Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
Resilient Flooring Compositions
FIELD OF THE INVENTION
This invention relates to multi-layer resilient flooring materials made with
elastomeric thermosetting/thermoplastic resin-impregnated papers or foils and
core
materials. In particular, however, it relates to a resilient flexible floor
coverings or high
pressure laminated composite material made of layered papers and an optional
flexible
core material.
BACKGROUND OF THE INVENTION
It is known that resilient floor covering materials can be made using several
technologies. These technologies include rubber flooring, linoleum, cork,
vinyl, etc. Vinyl
flooring includes luxury vinyl tile (LVT), vinyl composition tile (VCT), and
sheet vinyl
flooring. Luxury vinyl tile (LVT) is a popular flooring product.
Over the last couple of decades, luxury vinyl flooring's battle for market
share
has largely been fought against public perception. A major negative perception
about
vinyl relates to the materials used to produce vinyl flooring. PVC is a major
component
of vinyl flooring.
Vinyl flooring is thermoplastic, which means that it can be remelted. However,
there are substantial barriers to broad scale reclamation and reuse.
Vinyl flooring contains stabilizers and plasticizers. There is no standard
formula
for these additives and there are differences between manufacturers, so there
is no
uniformity to reclaimed vinyl - and therefore no easy or cost effective way of
extracting
these chemicals.
1
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
The same is true for limestone, the standard filler for vinyl. Limestone,
which is
calcium carbonate, makes up about 80% of vinyl composition tile (VCT) and VCT
accounts for about 63% by volume of all commercial hard surface flooring, and
its
composition presents considerable barriers for reclamation.
Furthermore, there is no infrastructure for vinyl flooring reclamation.
Creating
such an infrastructure requires much effort and coordination, and even the
most focused
efforts cannot shield it from market pressures. The carpet industry has faced
similar
issues.
Even though PVC requires less petroleum in its formulation than other
plastics,
the chlorine extraction process is energy intensive. PVC is a petroleum based
plastic,
and that means that its production from virgin materials comes at a
substantial
environmental price.
Vinyl is the only plastic made largely from a non-petroleum source. The raw
materials for polyvinyl chloride (PVC) are 43% petroleum and 57% salt (sodium
chloride). The salt, derived from seawater, goes through electrolysis to
release its
chlorine, which is combined with ethylene, a petroleum derivative, to create
ethylene
dichloride. This chemical is converted at high temperatures to vinyl chloride,
the
monomer that is polymerized into polyvinyl chloride.
Vinyl is brittle by nature so for use in flooring and other applications,
plasticizers
and stabilizers are added. These days, stabilizers tend to be made of zinc,
calcium and
tin, as opposed to a couple of decades ago, when heavy metals like lead and
cadmium
were common. The vinyl flooring industry uses two plasticizers from the
phthalate family,
DINP and BBP, while in the past DEHP was used.
Another issue with vinyl is the phthalates that can leach from it. Some
studies
have shown that animals exposed to high levels of DEHP, a phthalate that is
widely
used, but no longer used in flooring, have developmental abnormalities, while
other
studies have not shown the same correlation. BBP, one of the phthalates used
in
flooring, has not been implicated. However, according to the Healthy Building
Network,
DINP, also widely used, has been implicated in at least one study.
Fundamental to the arguments against PVC are the toxins associated with it,
particularly surrounding its chlorine content, and there is no debate about
PVC's
association with dioxins, a class of carcinogenic chemicals. Dioxins are
released when
PVC is burned, both in backyard barrel burning and in landfill fires.
2
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
LVT flooring is produced by assembling several layers including: a clear wear
layer made from PVC film; a printed layer made from PVC film; a core material
made
from calcium carbonate and chemical plasticizers; and a backing or balancing
layer
made from PVC. The loose individual layers are pressed in a high pressure
press, with
embossing texture plates, at high temperatures. Once cured, the large sheets
are die
cut into tiles or planks.
Vinyl flooring is generally installed with adhesives to a smooth wood or
concrete
subfloor. Because of the thermoplastic nature of the vinyl, the subfloor
surfaces must be
smooth. Any surface imperfections such as cracks in concrete, bumps, etc. tend
to
telegraph or show through the floor.
Another negative perception has to do with vinyl's appearance - the glare of
plastic, outdated looks, and poor representations of wood and stone.
This patent describes a new resilient flooring material that would be an
alternative to vinyl made from recycled materials. The present invention aims
to provide
a new alternative resilient flooring material combining the natural appearance
of wood,
stone, tile or modern patterns and colors; containing no PVC or plasticizers;
made from
materials including paper, cork, wood fibers, recycled rubber sheet or natural
mineral
fillers; with the feel of traditional wood flooring, and being a resilient,
sound reducing
composition. This new product could be made in a variety of thicknesses, and
installed
with or without adhesive or manufactured with a self-adhesive peel and stick
backing
layer.
Surface texture impressions can be realized to obtain an imitation of wood
grain,
stone and other textures. With the known embodiments, this is performed by
providing a
series of impressions in the floor panels, which impressions substantially
extend in the
same direction or in random directions.
The significant advantages of this invention over vinyl tile would be
including, but
not be limited to: no PVC or harmful plasticizers; environmentally friendly
water-based
elastomeric resin technology; low manufacturing cost; use of post consumer or
post
industrial recycled materials; recyclability; good material properties
including excellent
UV resistance, chemical and stain resistance, high moisture stability and
resistance to
scratching; realistic design and feel, and durability.
3
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
SUMMARY OF THE INVENTION
The present invention describes a resilient, flexible panel having multiple
flexible
layers, including floor coverings, and more particularly floor panels, whereby
one or
more layers comprising the resilient layer panel structure are made from
papers, foils, or
woven materials that may be impregnated and or coated with an elastomeric
resin, film
or material.
Thereby, a new resilient floor product is offered. The new invention consists
of
several independently treated loose flexible layers which are placed in a
heated press
and pressed under pressure for a period of time. The pressed panel is removed
from
the press and subsequently die cut or machine cut to a specific size.
The flexible layers might include (i) an optional impregnated and coated wear
paper layer that has a translucent surface; (ii) an impregnated and coated
decorative
paper layer that has a printed surface; (iii) a core layer made from a variety
of materials;
(iv) a backer layer consisting of impregnated and coated paper. The above
description
may be modified to remove or add one or more layers depending upon the type of
floor
product and performance characteristics that are required.
Additional flexible layers may include one or more of the following: (i) a
felt layer
to add stability and reduce the possibility of telegraphing subfloor surface
imperfections;
(ii) a linoleum core layer; (iii) a cork core layer; (iv) a natural or
synthetic rubber core
layer; (v) a natural or synthetic rubber backing layer where the flooring is
designed to be
loose-laid without adhesive; and (vi) a pressure sensitive adhesive layer. Any
of the
layers may be applied in a single-step during the pressing/forming cycle or in
subsequent steps after the panels have been formed from multiple layers.
The surface texture plates may also be designed for register embossing where
the texture (e.g. wood plank) can correspond with the graphic image printed on
the
decorative layer with an embossing texture that is aligned to a graphic image.
The press may have texture plates made from chromium steel or other similar
material attached to the upper and lower press platens. The surface texture
plates may
have various textures which correspond to the decorative paper style. An
example of
this would be to have wood grain texture plates combined with wood-grain
printed
decorative papers.
However, other materials, such as films, either based on cellulose or not, are
not
excluded. Moreover, each layer can be processed in different manners, for
example,
4
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
previous to the application thereof on the underlying basic layer, a layer may
be soaked
or coated in elastomeric resin or such. In addition, the elastomeric resin may
consist of
a solution polymer or a dispersion, or both applied in different steps to the
paper or film.
Alternatively, a printed decoration can be printed directly on to the
impregnated
paper core layer and the decorative layer may thereby be eliminated. Further,
in such a
case, the elastomeric material may be impregnated onto the wear layer, or, in
some
cases, substituted for the wear layer. In this later case, the elastomeric
material can also
be modified to include wear particles for improved wear resistance, as
discussed herein
below. Accordingly, the entire panel assembly may be "tuned" to reduce noise
depending upon the characteristics of the core panel. Each of the layers may
be
impregnated or receive coatings of elastomeric material. As well, the
elastomeric
material may also be of differing hardness.
Preferably, this elastomeric coating, film or material consists of a natural
or
synthetic resin with elastomeric properties, applied, for example, in very
thin layers to the
paper layers and/or the core. In a preferred embodiment, the papers or woven
materials
are saturated with the elastomeric resin, film or material.
In a second aspect, the present invention also relates to a method of
production
of the resilient materials, and in particular, the resilient flooring material
or coverings
described herein. As such, the present invention also provides a method for
the
production of a resilient material, and preferably a resilient flooring
material, comprising
preparing multiple component layers, and pressing said component layers
together,
wherein one or more layers comprising the resilient material are made from
papers, foils
or woven materials, which papers, foils or woven materials are impregnated
with, or
coated with, an elastomeric resin, film or material.
A further embodiment of the invention would be, to apply the impregnated
decorative paper with wear particles to a linoleum, rubber or cork sheet. A
loose
assembly including an impregnated decorative linoleum core layer and the
impregnated
paper backing layer would be placed in a heated fast-cycle press to fuse the
layers
together into a layered resilient floor panel. Subsequent operations may
include die
cutting, edge machining, inspection, and packaging.
Although the invention aims at creating a new alternative resilient floor
product, it
will be obvious to a person skilled in the art that this inventive idea can be
realized in
different ways.
5
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
For resilient floor covering, and more particularly each floor panel
concerned, the
same elastomeric coatings may be applied to decorative papers and foils or
even wood
elastomeric resin impregnated wood-veneers as a core material. Further, the
backing
layer may have an adhesive or self-adhesive coating applied to allow for a non-
glue
"press and stick" product. Additionally, an elastomeric film or films may be
substituted for
the coating.
Of course, the invention also relates to resilient floor panels which may be
produced with direct printing technology where the paper or core materials are
printed
directly and subsequently a translucent an impregnated elastomeric film or
thermoset
paper wear layer is applied to the upper surface of the panel and a pre-
impregnated
thermoset paper backing layer is also applied to the lower surface.
The water-based elastomeric impregnating resin (approximately 40% solids) may
be applied to the thick paper-based core layer and subsequently the core panel
may be
placed in a vacuum chamber to allow the elastomeric dispersion resin to
completely
impregnate the core. Alternatively, the core paper or any of the decorative or
backing
papers may be subjected to a multi-step treatment using a water-based
elastomeric
solution that easily penetrates the papers and in a secondary step the papers
may be
treated with a water-based elastomeric dispersion. After the impregnation
process is
complete, the papers must be dried to remove all excess moisture. The papers
may be
processed in continuous roll form using impregnating and coating lines well
known in the
paper industry such as a VITS impregnation line.
The invention also relates to a method for realizing a floor panel, where the
wear
layer has a thermoplastic film instead of the thermoset resin-impregnated
paper wear
layer. This wear layer could be assembled over a decorative paper or vinyl
foil or a
directly printed panel, a core and a paper or thermoplastic balance layer.
Typically, the floor panels hereby are formed from larger panels.
These panels may consist of (i) a wear layer paper or foil that has been
impregnated with an elastomeric thermosetting/thermoplastic resin which may
include
aluminum oxide or other abrasion resistant particles; (ii) a decorative layer
that may be
treated with a thermosetting/thermoplastic elastomeric impregnating resin;
(iii) a core
consisting of one or more layers of resin-impregnated paper board, linoleum,
cork,
natural or synthetic rubber, or flexible wood (and any combinations thereof)
that may be
treated with a thermosetting/thermoplastic elastomeric coating or impregnating
resin;
6
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
and/or (iv) a lower balancing paper or foil layer that has been impregnated
with a
thermosetting/thermoplastic elastomeric impregnating resin; and other possible
layers.
The application of a thermosetting/thermoplastic elastomeric impregnating
resin
may occur during the production of any of the components of the layered
assembly, or
in the manufacture of any of the individual components which comprise the
layered
assembly. The loose assembly is transferred to a heated press to compress and
fuse
the layers into a whole, whereby the thermosetting/thermoplastic elastomeric
impregnating resin provides for adhesion. Simultaneously during the pressing,
the
embossed impressions are applied, by the press, as either surface of the
pressing part
comes into contact with, the part to create a single layered part in
accordance with the
invention.
In a further embodiment, a thin elastomeric coating or film may also be
applied to
the upper decorative surface or the edge surfaces. The above-mentioned further
embodiment will also act to seal the floor panel from moisture and provide
improved
wear properties.
BRIEF DESCRIPTION OF THE DRAWINGS
With the intention of better showing the characteristics of the invention,
hereafter,
as an example without any limitative character, several preferred forms of
embodiment
are described, in the accompanying drawings, wherein:
FIG. 1 represents cross-sectional view of a typical luxury vinyl tile floor
covering
according to the prior art;
FIG. 2 represents an embodiment of the present invention with three
impregnated paper layers;
FIG. 3 represents another embodiment of the present invention with an
impregnated decorative paper layer with wear particles, multiple impregnated
paper
layers to build up the core layer, and an impregnated paper backer layer;
FIG. 4, represents the present invention described in Figure 2 with a linoleum
core layer;
FIG. 5, represents the present invention described in Figure 2 with a flexible
natural fiber composite core layer;
FIG. 6, represents the present invention described in Figure 2 with a flexible
cork
core layer;
7
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
FIG. 7 represents the present invention described in Figure 2 with a flexible
natural or synthetic rubber core layer;
FIG. 8 represents the present invention described in Figure 2 with a flexible
expanded or solid polyethylene or polypropylene core layer;
FIG . 9 represents the present invention described in Figure 2 with a high
density
flexible foam core layer;
FIG. 10 represents the present invention described in Figure 2 with an
additional
felt layer below the paper core layer; and
FIG 11. represents the present invention described in Figure 2 with an
additional
impregnated glass fiber layer below the paper core layer.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is an expanded three-dimensional view of a typical luxury vinyl tile of
the
prior art which incorporates the clear thermoplastic PCV wear layer 1, a
printed PVC
decorative layer 2, a core made with calcium carbonate, plasticizers and other
additives
3, and a thermoplastic PVC backer layer 4.
FIG. 2 shows an expanded three-dimensional view of a preferred embodiment of
the present invention which incorporates a printed paper decorative layer
impregnated
with an elastomeric thermosetting/thermoplastic resin which, in an optional
feature,
incorporates abrasion particles 5, a paper board core layer impregnated with
an
elastomeric thermosetting/thermoplastic resin 6, and a paper backer layer with
a weight
of approximately 125 g/m2 impregnated with an elastomeric
thermosetting/thermoplastic
resin 7.
FIG. 3 is an expanded cross section of another preferred embodiment of the
present invention which includes a translucent wear layer paper with a weight
of
approximately 25 g/m2 impregnated with an elastomeric
thermosetting/thermoplastic
resin which incorporates abrasion particles 8, a decorative printed paper
layer with a
weight of approximately 60 g/m2 impregnated with flexible water based
polyurethane
dispersion 9, a core layer consisting of multiple core layer papers with a
weight of
approximately 125 g/m2 impregnated with an elastomeric
thermosetting/thermoplastic
resin 10, and a paper backer layer with a weight of approximately 125 g/m2
impregnated
with an elastomeric thermosetting/thermoplastic resin 7.
8
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
FIG. 4 is an expanded cross section of another embodiment of the present
invention which includes a printed decorative paper layer with a weight of
approximately
60 g/m2 impregnated with an elastomeric thermosetting/thermoplastic resin
which
incorporates abrasion particles 5, a linoleum core layer 11, and a paper
backer layer
impregnated with an elastomeric thermosetting/thermoplastic resin 7.
FIG. 5 is an expanded cross section of another embodiment of the present
invention which includes a printed decorative paper layer with a weight of
approximately
60 g/m2 impregnated with an elastomeric thermosetting/thermoplastic resin
which
incorporates abrasion particles 5, a resilient natural fiber composite core
layer 12, and a
paper backer layer with a weight of approximately 125 g/m2 impregnated with an
elastomeric thermosetting/thermoplastic resin 7.
FIG. 6 is an expanded cross section of another embodiment of the present
invention which includes a printed decorative paper layer with a weight of
approximately
60 g/m2 impregnated with an elastomeric thermosetting/thermoplastic resin
which
incorporates abrasion particles 5, a flexible cork core layer 13, and a paper
backer layer
with a weight of approximately 125 g/m2 impregnated with an elastomeric
thermosetting/thermoplastic resin 7.
FIG. 7 is an expanded cross section of another embodiment of the present
invention which includes a printed decorative paper layer with a weight of
approximately
60 g/m2 impregnated with an elastomeric thermosetting/thermoplastic resin
which
incorporates abrasion particles 5, a flexible natural or synthetic rubber core
layer 14, and
a paper backer layer with a weight of approximately 125 g/m2 impregnated with
an
elastomeric thermosetting/thermoplastic resin 7.
FIG. 8 is an expanded cross section of another embodiment of the present
invention which includes a printed decorative paper layer with a weight of
approximately
60 g/m2 impregnated with an elastomeric thermosetting/thermoplastic resin
which
incorporates abrasion particles 5, a flexible expanded or solid polyethylene
or
polypropylene core layer core layer 15, and a paper backer layer with a weight
of
approximately 125 g/m2 impregnated with an elastomeric
thermosetting/thermoplastic
resin 7.
FIG. 9 is an expanded cross section of another embodiment of the present
invention which includes a printed decorative paper layer with a weight of
approximately
60 g/m2 impregnated with an elastomeric thermosetting/thermoplastic resin
which
9
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
incorporates abrasion particles 5, a flexible high density flexible foam core
layer core
layer 16, and a paper backer layer with a weight of approximately 125 g/m2
impregnated
with an elastomeric thermosetting/thermoplastic resin 7.
FIG. 10 is an expanded cross section of another embodiment of the present
invention which includes a printed decorative paper layer with a weight of
approximately
60 g/m2 impregnated with an elastomeric thermosetting/thermoplastic resin
which
incorporates abrasion particles 5, a paper board core layer impregnated with
an
elastomeric thermosetting/thermoplastic resin 6, a felt layer 17, and a paper
backer layer
with a weight of approximately 125 g/m2 that has been impregnated with an
elastomeric
thermosetting/thermoplastic resin 7.
FIG. 11 is an expanded cross section of another embodiment of the present
invention which includes a printed decorative paper layer with a weight of
approximately
60 g/m2 impregnated with an elastomeric thermosetting/thermoplastic resin
which
incorporates abrasion particles 5, a paper board core layer impregnated with
an
elastomeric thermosetting/thermoplastic resin 6, a glass fibre layer
impregnated with
flexible water based polyurethane dispersion 18, and a paper backer layer with
a weight
of approximately 125 g/m2 impregnated with an elastomeric
thermosetting/thermoplastic
resin 7.
Alternatively, the glass fibre layer can be replaced with a flexible cloth
layer made
of a natural or synthetic woven material, such as, for example, cotton, jute,
polyester, or
the like.
In all examples, the thermosetting/thermoplastic resin could be made from an
elastomeric material in various forms including liquid, solid, film, one
component or multi-
component; thermoset, thermoplastic (TPE), solution polymer or water-based
dispersion
and latexes. Either block or alternating or random copolymers may be used. The
said
material can be based on, but not limited to the following polymers: PE, all
grades
(LLDPE, LDPE, MDPE, HDPE); Polyurethane; Polypropylene; Ethylene vinyl
acetate;
Ethylene vinyl alcohol; Polyester; Polyolefin (TPO); Urea and Urea-modified
thermoset
resins; modified Melamine-based thermoset resins; Phenolic resins; ESI -
ethylene
styrene interpolymer or any of the styrene acrylic copolymers and Acrylic
resins; rubber
based materials, NBR (nitrite Butadiene), SBR (styrene butadiene), CR
(chloroprene),
silicone, fluorocarbon, acrylamide, epichlorohydrin, and/or carboxylated
natural and
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
synthetic latexes. The resins may be used individually, in combinations, or as
flexiblizing
additives to traditional paper impregnation resins such as Melamine, Urea, and
Phenolic-
based resins.
The thickness of the coating is preferably from 1 micron to 3 mm, but thinner
or
thicker coatings might also be used. The application of the elastomeric
material shall not
be limited to the coating of the core or the layering papers top or bottom.
The
elastomeric material may comprise of a modified paper or flexible foil or a
paper or foil
with an elastomeric coating.
As such, the elastomeric thermosetting/thermoplastic resin could also be a
flexible resin system used to coat or impregnate any or all of the paper or
core layers,
and/or combinations thereof. Preferably, this elastomeric material may be in
the form of
a water-based dispersion or a water-based solution polymer which by itself may
have
defined limits of elongation of 0 - 2000%, a 100% modulus between 0-1500 psi,
and a
tensile strength between 0 - 5000 psi by ASTM D-412 .
According to a variant, the elastomeric material and the decorative layer,
before
their application on the base (or core) panel, may consist of a single layer,
for example,
in that the decorative layer is soaked such that sufficient elastomeric
material is present
thereupon to provide the sound absorbing and improved stress relieving
properties
therein. It is also not excluded to start from a layer of elastomeric material
which is
provided with a decorative layer at the underside, which layer is exclusively
formed by a
print. The term print must be interpreted in the broadest sense, and thereby
any
technique is intended to provide for a decorative graphic image for the panel
surface.
Also, other layers may be taken up in the top layer, such as, for example, a
layer
of white paper, also impregnated with resin, which is provided under the
decorative
layer, which has the purpose of forming a neutral background.
A transparent wear layer consisting of a thermoplastic material such as PTO,
polyethylene or polypropylene in various thicknesses may be added depending
upon the
desired performance properties. Variations in the type of material used to
produce a
core panel, the density of the core panel, the use of different resins or
bonding agents,
composites made with combinations of different resilient materials, and core
panels
made from other materials which may be natural-fiber based or which may be
synthetic
such as extruded plastics and flexible core materials, may further all benefit
from the
invention described herein.
11
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
Also, other materials known in the industry, such as fire retardant materials
and
the like, can be included within the papers, or other layers. The papers or
other layers
can be pretreated with these materials prior to their use in the present
invention.
Moreover, it will be clear that any of the resins used herein, may also
include other
known additives such as release agents, colouring agents, flame and smoke
retardants,
wear particles, and the like.
EXAMPLES
The following examples were produced on a laboratory scale to mimic the
production model to manufacture a product of the present invention. In a large-
scale
production, the paper layers would be impregnated using a VITS impregnation
line
normally used to impregnate papers for other industries such as the laminate
floor
industry. Once treated the papers may be stored in a roll-form awaiting
pressing and die
cutting operations. Pressing methods may include platen presses, continuous
roll
presses or calendaring-type presses.
Example 1
Decorative papers printed with a woodgrain pattern with a weight of
approximately
65 g/m2 as normally used in the production of laminate flooring were cut to 20
x 30 cm
size. A laboratory roller impregnator that consisted of a metal tray under an
assembly
with two rollers was used. A pre-impregnation solution bath was prepared
consisting of
50% H2O and 50% WB-90 PURchem Solution Polymer and poured into the tray. Each
sheet was placed in the solution polymer and gently pulled between the rollers
to
remove any excess. The sheets were dried to remove excess moisture in an oven
with a
temperature of 900 C for 3 minutes.
A second bath with a solution was prepared consisting of 20% H2O and 80% WB-
100 PURchem Polyurethane Water-Based Dispersion and poured into the tray. Each
sheet was placed in the solution polymer and gently pulled between the rollers
to
remove any excess. The sheets were dried to remove excess moisture in an oven
with a
temperature of 90 C for 3 minutes.
The decorative papers were coated with a solution consisting of 10% H2O and
80%
WB-110 PURchem Polyurethane Water-based Dispersion resin with Internal Mold
Release (IMR) + 10% of Corundum particles (A1203) with internal mold release.
Each
12
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
sheet was placed in the solution and gently pulled between the rollers to
remove any
excess. The sheets were dried to remove excess moisture in an oven with a
temperature
of 90 C for 3 minutes. The dried decorative sheets were set aside. Similar
steps were
used to produce seven core paper sheets made from saturating kraft paper with
a weight
of 125 g/m2. Each of the sheets had a film build of 150 g per m2.
Once the sheets were pre-impregnated and subsequently dried, the loose
assembly consisting of seven impregnated kraft paper sheets + the impregnated
decorative sheet was placed in 100 ton heated hydraulic with upper and lower
platens
having a surface temperature of 150 C. The press machine was equipped with a
chromium-plated steel press plate having a woodgrain texture installed on one
surface
designed to make impressions into the printed decorative paper. The press was
closed
with a surface pressure of 45 kg/m2 for 60 seconds to allow the dried PURchem
Polyurethane Water-Based Dispersion polymer to melt and bond the multiple
sheets
forming a resilient floor panel sample with a wood-grain design and
corresponding
surface texture.
As the end of the cycle, the sample was removed from the press, allowed to
cool
and cut to the desired dimensions.
Example 2
Decorative papers printed with a woodgrain pattern with a weight of
approximately
65 g/m2 as normally used in the production of laminate flooring were cut to 20
x 30 cm
size. A laboratory roller impregnator that consisted of a metal tray under an
assembly
with two rollers was used. A pre-impregnation solution bath was prepared
consisting of
50% H2O and 50% WB-90 PURchem Solution Polymer and poured into the tray. Each
sheet was placed in the solution polymer and gently pulled between the rollers
to
remove any excess. The sheets were dried to remove excess moisture in an oven
with a
temperature of 90 C for 3 minutes.
A second bath with a solution was prepared consisting of 20% H2O and 80% WB-
100 PURchem Polyurethane Water-Based Dispersion and poured into the tray. Each
sheet was placed in the solution polymer and gently pulled between the rollers
to
remove any excess. The sheets were dried to remove excess moisture in an oven
with a
temperature of 90 C for 3 minutes.
13
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
The decorative papers were coated with a solution consisting of 10% H2O and
80%
WB-1 10 PURchem Polyurethane Water-based Dispersion resin with Internal Mold
Release (IMR) + 10% of Corundum particles (A1203). Each sheet was placed in
the
solution and gently pulled between the rollers to remove any excess. The
sheets were
dried to remove excess moisture in an oven with a temperature of 90 C for 3
minutes.
The dried decorative sheets were set aside. Each of the sheets had a minimum
film build
of 150 g per m2.
Once the sheets were pre-impregnated and subsequently dried, the loose
assembly consisting of a 3.0 mm thick linoleum panel + the impregnated
decorative
sheet + an impregnated kraft paper backing sheet was placed in 100 ton heated
hydraulic with upper and lower platens having a surface temperature of 150 C.
The
press machine was equipped with a chromium-plated steel press plate having a
woodgrain texture installed on one surface designed to make impressions into
the
printed decorative paper. The press was closed with a surface pressure of 45
kg/m2 for
60 seconds to allow the dried PURchem Polyurethane Water-Based Dispersion
polymer
to melt and bond the loose assembly forming a resilient floor panel sample
with a wood-
grain design and corresponding surface texture with a linoleum core.
As the end of the cycle, the sample was removed from the press, allowed to
cool
and cut to the desired dimensions.
Example 3
Decorative papers printed with a woodgrain pattern with a weight of
approximately
65 g/m2 as normally used in the production of laminate flooring were cut to 20
x 30 cm
size. A laboratory roller impregnator that consisted of a metal tray under an
assembly
with two rollers was used. A pre-impregnation solution bath was prepared
consisting of
50% H2O and 50% WB-90 PURchem Solution Polymer and poured into the tray. Each
sheet was placed in the solution polymer and gently pulled between the rollers
to
remove any excess. The sheets were dried to remove excess moisture in an oven
with a
temperature of 90 C for 3 minutes.
A second bath with a solution was prepared consisting of 20% H2O and 80% WB-
100 PURchem Polyurethane Water-Based Dispersion and poured into the tray. Each
sheet was placed in the solution polymer and gently pulled between the rollers
to
14
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
remove any excess. The sheets were dried to remove excess moisture in an oven
with a
temperature of 900 C for 3 minutes.
The decorative papers were coated with a solution consisting of 10% H2O and
80%
WB-110 PURchem Polyurethane Water-based Dispersion resin with Internal Mold
Release (IMR) + 10% of Corundum particles (A1203) with internal mold release.
Each
sheet was placed in the solution and gently pulled between the rollers to
remove any
excess. The sheets were dried to remove excess moisture in an oven with a
temperature
of 90 C for 3 minutes. The dried decorative sheets were set aside. Each of
the sheets
had a film build of 150 g per m2.
Once the sheets were pre-impregnated and subsequently dried, the loose
assembly consisting of a 1.5 mm thick cork panel + the impregnated decorative
sheet +
an impregnated kraft paper backing sheet was placed in 100 ton heated
hydraulic with
upper and lower platens having a surface temperature of 1500 C. The press
machine
was equipped with a chromium-plated steel press plate having a woodgrain
texture
installed on one surface that is designed to make impressions into the printed
decorative
paper. The press was closed with a surface pressure of 45 kg/m2 for 60 seconds
to
allow the dried PURchem Polyurethane Water-Based Dispersion polymer to melt
and
bond the loose assembly forming a resilient floor panel sample with a wood-
grain design
and corresponding surface texture with a cork core.
As the end of the cycle, the sample was removed from the press, allowed to
cool
and cut to the desired dimensions.
Example 4
Decorative papers printed with a woodgrain pattern with a weight of
approximately
65 g/m2 as normally used in the production of laminate flooring were cut to 20
x 30 cm
size. A laboratory roller impregnator that consisted of a metal tray under an
assembly
with two rollers was used. A pre-impregnation solution bath was prepared
consisting of
50% H2O and 50% WB-90 PURchem Solution Polymer and poured into the tray. Each
sheet was placed in the solution polymer and gently pulled between the rollers
to
remove any excess. The sheets were dried to remove excess moisture in an oven
with a
temperature of 90 C for 3 minutes.
A second bath with a solution was prepared consisting of 20% H2O and 80% WB-
100 PURchem Polyurethane Water-Based Dispersion and poured into the tray. Each
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
sheet was placed in the solution polymer and gently pulled between the rollers
to
remove any excess. The sheets were dried to remove excess moisture in an oven
with a
temperature of 90 C for 3 minutes.
The decorative papers were coated with a solution consisting of 10% H2O and
80%
WB-110 PURchem Polyurethane Water-based Dispersion resin with Internal Mold
Release (IMR) + 10% of Corundum particles (A1203) with internal mold release.
Each
sheet was placed in the solution and gently pulled between the rollers to
remove any
excess. The sheets were dried to remove excess moisture in an oven with a
temperature
of 90 C for 3 minutes. The dried decorative sheets were set aside. Each of
the sheets
had a film build of 150 g per m2.
Once the sheets were pre-impregnated and subsequently dried, the loose
assembly consisting of a 6.0 mm thick cork panel + the impregnated decorative
sheet +
an impregnated kraft paper backing sheet was placed in 100 ton heated
hydraulic with
upper and lower platens having a surface temperature of 150 C. The press
machine
was equipped with a chromium-plated steel press plate having a woodgrain
texture
installed on one surface that is designed to make impressions into the printed
decorative
paper. The press was closed with a surface pressure of 45 kg/m2 for 60 seconds
to
allow the dried PURchem Polyurethane Water-Based Dispersion polymer to melt
and
bond the loose assembly forming a resilient floor panel sample with a wood-
grain design
and corresponding surface texture with a cork core.
As the end of the cycle, the sample was removed from the press, allowed to
cool
and cut to the desired dimensions.
Example 5
Decorative papers printed with a woodgrain pattern with a weight of
approximately
65 g/m2 as normally used in the production of laminate flooring were cut to 20
x 30 cm
size. A laboratory roller impregnator that consisted of a metal tray under an
assembly
with two rollers was used. A pre-impregnation bath was prepared consisting of
100%
WB-90 PURchem Solution Polymer and poured into the tray. Each sheet was placed
in
the solution polymer and gently pulled between the rollers to remove any
excess. The
sheets were dried to remove excess moisture in an oven with a temperature of
90 C for
3 minutes.
16
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
A second bath was prepared consisting of 100% WB-100 PURchem Polyurethane
Water-Based Dispersion and poured into the tray. Each sheet was placed in the
solution
polymer and gently pulled between the rollers to remove any excess. The sheets
were
dried to remove excess moisture in an oven with a temperature of 900 C for 3
minutes.
The decorative papers were coated with 100% WB-110 PURchem Polyurethane
Water-based Dispersion resin with Internal Mold Release (IMR) + 10% of
Corundum
particles (AI203) with internal mold release. Each sheet was placed in the
solution and
gently pulled between the rollers to remove any excess. The sheets were dried
to
remove excess moisture in an oven with a temperature of 90 C for 3 minutes.
The dried
decorative sheets were set aside. Similar steps were used to produce seven
core paper
sheets made from saturating kraft paper with a weight of 125 g/m2. Each of the
sheets
had a film build of 150 g per m2.
Once the sheets were pre-impregnated and subsequently dried, the loose
assembly consisting of seven impregnated kraft paper sheets plus the
impregnated
decorative sheet was placed in 100 ton heated hydraulic with upper and lower
platens
having a surface temperature of 150 C. The press machine was equipped with a
chromium-plated steel press plate having a woodgrain texture installed on one
surface
designed to make impressions into the printed decorative paper. The press was
closed
with a surface pressure of 45 kg/m2 for 60 seconds to allow the dried PURchem
Polyurethane Water-Based Dispersion polymer to melt and bond the multiple
sheets
forming a resilient floor panel sample with a wood-grain design and
corresponding
surface texture.
As the end of the cycle, the sample was removed from the press, allowed to
cool
and cut to the desired dimensions.
The present invention is in no way limited to the forms of embodiment
described
as an example and represented in the figures. On the contrary, the present
invention,
including floor covering, and more particularly said panels, as well as the
methods
described herein, may be realized in different variants without leaving the
scope of the
invention. The technology described herein shall not be limited to floor
covering
products and therefore can be used in the production of floor or wall panels,
wallpapers,
doorskins, furniture panels and components, automotive components, consumer
goods,
electronics components, foot-ware, clothing, packaging products, etc.
17
CA 02785734 2012-06-27
WO 2011/082491 PCT/CA2011/000025
Thus, there has been provided, in accordance with the present invention, a
resilient flooring material, and a process for producing such a flooring
material, which
fully satisfies the goals, objects, and advantages set forth hereinbefore.
Therefore,
having described specific embodiments of the present invention, it will be
understood
that alternatives, modifications and variations thereof may be suggested to
those skilled
in the art, and that it is intended that the present specification embrace all
such
alternatives, modifications and variations as fall within the scope of the
appended claims.
Unless otherwise specifically noted, the features described herein may be
combined with
any of the above aspects, in any combination.
Additionally, for clarity and unless otherwise stated, the word "comprise" and
variations of the word such as "comprising" and "comprises", when used in the
description and claims of the present specification, is not intended to
exclude other
additives, components, integers or steps. Moreover, the words "substantially"
or
"essentially", when used with an adjective or adverb is intended to enhance
the scope of
the particular characteristic; e.g., substantially planar is intended to mean
planar, nearly
planar and/or exhibiting characteristics associated with a planar element.
Further, use of the terms "he", "him", or "his", is not intended to be
specifically
directed to persons of the masculine gender, and could easily be read as
"she", "her", or
"hers", respectively. Also, while this discussion has addressed prior art
known to the
inventor, it is not an admission that all art discussed is citable against the
present
application.
18
