# US 11,078,377 B2 · Actinic radiation cured polyurethane coating for decorative surface coverings

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- Number: US 11,078,377 B2
- Document ID: US11078377B2
- Status: Granted
- Kind: B2
- Application number: 15/304,916
- Filed: 2015-04-09
- Published: 2017-06-22
- Granted: 2021-08-03
- Earliest claimed: 2014-04-18
- Assignees: Tarkett GDL
- Applicants: Tarkett GDL S.A.
- Inventors: Diego Gourdin; Dominique Robert; Richard Peres; Jean-Yves Simon
- Web page: https://patentgrep.com/patent/US11078377B2

## CPC

- C09D 175/16: having terminal carbon-to-carbon unsaturated bonds
- B05D 3/06: by exposure to radiation (B05D3/02 takes precedence {; plasma treatment B05D3/141})
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/08: of synthetic resin
- B32B 27/16: specially treated, e.g. irradiated
- B32B 27/22: using plasticisers
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/40: comprising polyurethanes
- C09D 127/06: Homopolymers or copolymers of vinyl chloride
- E04F 13/18: of organic plastics with or without reinforcements or filling materials (of plastic-bound fibres or chips E04F13/16 ){or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles (E04F13/0864 takes precedence)}
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/26: Polymeric coating
- B32B 2307/554: Wear resistance
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2607/02: Wall papers, wall coverings
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)

## Abstract

The present invention is related to decorative surface coverings, in particular floor or wall coverings, exhibiting low volatile organic compounds (VOC) emission, comprising one or more adjacent plasticized polyvinyl chloride layers and a polyurethane top-layer, said top-layer being obtained from radiation curing a 100% solids polyurethane formulation.

## Claims

### Claim 1

Decorative surface covering exhibiting low volatile organic compound (VOC) emission, said surface covering comprising one or more adjacent plasticized polyvinyl chloride layers and a polyurethane top-layer comprising acid functionalities, the polyurethane top-layer being obtained from a 100% solids radiation curable polyurethane composition, wherein the decorative surface covering has 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.

### Claim 2 (depends on 1)

Decorative surface covering according to claim 1 wherein the sum of the total volatile organic compound emission (TVOC), the semi-volatile organic compound emission (SVOC) and the 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.

### Claim 3 (depends on 1)

Decorative surface covering according to claim 1, comprising a mechanical embossed textured and/or patterned structure.

### Claim 4 (depends on 3)

Decorative surface covering of claim 3, wherein the mechanical embossed textured and/or patterned structure has a depth between 0 to 100 μm, a width between 125 to 400 μm, a wall angle between 5 to 40 degrees and a frequency of 4 to 20 features per cm.

### Claim 5 (depends on 1)

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

### Claim 6 (depends on 1)

Decorative surface covering according to claim 1, wherein the polyurethane top-layer comprises acid functionalities selected from the group consisting of —SO3H, —OSO3H, —COOH, —OPO3H2 and —OPO2HO—.

### Claim 7 (depends on 1)

Decorative surface covering according to claim 1, wherein the polyurethane top-layer is obtained from radiation curing of a radiation curable polyurethane formulation comprising from 50 to 100% by weight of ethylenically unsaturated group comprising compounds said compounds comprising:
a) from 5 to 95% by weight of at least one radiation curable polyurethane,
b) from 0.1 to 10% by weight of at least one acidic adhesion promoter,
c) from 5 to 90% by weight of at least one mono- and/or polyfunctional reactive diluent.

### Claim 8 (depends on 7)

Decorative surface covering according to claim 7 wherein the radiation curable polyurethane (a) of the radiation curable polyurethane formulation is an aliphatic polyurethane acrylate.

### Claim 9 (depends on 7)

Decorative surface covering according to claim 7 wherein the acidic adhesion promotor (b) of the radiation curable polyurethane formulation comprises one or more carboxylic acid groups.

### Claim 10 (depends on 7)

Decorative surface covering according to claim 7 wherein the reactive diluent (c) of the radiation curable polyurethane formulation comprises at least two ethylenically unsaturated groups.

### Claim 11 (depends on 1)

Decorative surface covering according to claim 1, wherein the polyurethane top-layer prevents plasticizer migration and exudation.

### Claim 12

Decorative surface covering exhibiting low volatile organic compound (VOC) emission, comprising a mechanical embossed textured and/or patterned structure, said surface covering further comprising one or more adjacent plasticized polyvinyl chloride layers and a polyurethane top-layer comprising acid functionalities, the polyurethane top-layer being obtained from a 100% solids radiation curable polyurethane composition, wherein the polyurethane top-layer prevents plasticizer migration and exudation and wherein the decorative surface covering has 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.

### Claim 13 (depends on 1)

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. cooling down the fused and gelled plastisol layer:
V. applying the 100% solids radiation curable polyurethane composition, comprising from 50 to 100% by weight of ethylenically unsaturated group comprising compounds said compounds comprising:
a) from 5 to 95% by weight of at least one radiation curable polyurethane,
b) from 0.1 to 10% by weight of at least one acidic adhesion promoter,
c) from 5 to 90% by weight of at least one mono- and/or polyfunctional reactive diluent,
VI. irradiating said radiation curable polyurethane formulation.

### Claim 14 (depends on 13)

The process according to claim 13, 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.

### Claim 15 (depends on 13)

The process according to claim 13, comprising fusing and gelling the one or more adjacent plastisol layers in step (III) at a temperature between 130° C. and 200° C.

### Claim 16 (depends on 13)

The process according to claim 13 comprising the additional step of embossing the fused and gelled plastisol layer before cooling down in step (IV).

### Claim 17 (depends on 13)

The process according to claim 13, comprising cooling down the one or more fused and gelled adjacent plastisol layers in step (IV) to a temperature comprised between 15° C. and 40° C.