Actinic Radiation Cured Polyurethane Coating for Decorative Surface Coverings

Patent metadata

Field	Value
Publication number	US-2017197459-A1
Application number	US-201515304923-A
Country	US
Kind code	A1
Filing date	Apr 9, 2015
Priority date	Apr 18, 2014
Publication date	Jul 13, 2017
Grant date	—

Abstract

The present invention is related to decorative surface coverings, in particular floor or wall coverings, exhibiting low VOC emission, comprising one or more adjacent plasticized polyvinyl chloride layers and a polyurethane top-layer, said top-layer being obtained from the actinic irradiation of an aqueous ethylenically unsaturated polyurethane dispersion after evaporation of the water part. The decorative surface coverings comprise a mechanical embossed textured and/or patterned structure.

First claim

1 . Decorative surface covering, in particular floor or wall covering, exhibiting low VOC emission, said surface covering comprising one or more adjacent plasticized polyvinyl chloride layers and a polyurethane top-layer comprising anionic or cationic salt groups, characterized in that said surface covering comprises a mechanical embossed textured and/or patterned structure.

2 . Decorative surface covering according to claim 1 having a total volatile organic compound (TVOC) emission lower than 100 μg·m-3, measured after 28 days in accordance with ISO 16000-6, ISO 16000-9 or ISO 16000-10.

3 . Decorative surface covering according to claim 1 wherein the sum of the total volatile organic compound emission (TVOC), semi-volatile organic compound emission (SVOC) and formaldehyde emission is lower than 10 μg·m-3, measured after 28 days in accordance with ISO 16000-6, ISO 16000-9 or ISO 16000-10.

4 . Decorative surface covering according to claim 1 , characterized in that one or more polyvinyl chloride layers comprise 100 parts of polyvinyl chloride and 5 to 250 parts of one or more plasticizers.

5 . Decorative surface covering according claim 1 , wherein the polyurethane top-layer is obtained from radiation curing of an aqueous radiation curable polyurethane dispersion comprising 20 to 80% by weight, preferably 25 to 60% by weight of radiation curable compounds, said compounds comprising at least one ethylenically unsaturated polyurethane resin and optionally one or more reactive diluent(s), and from 0.5 to 8% by weight, preferably from 2 to 5% by weight, relative to the radiation curable compounds, of at least one photoinitiator.

6 . Decorative surface covering according to claim 5 , wherein said ethylenically unsaturated polyurethane is prepared from the reaction of:
a) at least one polyisocyanate, b) at least one hydrophilic compound containing at least one reactive group capable to react with isocyanate groups and at least one group which is capable to render the polyurethane dispersible in aqueous medium either directly or after a reaction with a neutralizing agent to provide a salt, c) at least one polymerizable ethylenically unsaturated compound containing at least one reactive group capable to react with isocyanate groups and d) at least one compound which differs from compound (c) containing at least one reactive group capable to react with isocyanate groups.

7 . Decorative surface covering according to claim 6 wherein component d) of the ethylenically unsaturated polyurethane, comprises an oligomeric or polymeric polyester having a weight average molecular weight comprised between 300 and 4000 g·mol-1, preferable between 500 and 2500 g·mol-1.

8 . Process for the preparation of the decorative surface covering according to claim 1 , comprising the steps of:
I. supplying a backing layer; II. contacting the backing layer with a plastisol composition comprising polyvinyl chloride and one or more plasticizers; III. fusing and gelling said plastisol composition; IV. applying the aqueous radiation curable polyurethane dispersion of claim 65 ; V. evaporating water from the aqueous polyurethane dispersion; VI. embossing the polyvinyl chloride layer comprising the uncured ethylenically unsaturated polyurethane resin; VII. irradiating the ethylenically unsaturated polyurethane resin.

9 . The process according to claim 8 , wherein step (II) comprises more than one adjacent plastisol layer, and wherein fusing and gelling in step (III) is performed after application of each separate plastisol layer or after application of all the plastisol layers

10 . The process according to claim 8 , comprising fusing and gelling the one or more adjacent plastisol layers in step (III) at a temperature comprised between 130° C. and 200° C.

11 . The process according to claim 8 , comprising applying the aqueous curable polyurethane dispersion in step (IV) at a temperature comprised between 25° C. and 60° C. and preferably between 30° C. and 50° C.

12 . The process according to claim 8 , comprising performing mechanical embossing in step (VI) at a surface temperature comprised between 130° C. and 200° C.

13 . The process according to claim 8 , comprising irradiating the dried coating in step (VII) at a temperature comprised between 20° C. and 70° C.,

Assignees

• Tarkett Gdl Sa

Inventors

• Gourdin Diego
• Robert Dominique
• Peres Richard
• Simon Jean-Yves

Classifications

• C09D175/14

  Polyurethanes having carbon-to-carbon unsaturated bonds · CPC title

• B32B2307/728

  Hydrophilic · CPC title

• E04F15/105

  of organic plastics with or without reinforcements or filling materials · CPC title

• B05D3/12

  by mechanical means · CPC title

• B32B27/22

  using plasticisers · CPC title