SE433726B - FLOOR OR WALL COVERING WITH PROFILED SURFACE AND COVERING A FOAMED POLYMER LAYER AND PROTECTIVE LAYER - Google Patents

Description

771-0991--6 uniform layer of foamable material on a substrate and then foamed, generally after application of the wear-resistant layer, and then pattern pressed mechanically to give the desired profiled effect. Such a process is described in U.S. Pat. No. 3,741,851.

The second method of making resilient (cushionei floor or wall coverings having a profiled surface has been used more widely commercially and comprises depositing a layer of a foamable material capable of foaming to a surface level in first areas above the level in the remainder of the other surface areas, on a substrate and providing such foaming, usually after application of the protective layer.On one of these methods, foamable composition is applied to the substrate so that different areas of the substrate carry different amounts of the same composition (e.g. by spreading on a profiled substrate or by printing) or the same or different amounts of different compositions, for example compositions containing different amounts of blowing agents, such methods are described, for example, in U.S. Pat. Nos. 2,920,977 and 3,239,365 and British Pat. Nos. 968,991 and 1,409,295. In the second main method of implementing this method, e A substantially uniform layer of foamable composition and chemical agent is provided only in selected areas, for example by pressing below it, over it or over a wear-resistant layer above it, which will cause preferential foaming in different areas. An inhibitor of the blowing agent can thus be applied in some areas to cause less foaming in these areas than in others. Such methods are described, for example, in British Pat. Nos. 1,069,998 and 1,150,902.

There has been a production on a very large scale of profiled resilient wall and floor coverings and this has been followed by the production of patterns of ever-increasing richness of detail and complexity. For example, it is now common to perform, for example, six different printing processes over the foamable layer before the transparent wear layer is applied and sometimes to also rely on pattern properties in the foamable layer itself. This increasing complexity of patterns creates significant difficulties and expenses in carrying out the actual printing and there is thus in practice an urgent need to develop some new auAuTv in 7710991 * and simple ways to improve the decorative attraction of profiled resilient wall - or floor coverings.

It is well accepted that for good wear resistance and cleaning properties, it is essential to provide a protective layer such as the top surface of floor or wall coverings. For example, British Pat. No. 968,991 and U.S. Pat. No. 3,239,365 disclose that a colored material is printed on a substantially uniform top layer of a foamable composition, but the process described therein is found to be capable of: limited range of patterns both of color and profiled effect and turns out not to have been commercially successful. What has been commercially successful are processes in which a single color-protective coating, generally a clear transparent coating, is usually applied over the entire surface of the coating but sometimes over only the raised areas of the coating. This protective layer has thus not contributed to the decorative effect. British Patent Specification 1,069,998 describes such a process in which paints containing chemical reagents are printed over the protective layer. Inhibitor-like inks are usually printed in only small amounts and it is found that such deposits do not form part of the protective layer: In any case, as shown in Fig. 9 of the said patent, they are printed in areas to be immersed while not are fall: on the raised surfaces of the profiled floor or wall covering that is to support the wear.

A floor or wall covering according to the present invention comprises a foamed polymer layer comprising raised areas separated by submerged areas and a main protective layer covering at least the raised areas and comprising first and second non-foamed layers of which at least one is discontinuous and which each one is at least 0.05 mm thick. and which are of different color and / or opacity and in which at least parts of both the first and second non-foamed layers are visible.

Thus, in the present invention, the decorative effect of the coating is increased by utilizing the protective layer which must be present in each case over at least the raised areas. This protective layer is at least 0.05 mm thick and in any parts where the first and second non-foamed layers lie on top of each other, it will be at least 0.1 mm thick.

The first layer is usually a total layer but if desired both can. the first and second layers may be discontinuous in which case they may be in adjacent conditions or may overlap or the second layer may be completely over the first layer.

Each of the first and second layers of the main protective coating will be composed of such materials that they serve as wear resistance layers. They will have sufficient strength to provide good abrasion and wear resistance and cleaning properties.

The main protective layer usually covers the entire surface of the sheet or web material, but in some cases it does not have to cover all the immersed areas. For example, if the profiled pattern comprises some relatively small submerged areas, it need not carry a protective layer in these parts and in some cases some or all of the submerged areas may be covered only by a thin protective layer which may not contribute to the decorative effect. A thin protective layer, for example 0.01 - 0.04 mm thick, can thus only be deposited in these immersed areas or can be applied over a total layer, for example over the main protective layer and the immersed areas or under the main protective layer and over the immersed areas. . This thin protective layer can be applied mainly for visual effects and for improving cleaning properties. It is preferably made of polyurethane.

The main protective layer may consist only of the specified first and second layers or they may comprise one or more additional layers, always provided that such additional layers do not completely obscure the distinguishing color or the opacity effect. Thus, if these additional layers are continuous, they will be below the first layer, but if they are discontinuous, they may be over some of the parts of the first layer that are not covered by the second layer or they may be over a part of the second layer. , or both. Any additional layer may be composed of polymeric materials which are the same: as, or different from, the primary and / or other polymeric materials, for example, it may serve to give a profiled effect 7710991-6 or to give a different color or to give a different gloss or any combination thereof as described in our co-pending British patent applications 40930/76 and 40932/76.

Normally the first and second layers are each 0.05 to 0.77 mm thick and give a total thickness of the main protective layer of 0.1 to 0.8 mm. For example, the first layer may be 0.1 to 0.7 mm and the second layer 0.05 to 0.15 mm thick when it is over the first layer or thicker (for example 0.1 to 0.3 mm) when present. in adjacent connection with the first layer.

Any additional layers may suitably be from 0.02 to 0.35 mm and preferably from 0.05 to 0.25 mm thick.

Particularly preferred products of the present invention are obtained when a decorative pattern is printed between the foamed layer and the main protective layer and at least one of the first and second non-foamed layers is transparent, so that at least parts of the pattern are visible. One of the layers is preferably a continuous transparent layer and the other is a discontinuous colored layer § The continuous transparent layer may be below or above the discontinuous colored layer or layers. It is often preferred that the decorative pattern be applied to only parts of the foamed layer and that one of the first and second non-foamed layers be a discontinuously colored layer applied in a pattern corresponding to areas of the coating which do not bear said decorative pattern. .

The first and second, and any other, layers of the protective layer will be composed of vinyl polymer, usually P V C, or polyurethane or other suitable polymer.

Any polyurethane used is preferably curable by UV radiation, so that the coated product can be rapidly cured by radiation.

A floor or wall covering according to the invention can be produced by depositing a layer of foamable material, if desired printing a decorative pattern over this layer, depositing said first layer over it, printing the second layer, wherein said first and second layers are of non-foamable material, and then foaming of the foamable material and producing the profiled effect. Although the production of the profiled effect can be achieved by pattern pressing the product after foaming, for example as described in U.S. Pat. No. 3,741,851, it is usually preferred to achieve this profiled effect during foaming. Thus, the foamable layer is prepared from different amounts of the same composition or the same or different amounts of different compositions or the foamable layer may be a uniform layer in which in only selected areas a chemical agent is incorporated which will selectively control the foaming. in different areas, all in accordance with what was described above.

The foamable polymer is generally of P V C or other vinyl polymer. A combination of these methods for obtaining a profiled effect can be used as described in our co-pending British patent application 40928 / 76Å, although some decorative patterns may be produced during the deposition of the foamable layer by printing differently. colored foamable plastic inserts for making the foamable layer are at least a portion, and usually the whole, of the decorative pattern visible through the wear layer produced by printing; of non-foamable paints above the foamable layer and below the wear layer. These inks can be printed directly on the foamable layer or over a total non-foamable layer spread over the foamable layer E 'to provide a smoother base and / or better color for printing. Continuous layers in the protective layer can be applied, for example, by opposing roll or knife roll coating methods or by printing, while discontinuous layers are applied by printing. . In a preferred process, a total foamable layer is applied, paints are applied by rotogravure or rotary screen printing, the foamable layer and / or at least one of the paint compositions containing a foam modifying ingredient; the first layer is then applied, usually by rotary screen printing through an open mesh, the second layer is then applied by rotary screen printing, each other layer is applied if desired and the product is then heated for foaming and curing. In another preferred method, the foamable layer is produced by rotary screen printing by one or more foamable compositions and the pattern and every second layer, and usually also the first layer and every third layer, is also produced by rotary screen printing and the product. then heated for foaming and curing.

It is normally preferred that the areas with different color and / or opacity should be exactly in accordance with the areas with different surface levels. Thus, in the preferred embodiment, the first layer material is exposed in the first regions of the foamable layer while the second layer material is exposed only in other regions, or vice versa. Thus, in typical cases, materials having a color and / or opacity cover the raised areas and materials with a different color and / or opacity cover the sunken areas. This can be achieved by printing the other layers in accordance with the foamable pattern.

The first layer must be transparent for the pattern to be visible through it. Every second layer must also be transparent, in which case it must have such a color that it gives the wear layer a color difference from that of the first layer. Thus, if a second layer is colorless and is only printed over a colored first layer, it will be ineffective, but if it is printed directly on the decorative pattern, it will be effective. Usually the first layer is colorless and at least one of the other layers is colored.

It is often preferred that the second layer be more opaque than the first layer. It can be purely translucent or it can be opaque, so that it obscures every pattern underneath. The other layers may be printed in two or more processes of two or more different materials, so as to provide a pattern of areas of different color and / or opacity.

The polymeric material printed to produce the first and second layers may be formulated to provide the desired color and opacity using conventional polymers, dyes, pigments, etc.

The foamable layer is prepared on a substrate which can be removed afterwards, but usually the substrate forms part of the final product. Substrates suitable for known resilient wall or floor coverings may be used and may be made of asbestos, fiberglass or cellulosic material. Although the foamed layer may be a continuous layer 771-0991 ~ 6 so that there is foamed material over the entire substrate, particularly advantageous results are sometimes obtained if it is a discontinuous layer. In particular, the foamed layer may be discontinuous and applied over a visible decorative layer and this decorative layer may then serve as part of the protective layer or it may be visible through the protective layer.

The substrate may comprise a layer of fibrous material, as discussed above, which may optionally have a coating of a solid or foamed plastic material or may consist of a solid plastic material. If the substrate comprises a layer of solid plastic material, then this layer can serve as the decorative plastic layer. However, the decorative plastic layer is usually deposited on a substrate which preferably, at the time of deposition, carries a layer of foamable plastic material. The decorative plastic layer can be deposited as a single layer, but normally it is deposited in two or more layers, for example by printing a decorative pattern and then covering it with a transparent wear-resistant layer through which the pattern can be seen. The decorative plastic layer usually comprises a surface V which will serve as a wear layer.

The decorative plastic layer may be a continuous layer or it may be a discontinuous layer, the areas of foamed layer extending beyond at least partially being in the areas where there is no decorative solid layer.

It is usually preferred that the decorative plastic layer should comprise a continuous wear-resistant layer and below this a continuous or discontinuous decoration pattern.

A discontinuous layer of foamable polymeric material is then printed over the decorative plastic layer, leaving at least parts of the decorative plastic layer visible.

The accompanying drawing schematically illustrates the preferred products according to the invention. The product shown in Fig. 1 comprises a fibrous substrate 1 carrying a layer 2 of foamed plastic material which in turn carries a continuous decorative coating of solid plastic material 3. over this is foamed plastic material 4. If desired, the layer 3 can be a discontinuous coating present only in the areas not covered by the material 4. Decorative paints, not shown, are printed on them, which have been applied before foaming. over 77IÛ991-6 these cover a first non-foamed layer 5 which is more than 0.05 mm thick the whole surface area and a second, differently colored, non-foamed layer 6, which is also at least 0.05 mm thick, covers a part of the elevated areas.

In one example, the layer 3 can be provided by applying to a 0.25 mm thick layer of foamable plastisol a total coating of a paint containing gold-colored metal particles. Foamable compositions for making the foamed product 4 are then pressed onto it and the wear layers are applied to the top and the product is heated to effect foaming and to cure the product.

While the presence of deposits 4 in the product of Fig. 1 leads to differences in thickness, similar differences have been obtained in the product of Fig. 2 by a chemical process. Thus, a layer of foamable plastisol was spread on the substrate, printed with ink containing a foaming inhibitor or activator and optionally also inert, decorative inks (not shown), a protective layer was applied and the product was foamed and cured. In the product shown, the main ash layer 3 comprises non-foaming layers 5 and 6, but there is also a protective layer 7, the layers 5, 6 and 7 all being printed on the foamable layer 2 before foaming. The layer 5 is printed on the entire surface area with the exception of the immersed areas, while a differently colored layer 6 is printed only on parts of the raised areas. Both layers 5 and 6 are more than 0.05 mm thick.

In the areas that are immersed (for example where foaming inhibitor paints have been printed) a layer 7, which is 0.01 to 0.04 mm thick of polyurethane varnish, has been applied. Alternatively, the layer 7 may cover the entire surface area with the layers 5 and 6 applied over parts thereof.

Layer 5 may be colorless. Instead of, or in addition to being different colored, layers 5 and 6 may have different opacity. Layer 5 may, for example, be colorless and clear while layer 6 may be opaque and colored, for example having a pigment dispersed therein.

A general method of carrying out the invention will now be described.

An ash felt is coated with a layer of polyvinyl chloride composition containing blowing agents which will expand the layer upon melting. This coated substrate is printed with several different colors by means of a rotary screen printing process, one of the colors containing a blowing agent inhibitor for the expansion process. At the penultimate station of the rotary screen printing machine, a continuous application of a colorless, transparent, plastisol P V C - wear layer with a thickness of 0.15 mm is applied which is so composed that, when melted, it produces a transparent glossy film. At the final printing station, another plastisol P V C wear layer is printed, which is so composed that upon melting a 0.075 mm thick colored film is obtained, so that it coincides with the areas which have not been printed with ink containing inhibitor.

When the printed and wear layered material is heated to melting and foaming expansion temperature, the resulting product is a textured, resilient, patterned material in which the sunken areas of the textured pattern show the true color of the printed colors and the raised colors. the threads have a consistent hue.

The substrate usually has a weight of 150 - 1000 g / m2, preferably 200 - 700 g / m2 of fibers and binder, the binder often constituting from 10 to 50% of the total weight. The substrate may have a full coating of plastic material over it but usually the total weight of substrate, including each such plastic coating, is less than 2,000 g / m 2 and the thickness is usually less than 1.2 nm. Normally the thickness is at least 0.3 mm, where 0, 5 - 1 mm is usually preferred. Greater weight and thickness are preferred when the substrate is to be used for a floor covering than when it is to be used for wall covering. The total amount of foamable plastisol is generally 200 - 800 g / m2, preferably 300 - 500 g / m2, if the material is to be used as a floor covering, but can be 50 '300 Q / m2 if the material is to be used as a wall covering. If the material is to be used as a wall covering, it may then be satisfactory for the protective layer to be a varnish with a thickness of 0.01 - 0.04 mm at least in the valleys, but for floor coverings it is preferred that the protective layer should be at least 0.05 mm thick over the entire surface area.

Claims (7)

7710991-6 PATENT REQUIREMENTS Floor or wall covering, characterized in that it comprises a foamed polymer layer comprising raised areas separated by submerged areas and a main protective layer which at least covers the raised areas and which comprises first and second non-foamed layers of which at least one is discontinuous life: and each of which is at least 0.05 mm thick and which has a different color and / or opacity and in which at least parts of both the first and second non-foamed layers are visible. Coating according to claim 1, characterized in that one of the non-foamed layers constitutes a continuous transparent layer and the other constitutes a discontinuously colored layer. Coating according to Claim 1 or 2, characterized in that all parts of the coating other than the main protective layer carry a protective layer which is up to 0.04 mm thick. Coating according to one of the preceding claims. characterized in that the entire surface of the coating carries an outer, transparent protective layer up to 0.04 mm thick. Coating according to any one of the preceding claims, characterized in that the foamed polymer layer is a layer obtained by printing different foamable compositions or different amounts of foamable composition or by selectively controlling foaming of areas of a foamable composition, and foaming of the resulting layer. Coating according to claim 5, characterized in that the foamed layer is discontinuous and is present over a visible decorative layer which serves as part of the protective layer or is visible through the protective layer. Coating according to any one of claims 1 to 5, characterized in that it comprises a decorative pattern printed between the foamed layer and the main protective layer and wherein at least one of the first and second non-foamed layers is transparent and at least parts of the pattern are visible.