Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
  • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
  • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
  • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B9/045—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N1/00—Linoleum, e.g. linoxyn, polymerised or oxidised resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
  • B32B2264/06—Vegetal particles
  • B32B2264/062—Cellulose particles, e.g. cotton
  • B32B2264/067—Wood particles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
  • B32B2264/10—Inorganic particles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/732—Dimensional properties
  • B32B2307/734—Dimensional stability
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2471/00—Floor coverings
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2201/00—Chemical constitution of the fibres, threads or yarns
  • D06N2201/02—Synthetic macromolecular fibres
  • D06N2201/0254—Polyolefin fibres
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2201/00—Chemical constitution of the fibres, threads or yarns
  • D06N2201/02—Synthetic macromolecular fibres
  • D06N2201/0263—Polyamide fibres
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2201/00—Chemical constitution of the fibres, threads or yarns
  • D06N2201/08—Inorganic fibres
  • D06N2201/082—Glass fibres
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2211/00—Specially adapted uses
  • D06N2211/06—Building materials
  • D06N2211/066—Floor coverings
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2211/00—Specially adapted uses
  • D06N2211/12—Decorative or sun protection articles

Definitions

• the present disclosure relates to surface coverings having improved dimensional stability and aesthetics.
• the present invention provides a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and a first inorganic filler; and a second linoleum composition adjacent to the first linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands; wherein the V max of the first linoleum composition is from about 300 cmm/s to about 1000 cmm/s; and wherein the V max of the second linoleum composition is less than 200 cmm/s.
• a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and from about 25 wt. % to about 35 wt. of a first inorganic filler; and a second linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands; and wherein the ratio of the first linoleum composition flow rate (V max ) to the second linoleum composition flow rate (V max ) is from about 8: 1 to about 15: 1.
• a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and a first inorganic filler; and a second linoleum composition adjacent to the first linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands comprising from about
• the first inorganic filler comprises particles having an average particle size of from about 0.5 ⁇ to about 20 ⁇ .
• the present invention provides methods of improving the aesthetics of a linoleum based surface covering.
• the term "show through” refers to the perceivability of a carrier, visually and/or tactilely, from the top surface of a surface covering.
• the present invention provides a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and a first inorganic filler; and a second linoleum composition adjacent to the first linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands; wherein the V max of the first linoleum composition is from about 300 cmm/s to about 1000 cmm/s; and wherein the V max of the second linoleum composition is less than 200 cmm/s.
• the surface coverings of the present invention comprise a linoleum core.
• the linoleum core comprises a first linoleum layer and a second linoleum layer.
• the first linoleum layer comprises a first linoleum composition.
• the second linoleum layer comprises a second linoleum composition.
• the first linoleum layer comprises a first linoleum composition; and the second linoleum layer comprises a second linoleum composition.
• a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and from about 25 wt. % to about 35 wt. of a first inorganic filler; and a second linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands; and wherein the ratio of the first linoleum composition flow rate (V max ) to the second linoleum composition flow rate (V max ) is from about 8: 1 to about 15: 1.
• a surface covering comprising: a carrier; a first linoleum composition adjacent to the carrier comprising: linoleum cement; a first organic filler; and a first inorganic filler; and a second linoleum composition adjacent to the first linoleum composition comprising: linoleum cement; a second organic filler; and a second inorganic filler; wherein the carrier comprises an intersecting grid of first strands and second strands comprising from about
• the first inorganic filler comprises particles having an average particle size of from about 0.5 ⁇ to about 20 ⁇ .
• the overall thickness of the surface covering may be varied, e.g. 2 mm being used for lighter wear applications and greater thicknesses such as 2.5 mm and 3.2 mm being used for more durable applications.
• the surface covering can have an overall thickness of from 1 mm to 6 mm; alternatively from 1.5 mm to 4 mm.
• the surface covering may be used as a linoleum floor covering and have a total thickness of about 1 mm to about 6 mm; alternatively from about 2 mm to about 4 mm.
• the carrier enhances mechanical integrity by acting as a backbone to the overall surface covering.
• the carrier may have a first side and a second side - the first side facing toward a subfloor and the second side facing towards a building space or room environment.
• the carrier may include a binder and a fibrous material.
• the fibrous material is woven or knitted.
• the binder may be present in an amount ranging from about 0 wt. % to about 40 wt. , based on the weight of the carrier. In other embodiments, the binder may be present in an amount ranging from about 1 wt. % to about 30 wt. % based on the weight of the carrier.
• the fibrous material may be selected from synthetic fiber, a cellulosic fiber, a natural fiber, a synthetic fabric, and a combination of two or more thereof.
• the synthetic fiber may be selected from a polyester (e.g. polyethylene terepthalate), a polyolefin (e.g. polypropylene), polytetrafluoroethylene, polyacrlyonitrile, a polyamide (e.g. nylon), polyacrylate, fiberglass, etc., and a combination of two or more thereof.
• the cellulosic fiber and natural fiber may be selected from cotton, jute, viscose, kraft paper, rayon, sisal, and a combination of two or more thereof.
• the carrier may comprise a material selected from: jute fabric; a mixed fabric of natural fibers; carbon fibers; aramid fibers; quartz fibers; alumina fibers; silicon carbide fibers; and a combination of two or more thereof.
• the binder may comprise a thermoplastic resin or a thermoset resin that is selected from, epoxies, polyurethanes, acrylic latex, phenolic resin, polyvinyl alcohol, carbohydrate polymers (i.e. starch), a cellulosic resin, a polyacrylamide, urea-formaldehyde, a melamine resin (e.g. melamine-formaldehyde, melamine-phenol-formaldehyde copolymer), an acrylic copolymer, styrene butadiene rubber, and a combination of two or more thereof.
• a thermoplastic resin or a thermoset resin that is selected from, epoxies, polyurethanes, acrylic latex, phenolic resin, polyvinyl alcohol, carbohydrate polymers (i.e. starch), a cellulosic resin, a polyacrylamide, urea-formaldehyde, a melamine resin (e.g. mel
• the binders may include one or more resins derived from the following monomers vinyl acetate, vinyl propionate, vinyl butyrate, vinyl chloride, vinylidine chloride, vinyl fluoride, vinylidene fluoride, ethyl acrylate, methyl acrylate, propyl acrylate, butyl acrylate, ethyl methacrylate, methyl methacrylate, butyl methacrylate, hydroxyethyl methylacrylate, styrene, butadiene, urethane, epoxy, melamine, and an ester.
• the carrier comprises polyethylene terephthalate. In some embodiments, the carrier comprises polyethylene terephthalate and fiberglass.
• the carrier is more or less an open structure and/or substantially porous material so as to facilitate penetration of the first linoleum composition through the carrier.
• the carrier may be provided with an adhesive coating
• the adhesive coating comprises a natural drying oil (e.g. linseed oil or soya oil) or a synthetic material (e.g. acrylic, styrene butadiene rubber or similar) in order to enhance bonding of the first linoleum composition to the carrier.
• a natural drying oil e.g. linseed oil or soya oil
• a synthetic material e.g. acrylic, styrene butadiene rubber or similar
• the carrier comprises a matrix.
• the matrix is comprised of first strands and second strands, wherein each of the first and second strands are made of a fibrous material.
• the first strands comprise a plurality of micro-strands that are oriented parallel to one another and face a first direction.
• the second strands comprise a plurality of micro-strands that are oriented parallel to one another and face a second direction.
• the first and the second direction may be offset by angle ranging from about 10° to about 90°. According to some embodiments, the angle offset between the first strands and the second strands create an intersecting grid of first stands and second stands.
• the carrier comprises first, second, third, fourth, fifth, sixth, etc., strands - each of which may be oriented by an offset angle.
• the first strands may be separated from one another by a first distance - i.e. "length.” In another embodiment, the second strands may be separated from one another by a second distance - i.e. "width.”
• the length may range from about 0.1 mm to about 5 mm. In some embodiments, the length may range from about 0.5 mm to about 2 mm. In some embodiments, the length may be about 1 mm. In some embodiments, the width may range from about 0.1 mm to about 5 mm. In some embodiments, the width may range from about 0.5 mm to about 2 mm. In some embodiments, the width may be about 1 mm.
• the space between adjacent first strands and space between adjacent second strands creates voids in the carrier.
• the dimensions of each void are directly related to the length and width between respective first and second adjacent strands, as well as the offset angle of intersecting first and second strands.
• the first strands are separated by a length of about 1 mm
• the second strands are separated by a width of about 1 mm
• the first and second strands have an offset angle of about 90° - thereby resulting in substantially square voids having a length and a width of about 1 mm.
• the voids may be a variety of shapes, including triangular, rectangular, rhombus, trapezoidal, and polygonal, depending on the offset angle, the length, and the width.
• the offset angle, width, and length may be selected such that the resulting carrier comprises greater than about 10 voids/cm , across the surface of the carrier. In some embodiments, the offset angle, width, and length may be selected such that the resulting carrier comprises less than about 100 voids/cm , across the surface of the carrier. In some embodiments, the offset angle, width, and length may be selected such that the resulting carrier comprises from about 10 voids/cm 2 to about 100 voids/cm 2 across the surface of the carrier. In some embodiments, the offset angle, width, and length may be selected such that the resulting carrier comprises from about 15 voids/cm 2 to about 50 voids/cm 2 across the surface of the carrier.
• the offset angle, width, and length may be selected such that the resulting carrier comprises from about 20 voids/cm 2 to about 30 voids/cm 2 across the surface of the carrier. In some embodiments, the offset angle, width, and length are selected such that the resulting carrier comprises about 25 voids/cm across the surface of the carrier.
• the first and second strands may be oriented so that the voids extend all the way through the body of the carrier - i.e. from the first side of the carrier to the second side of the carrier. In other embodiments, the first and second strands may be oriented so that the voids only extend into the interior of the carrier from the first side or the second side. In some embodiments, the voids have a depth ranging from about 0.1 mm to about 0.5 mm; alternatively a depth of about 0.25 mm - when measured from the first or second side of the carrier into the body of the carrier.
• the first linoleum composition comprises: linoleum cement, a first organic filler, and a first inorganic filler.
• the first linoleum composition has a viscosity that is less than the viscosity of the second linoleum composition when measured under the same testing conditions (e.g. temperature).
• the viscosity of the first and second linoleum compositions is measured by flow rate.
• flow rate is represented by V max .
• the first linoleum composition has a flow rate (V max ) that is greater than the flow rate of the second linoleum composition when both flow rates are measured under the same testing conditions (e.g. temperature, pressure).
• V max flow rate
• the V max values reported herein represent the flow rates for the first and second linoleum compositions prior to calendaring, i.e. as a fresh mixmass after 30 minutes settling time.
• V max is measured using a Rubber Capillary Rheometer (Goettfert model RCR).
• the temperature of the RCR cylinder is about 90 °C.
• the pressure in the RCR cylinder is about 160 bar, and the cylinder nozzle has a diameter of about 1.6 mm.
• the first linoleum composition comprises a first linoleum layer.
• the thickness of the first linoleum layer may be varied and ranges from about 0.1 mm to about 5 mm; alternatively about 0.2 mm to about 4 mm; alternatively from about 0.5 mm to about 3 mm; about 0.75 mm to about 2 mm; alternatively about 1 mm.
• the first linoleum composition comprises: linoleum cement, a first organic filler, and a first inorganic filler. In some embodiments, the first linoleum composition comprises from about 30 wt. % to about 45 wt. % of linoleum cement, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 40 wt. % of linoleum cement, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 41 wt. % of linoleum cement, based on the total weight of the first linoleum composition.
• the linoleum cement acts as a binder and comprises a drying oil and a resin, such as rosin, to act as a tackifier.
• the drying oil comprises a fully or partially esterified fatty acid.
• the drying oil comprises a polyunsaturated oil.
• the drying oil comprises a dimer, a trimer or an oligomer obtained by reacting di, tri, and tetra-functional polyol compounds - such as glycerol or polyethylene glycol - with fatty acid compounds - such as palmitic acid, stearic acid, oleic acid, linoleic acid, pinolenic acid.
• these drying oils include linseed oil, tall oil, soya oil, palm oil, castor oil, tung oil, olive oil, corn oil, canola oil, sunflower oil, peanut oil, camelina oil, lesquerella oil, vernonia oil, cardanol oil, coconut oil, karanja oil, jatropha oil, and a combination of two or more thereof.
• the drying oil can be oxidized by atmospheric oxygen to form a dry solid.
• the drying oil comprises linseed oil.
• linseed oil is capable of drying faster than other oils.
• the resin may be selected from gums and rosin.
• the linoleum cement may comprise from about 15 wt. % to about 35 wt. % of a resin based on the total weight of the total weight of the linoleum cement.
• the first linoleum composition comprises from about 20 wt. % to about 40 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 20 wt. % to about 35 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 25 wt. % to about 35 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition.
• the first linoleum composition comprises from about 25 wt. % to about 30 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises about 28 wt. % of a first inorganic filler, based on the total weight of the first linoleum composition.
• the first inorganic filler comprises particles having an average particle size of from about 0.5 ⁇ to about 20 ⁇ . Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 1 ⁇ to about 10 ⁇ . Some embodiments provide that the first inorganic filler comprises particles having an average particle size of from about 1 ⁇ to about 5 ⁇ . In some embodiments, the particle size of the inorganic filler is selected to ensure a particular flow rate (e.g. V max ).
• the first and/or second inorganic filler may comprise limestone (calcium carbonate), kaolin clay, silica, vermiculite, ball clay or bentonite, talc, mica, gypsum, perlite, titanium dioxide, sand, barium sulfate, dolomite, wollastonite, calcite, pigments, zinc sulfate, or a combination of two or more thereof.
• limestone calcium carbonate
• kaolin clay silica
• vermiculite vermiculite
• ball clay or bentonite talc
• mica gypsum
• perlite titanium dioxide
• sand barium sulfate
• dolomite dolomite
• wollastonite wollastonite
• calcite pigments
• pigments zinc sulfate
• the first linoleum composition comprises from about 15 wt. % to about 30 wt. % of a first organic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises from about 18 wt. % to about 23 wt. % of the first organic filler, based on the total weight of the first linoleum composition. In some embodiments, the first linoleum composition comprises about 22 wt. % of the first organic filler, based on the total weight of the first linoleum composition.
• the first and/or second organic filler comprises a cellulosic, a polymeric material, a non-polymeric material, or a combination of two or more thereof.
• the first and/or second organic filler may be a fibrous material or a particulate material.
• the first and/or second organic filler comprises a cellulosic material selected from wood fibers, cork, wood shavings, wood flour, paper fibers, cotton linters, a combination of two or more thereof.
• the wood flour may be made from a hardwood or a softwood.
• the wood flour comprises particles having a particle size distribution as follows: ⁇ 160 ⁇ : 40-90%, and ⁇ 80 ⁇ 10-50%.
• the wood flour comprises particles having a particle size distribution as follows: ⁇ 160 ⁇ 50 - 85%; and ⁇ 80 ⁇ 10-30%.
• the polymeric material may include polyolefin, and the non- polymeric material may include a hydrophobic material.
• the hydrophobic material has a melting point below 100° C.
• the non-polymeric material is selected from Montan wax; Carnauba wax; bee wax; paraffin; and a combination of two or more thereof.
• the non-polymeric material may be present in an amount ranging from about 0.1 wt. % to about 1 wt. % based on the total weight of the first and/or second linoleum composition. In some embodiments, the non-polymeric material may be present in an amount ranging from about 0.1 wt. % to about 0.6 wt. % based on the total weight of the first and/or second linoleum composition.
• the first and/or second linoleum composition may further comprise a flame retardant, such as aluminum trihydrate, ammonium phosphate or dipentaerythritol; a flame retardants which form a barrier layer, such as borates and aluminum polyphosphates; a solid inorganic flame retardant, and a flame retardant which forms an insulating layer; an intumescence agent, or a combination of two or more thereof.
• halogenated organic compounds such as chlorinated paraffin, or halogenated organic phosphorus compounds may be used as an additional flame retardant.
• solid inorganic flame retardants are understood to include, for example, inorganic compounds, such as aluminum oxide hydrates, borates, e.g., zinc borates, ammonium phosphate, antimony oxides, aluminum hydroxides, preferably aluminum trihydroxide, and magnesium hydroxide, aluminum hydroxide and magnesium hydroxide also being referred to as water-releasing flame retardants.
• inorganic compounds such as aluminum oxide hydrates, borates, e.g., zinc borates, ammonium phosphate, antimony oxides, aluminum hydroxides, preferably aluminum trihydroxide, and magnesium hydroxide, aluminum hydroxide and magnesium hydroxide also being referred to as water-releasing flame retardants.
• the first and/or second linoleum composition further comprises a dispersant, a flocculant, a defoaming agent, a fungicide, a biocide, or a combination thereof.
• the first and/or second linoleum composition further comprises a metal oxide, a metal hydroxide, or a combination thereof.
• the metal oxide comprises zinc oxide.
• the second linoleum composition comprises linoleum cement, a second organic filler, and a second inorganic filler.
• the second linoleum composition has a viscosity that is greater than the viscosity of the first linoleum composition when measured under the same testing conditions (e.g. temperature).
• the V max of the first linoleum composition is from about 300 cmm/s to about 1000 cmm/s. In some embodiments, the V max of the first linoleum composition is from about 500 cmm/s to about 900 cmm/s.
• the V max of the first linoleum composition is from about 600 cmm/s to about 800 cmm/s. In some embodiments, the V max of the first linoleum composition is from about 650 cmm/s to about 750 cmm/s. In some embodiments, the V max of the first linoleum composition is about 730 cmm/s.
• the V max of the second linoleum composition is from about 30 cmm/s to about 200 cmm/s. In other embodiments, the V max of the second linoleum composition is from about 40 cmm/s to about 100 cmm/s. In further embodiments, the V max of the second linoleum composition is from about 50 cmm/s to about 100 cmm/s. In some embodiments, the V max of the second linoleum composition is less than about 200 cmm/s. In some embodiments, the V max of the second linoleum composition is less than about 100 cmm/s.
• the V max of the second linoleum composition is from about 10 cmm/s to about 100 cmm/s. In some embodiments, the V max of the second linoleum composition is less than about 75 cmm/s. In some embodiments, the V max of the second linoleum composition is about 60 cmm/s.
• the ratio of the first linoleum composition flow rate (V max ) to the second linoleum composition flow rate (V max ) is from about 5: 1 to about 20: 1. In some embodiments, the ratio of the first linoleum composition flow rate (V max ) to the second linoleum composition flow rate (V max ) is from about 5: 1 to about 15: 1. In some embodiments, the ratio of the first linoleum composition flow rate (V max ) to the second linoleum composition flow rate (V max ) is from about 8: 1 to about 15: 1.
• the ratio of the first linoleum composition flow rate (V max ) to the second linoleum composition flow rate (V max ) is from about 8: 1 to about 12: 1. In some embodiments, the ratio of the first linoleum composition flow rate (V max ) to the second linoleum composition flow rate (V max ) is about 12: 1.
• the first linoleum composition forms a first linoleum layer.
• the first linoleum layer has a thickness of from about 0.5 mm to about 5 mm; alternatively from about 0.75 mm to about 3 mm; alternatively from about 0.9 mm to about 1.1 mm.
• the second linoleum composition forms a second linoleum layer.
• the second linoleum layer has a thickness of from about 0.5 mm to about 5 mm; alternatively from about 0.75 mm to about 3 mm; alternatively from about 1 mm to about 1.5 mm; alternatively from about 1.1 mm to about 1.4 mm.
• the second linoleum composition comprises from about 17.5 wt. % to about 70 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 25 wt. % to about 45 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 30 wt. % to about 40 wt. % of linoleum cement, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 36 wt. % of linoleum cement, based on the total weight of the second linoleum composition.
• the second linoleum composition comprises from about 10 wt. % to about 20 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 12 wt. % to about 18 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 14 wt. % of the second inorganic filler, based on the total weight of the second linoleum composition.
• the second linoleum composition comprises from about 30 wt. % to about 45 wt. % of a second organic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 36 wt. % to about 41 wt. % of the second organic filler, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 39 wt. % of the second organic filler, based on the total weight of the second linoleum composition.
• the second linoleum composition comprises from about 30 wt. % to about 45 wt. % of wood flour, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises from about 36 wt. % to about 41 wt. % of wood flour, based on the total weight of the second linoleum composition. In some embodiments, the second linoleum composition comprises about 39 wt. % of wood flour, based on the total weight of the second linoleum composition. [0053] Previous attempts to manufacture flooring surfaces comprising linoleum cement and filler have been problematic in that the flooring surfaces exhibit unacceptable aesthetics. It has been discovered that positioning a first linoleum composition adjacent to a carrier, wherein the first linoleum composition has a low viscosity and high flow rate results in a surface covering that exhibits superior aesthetics.
• the use of a first linoleum composition that has low viscosity / high flow rate allows the first linoleum composition to better penetrate the voids present in the carrier.
• the penetration is sufficient for the carrier to be embedded in the first linoleum composition.
• greater penetration increases the amount of surface contact between the first linoleum composition and the carrier. While choosing not to be bound by theory, the present inventors believe that increased surface contact enhances the mechanical adhesion and leveling between the first linoleum composition and the carrier and decreases the amount of "show-through" on the surface covering.
• the overall volume of the carrier is V T , as measured by the surface area of the first side or the second side of the carrier and multiplied by the distance that spans from the first side to the second side through the carrier.
• V T includes the volume occupied by both strands and voids.
• the volume of the strands Vs is the volume occupied by the strands within the carrier, as calculated by measuring the weight of strands used in a single carrier and dividing it by the density of the strand.
• the volume of the voids Vy may be calculated by the following equation:
• greater than 50 % of the voids in the carrier are saturated with the first linoleum composition. In other embodiments, greater than 55 % of the voids in the carrier are saturated with the first linoleum composition. In further embodiments, greater than 60 % of the voids in the carrier are saturated with the first linoleum composition. In still further embodiments, greater than 65 % of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 70 % of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 75 % of the voids in the carrier are saturated with the first linoleum composition.
• greater than 80 % of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 85 % of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 90 % of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 95 % of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 97.5 % of the voids in the carrier are saturated with the first linoleum composition. In some embodiments, greater than 99 % of the voids in the carrier are saturated with the first linoleum composition.
• the surface covering may further comprise a coating.
• the coating is applied to the second linoleum composition.
• the coating may perform as a wear layer.
• the coating is UV curable, moisture curable or thermally curable.
• the coating may be transparent and cured by UV radiation.
• the coating provides good scratch and abrasion resistance and is sufficiently transparent to allow a print design to be visible from and through the topside of the product.
• the coating comprises a UV curable polyurethane.
• the coating comprises a moisture curable polyurethane.
• the coating comprises an acrylate.
• the coating comprises a polyurethane and an acrylate.
• the coating may comprise particles that enhance dimensional stability and/or scratch resistance.
• the particles are selected from chalk, barium sulfate, slate powder, silica, kaolin, quartz powder, talc, lignin, powdered glass, aluminum oxide, and glass fibers.
• the coating may have a thickness of from about 0.001 mm to 1 mm. In some embodiments, the coating may have a thickness of from about 0.005 mm to 0.5 mm. In some embodiments, the coating may have a thickness of from about 0.0075 mm to about 0.25 mm. In some embodiments, the coating may have a thickness of about 0.01 mm.
• the surface covering of the present invention may be made according to the following process.
• the first linoleum composition is produced by mixing the all components, such as the first linoleum cement, the first organic filler, and the first inorganic filler in a suitable mixing apparatus - e.g. a kneader, roll mill, or extruder, to form as homogenous a matrix as possible (mixed mass).
• a suitable mixing apparatus e.g. a kneader, roll mill, or extruder
• the first linoleum composition may further contain conventional additives, such as processing aids, antioxidants, UV stabilizers, slip agents and the like, which are selected as a function of the binder.
• the homogenous matrix of the first linoleum composition is then fed into a roll mill (e.g., a calendar) and pressed onto a carrier typically at a temperature of typically 10° C to 150° C.
• the roll mill may be adjusted such that the resulting first linoleum composition / carrier combination has the desired layer thickness.
• the second linoleum composition is produced separately and rolled into sheets and granulated.
• the granulates are then mixed together and fed into the roll mill (e.g. a calendar) to produce a linoleum sheet of the second linoleum composition.
• the second linoleum sheet can then be pressed either directly onto the carrier / first linoleum composition or rolled onto the carrier / first linoleum composition through a roll mill.
• Table 1 Described in Table 1 (below) are the compositions and flow rates of exemplary surface coverings of the present invention, along with the compositions and flow rates of comparative surface coverings.
• Table 2 (below) describes a comparison of the flow rates of the surface coverings described in Table 1 (above), and their respective abilities to prevent carrier show through. The show through results are based on visual inspection of the surface coverings from the exposed surface of the second linoleum layer.

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• Textile Engineering (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Compositions Of Macromolecular Compounds (AREA)

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• 2015
  • 2015-05-17 US US14/714,319 patent/US20160102428A1/en not_active Abandoned
  • 2015-05-17 CN CN201580057755.8A patent/CN107107552A/zh active Pending
  • 2015-05-17 WO PCT/US2015/031282 patent/WO2016057080A1/en not_active Ceased
  • 2015-05-17 EP EP15726827.7A patent/EP3204228A1/de not_active Withdrawn
  • 2015-05-17 AU AU2015328712A patent/AU2015328712A1/en not_active Abandoned

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