Surface covering and method for the manufacture thereof

Patent metadata

Field	Value
Publication number	US-12330188-B2
Application number	US-202117795138-A
Country	US
Kind code	B2
Filing date	Jan 29, 2021
Priority date	Jan 31, 2020
Publication date	Jun 17, 2025
Grant date	Jun 17, 2025

Abstract

Disclosed is a surface covering including: a wood-based substrate; a surface coating layer, the surface coating layer being obtained by the irradiation of a radiation-curable coating agent with UV light having a wavelength included from 120 nm to 230 nm; and a filler coating layer, the filler coating layer being located between the wood-based substrate and the surface coating layer. Also disclosed is a method for the manufacture of such a surface covering.

First claim

The invention claimed is:

1. A surface covering comprising:
a wood-based substrate comprising a bottom layer, a core layer and an upper layer applied on the core layer, the upper layer being made of wood or derived from wood,
a surface coating layer, said surface coating layer being obtained by the irradiation of a radiation-curable coating agent with UV light having a wavelength comprised from 120 nm to 230 nm, followed by the curing of said coating by irradiation with UV light having a wavelength comprised from 280 nm to 420 nm, and
a filler coating layer, said filler coating layer being located between the wood-based substrate and the surface coating layer,
wherein said filler coating layer is obtained by actinic radiation of oligomers and/or polymers selected from the group consisting of (meth)acrylate copolymers, polyether (meth)acrylates, polyester (meth)acrylates, epoxy (meth)acrylates, urethane (meth)acrylates, amino (meth)acrylates, melamine (meth)acrylates, silicone (meth)acrylates and phosphazene (meth)acrylates and has a thickness from 5 μm to 40 μm.

2. The surface covering of claim 1 , wherein the radiation-curable coating agent contains at least one radiation-curable binder and at least one photoinitiator.

3. The surface covering of claim 2 , wherein the radiation-curable binder derives from the oligomers and/or polymers selected from the group consisting of: (meth)acrylate copolymers, polyether (meth)acrylates, polyester (meth)acrylates, epoxy (meth)acrylates, urethane (meth)acrylates, amino (meth)acrylates, melamine (meth)acrylates, silicone (meth)acrylates, and phosphazene (meth)acrylates.

4. The surface covering of claim 1 , wherein the radiation-curable coating agent further contains at least one further ingredient, selected from the group consisting of: reactive thinners to reduce the viscosity, additives, light stabilisers, stabilisers, pigments, fillers, solvents, matting agents, and mixtures thereof.

5. The surface covering of claim 1 , wherein a primer coating layer is located between the wood-based substrate and the filler coating layer.

6. The surface covering of claim 5 , wherein the primer coating layer is obtained by actinic radiation.

7. The surface covering of claim 1 , wherein at least one sealer layer is located between the filler coating layer and the surface coating layer.

8. A method for the manufacture of a surface covering of claim 1 , comprising the following steps:
obtaining a wood-based substrate having at least a wood-based upper layer made of wood or derived from wood, the wood-based substrate comprising a bottom layer, a core layer and an upper layer applied on the core layer, the upper layer being made of wood or derived from wood;
coating the wood-based substrate, by applying a filler coating layer on the upper surface, the filler coating layer comprising a filler deriving from oligomers and/or polymers selected from the group consisting of (meth)acrylate copolymers, polyether (meth)acrylates, polyester (meth)acrylates, epoxy (meth)acrylates, urethane (meth)acrylates, amino (meth)acrylates, melamine (meth)acrylates, silicone (meth)acrylates and phosphazene (meth)acrylates and having a thickness from 5 μm to 40 μm;
applying a radiation-curable coating agent on the filler coating layer for the formation of a radiation-curable coating; and
irradiation of the radiation-curable coating with UV light having a wavelength comprised from 120 nm to 230 nm, further comprising curing the radiation-curable coating using actinic radiation with UV light having a wavelength comprised from 280 nm to 420 nm.

9. The method of claim 8 , comprising the following steps:
obtaining a wood-based substrate having at least an upper layer made of wood or derived from wood,
coating the wood-based substrate, by applying a first layer of coating on the upper surface, said first layer of coating being a primer coating layer,
applying a second layer of coating on the first layer of coating, said second layer of coating being a filler coating layer,
applying a third layer of coating on the second layer of coating, said third layer of coating comprising at least one sealer layer;
applying a radiation-curable coating agent on the third layer of coating for the formation of a radiation-curable coating; and
irradiating the radiation-curable coating with UV light having a wavelength comprised from 120 nm to 230 nm and subsequently curing the radiation-curable coating using actinic radiation in the form of UV light having a wavelength between 280 nm and 420 nm.

10. The method of claim 8 , wherein the irradiation of the radiation-curable coating takes place in an inert gas atmosphere.

11. The method of claim 8 , wherein the step of coating the wood-based substrate further comprises curing the filler layer of coating using actinic radiation, and the method comprises the further step of curing the radiation-curable coating using actinic radiation.

12. The method of claim 9 , further comprising sanding at least one of:
the upper surface defined by the upper layer;
the upper surface defined by the primer coating layer;
the upper surface defined by the filler coating layer; and
the upper surface defined by the third layer of coating.

13. The surface covering of claim 3 , wherein
the radiation-curable binder is derived from oligomers and/or polymers selected from the group consisting of polyester (meth)acrylates and urethane (meth)acrylates, and
the filler coating layer is obtained by actinic radiation of oligomers and/or polymers selected from the group consisting of polyester (meth)acrylates and urethane (meth)acrylates.

Assignees

• Tarkett Gdl Sa

Inventors

• Fascella Guillaume
• Cancellier Michel

Classifications

• C09D4/00

  Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond {; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16} · CPC title

• B05D2430/00

  Component used as a filler in the composition · CPC title

• B05D2425/01

  top layer/ last layer, i.e. first layer from the top surface · CPC title

• B05D2203/20

  Wood or similar material · CPC title

• B05D7/582

  all layers being cured or baked together · CPC title