mixture was stirred for at least 60 s. Superfine melamine powder (33.3 parts
by
weight), which was produced by Melamine Chemicals Inc. (Donaldson, La.),
was added to the blender and the mixture was stirred for at least 120 s.
Panel coating. OSB panel sections (1/4" x 6" x 12"; 20 count) comprised
primarily of aspen, maple and pine strands were randomized and then divided
into 2 groups of 10 sections each. All of the sections in one of these groups
were coated on the top surface with the basal stratum formulation described in
this Example by use of a roll coater at a spread rate of 3 g/ft2. The supra
stratum formulation described in Example 1 was then sprayed on top of the
basal stratum at a spread rate of 6 g/ft2. The coated samples were dried in a
forced air oven at a temperature of 100 C for 3 minutes.
Stain testing. The coated and uncoated panels were then subjected to
an accelerated floor sheathing staining test. Sections of vinyl-backed floor
sheathing (6" x 12"), known as SUCCESSOR TM from Armstrong World
Industries (Lancaster, Pa.), were stapled to the coated side of the coated OSB
samples. Other floor sheathing sections were also attached to one side of the
uncoated OSB samples.
These laminates were subjected to the same staining test described in
Example 2 with the exception that the test was only conducted for a 1 week
CA 02632436 2008-06-17
period. The results are shown in Table 13. The samples were conditioned at
50 C. at 90 percent relative humidity. In the tables, 0%=backside staining;
100%=most severe backside discoloration. Stains were yellow in color. The
400 ft2 area represents the approximate surface area of vinyl floor sheathing
5 used in many homes.
Table 13. Backside Vinyl Staining Expressed as a Percentage of the Most
Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 10 60
Example 11
10 The Preparation of a Representative Basal Stratum Formulation and Coating
Prepared Therefrom
In this example, the effectiveness of a representative coating of the
invention in inhibiting stain formation in a variety of commercial vinyl floor
coverings is described.
15 Basal stratum formulation. A basal stratum formulation that inhibits a
pine-based OSB panel from staining a vinyl floor covering under conditions of
elevated temperatures and high relative humidity values; and forms a coating
layer that can be covered with the aforementioned supra stratum to yield a two
strata coating that is perfectly compatible with vinyl adhesives and patching
20 compounds was prepared according to the following procedure.
A 1-liter WaringTM blender was charged with water (250.0 parts by
weight) and RCN-30 AviceITM (14.0 parts by weight), a blend of xanthan gum
and microcrystalline cellulose produced by FMC Corporation of (Philadelphia,
Pa.) and the mixture was stirred for 2 minutes at the highest rate of shear.
25 Pigment dispersions from Sun Chemical Corporation (Amelia, Ohio), known as
SunsperseTM YHD-6005 diarylide yellow dispersion (10.0 parts by weight),
CA 02632436 2008-06-17
56
SunsperseTM BHD-6000 phthalo blue dispersion (0.60 parts by weight), and
SunsperseTM LHD-9303 carbon black dispersion (0.80 parts by weight) were
added to the blender and the mixture was stirred for at least 60 s. Titanium
dioxide powder (50.0 parts by weight), known as TronoxTM CR-822, which was
produced by Kerr-McGee (Oklahoma City, Okla.), was added to the blender
and the mixture was stirred for at least 60 s. A non-ionic, carboxylated SBR
latex (400.0 parts by weight), known as TylacTM 97422-20 from Reichhold
Chemicals Inc. (Dover, Del.), was then added to the blender and the contents
were stirred for at least 30 s. Copper (II) nitrate trihydrate (70.0 parts by
weight)
from Shepherd Chemical Company (Cincinnati, Ohio) was added to the blender
and the mixture was stirred for at least 60 s. Morpholine (70.0 parts by
weight)
was added to the blender and the mixture was stirred for at least 60 s.
Superfine melamine powder (70.0 parts by weight), which was produced by
Melamine Chemicals Inc. (Donaldson, La.), was added to the blender and the
mixture was stirred for at least 120 s. Calcium carbonate powder (58.9 parts
by
weight) was added to the blender and the mixture was stirred for 60 s.
Panel coating. OSB panel sections (1/4" x 6" x 12"; 120 count)
comprised primarily of pine strands were randomized and then divided into 6
groups of 20 sections each. All of the sections in five of these groups were
coated on the top surface with the basal stratum formulation described in this
example by use of a roll coater at a spread rate of 3 g/ft2. The supra stratum
formulation described in Example 1 was then sprayed on top of the basal
stratum at a spread rate of 6 g/ft2. The coated samples were dried in a forced
air oven at a temperature of 1000 C for 3 minutes.
Stain testing. The coated and uncoated panels were then subjected to
an accelerated floor sheathing staining test. Sections of vinyl-backed floor
sheathing (6" x 12"), known as SUCCESSOR TM from Armstrong World
Industries (Lancaster, Pa.), were stapled to the coated side of 20 of the
coated
OSB samples. Sections of felt-backed floor sheathing (6" x 12"), known as
CA 02632436 2008-06-17
57
INITIATOR TM from Armstrong World Industries (Lancaster, Pa.), were stapled
to the coated side of 20 of the coated OSB samples. Sections of a fully-
adhered, vinyl floor sheathing (6" x 12"), known as SILVERADO BLUEBELL TM
from Mannington (Salem, N.J.), were stapled to the coated side of 20 of the
coated sections. Sections of a felt-backed, vinyl floor sheathing (6" x 12"),
known as VEGA IITM from Mannington (Salem, N.J.), were stapled to the
coated side of 20 of the coated sections. Sections of vinyl-backed floor
sheathing (6" x 12"), known as HIGHLIGHT TM from Congoleum Corporation
(Mercerville, N.J.), were stapled to the coated side of 20 of the coated OSB
samples. Other floor sheathing sections were also attached to one side of the
uncoated OSB samples.
These laminates were subjected to the same staining test described in
Example 2 with the exception that the test was only conducted for a 16-week
period. The results are shown in Tables 14-22. The samples were conditioned
15 at 50 C at 90 percent relative humidity. In the tables, 0%=backside
staining;
100%=most severe backside discoloration. Stains were yellow in color. The
400 ft2 area represents the approximate surface area of vinyl floor sheathing
used in many homes.
25
CA 02632436 2008-06-17
58
Table 14. Backside Mannington SILVERADOTM Vinyl Staining Expressed as a
Percentage of the Most Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 0
14 0 4
21 2 8
28 4 12
56 6 24
84 12 28
112 12 32
Table 15. Number of Topside Mannington SILVERADOTM Vinyl Stains
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 0
14 0 0
21 0 0
28 0 40
56 0 200
84 0 240
112 320 320
CA 02632436 2008-06-17
59
Table 16. Backside Armstrong SUCCESSOR TM Vinyl Staining Expressed as a
Percentage of the Most Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 6
14 4 14
21 6 22
28 10 26
56 14 44
84 16 56
112 22 66
Table 17. Number of Topside Armstrong SUCCESSOR TM Vinyl Stain Per 400
ft2
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 0
14 0 0
21 0 0
28 0 200
56 0 200
84 0 200
112 0 680
CA 02632436 2008-06-17
Table 18. Number of Topside Armstrong INITIATOR TM Vinyl Stains Per 400 ft2
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 0
14 0 0
21 0 0
28 0 0
56 0 160
84 0 160
112 0 440
5
Table 19. Backside Mannington VEGA IITM Vinyl Staining Expressed as a
Percentage of the Most Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 4
14 0 10
21 0 14
28 0 22
56 0 22
84 2 22
112 6 26
CA 02632436 2008-06-17
61
Table 20. Number of Topside Mannington VEGA IITM Vinyl Stains Per 400 ft2
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 0
14 0 0
21 0 0
28 0 0
56 0 0
84 0 0
112 0 0
Table 21. Backside Congoleum HIGHLIGHT TM Vinyl Staining Expressed as a
Percentage of the Most Intense Backside Stain Possible
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 2
14 0 4
21 0 22
28 0 30
56 6 36
84 6 40
112 8 52
CA 02632436 2008-06-17
62
Table 22. Number of Topside Congoleum HIGHLIGHT TM Vinyl Stains Per 400
ft2
Time (days) Coated OSB Uncoated OSB
0 0 0
7 0 0
14 0 0
21 0 0
28 0 0
56 0 0
84 0 0
112 0 0
The results demonstrate that the coatings of the invention containing a
copper:amine complex are effective in significantly inhibiting stain formation
in a
variety of commercial vinyl floor coverings.
While the preferred embodiment of the invention has been illustrated and
described, it will be appreciated that various changes can be made therein
without departing from the spirit and scope of the invention.
20
