# US 12,005,725 B2 · Method of forming a surface covering with substrate, phase transition liquid and plasticizer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,005,725 B2 - Document ID: US12005725B2 - Status: Granted - Kind: B2 - Application number: 16/349,412 - Filed: 2017-12-11 - Published: 2019-12-12 - Granted: 2024-06-11 - Earliest claimed: 2016-12-15 - Assignees: Ricoh Company, Ltd. - Applicants: John Hamilton; Andrew McVitie; Derek Smith - Inventors: John Hamilton; Andrew McVitie; Derek Smith - Web page: https://patentgrep.com/patent/US12005725B2 ## CPC - B41M 5/0011: {Pre-treatment or treatment during printing of the recording material, e.g. heating, irradiating (after-treatment of prints B41M7/00; printers for treating or overcoating copy materials before, during or after printing B41J11/0015)} - B41M 5/0017: {Application of ink-fixing material, e.g. mordant, precipitating agent, on the substrate prior to printing, e.g. by ink-jet printing, coating or spraying} - B41M 5/0047: {by ink-jet printing} - B41M 7/0081: {using electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams} - B41M 7/009: {using thermal means, e.g. infrared radiation, heat} - C09D 11/36: based on non-aqueous solvents - B41M 3/18: Particular kinds of wallpapers - B41M: PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING, (correction of typographical errors B41J; processes for applying transfer pictures or the like B44C1/16; fluid media for correction of typographical errors by coating C09D10/00; printing textiles D06P) - 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) ## Abstract The present invention relates to a method of forming a surface covering for example wallpaper or a floor covering and an apparatus for forming a surface covering, in which a surface covering raw material is supplied, the surface covering raw material comprising a substrate and a resin layer comprising a resin and a carrier liquid, the resin being dispersed in the carrier liquid and being capable of gelling or curing with the carrier liquid. A pattern is then applied to the resin layer by inkjet printing, and the surface covering raw material with the pattern formed on the resin layer is heated to gel or cure the resin layer to thereby prepare a surface covering. ## Claims ### Claim 1 A method of forming a surface covering, comprising the steps of: supplying a substrate; applying a liquid resin layer to the substrate, thereby forming a surface covering raw material, the liquid resin layer comprising a resin dispersed in a carrier liquid, and being capable of undergoing a phase transition from liquid to solid; discharging ink to the liquid resin layer by an inkjet printhead so as to form a pattern by inkjet printing, said ink being discharged to the liquid resin layer separately from the liquid resin layer, and causing the liquid resin layer with the pattern formed on the liquid resin layer to undergo a phase transition from liquid to solid to thereby prepare a surface covering, wherein the ink is an oil-based ink, and the oil-based ink comprises an oily component, the liquid resin layer of the surface covering raw material comprises a plasticizer selected from the group consisting of phthalate-based plasticizer, phosphate based plasticizer, adipate-based plasticizer, trimellitate-based plasticizer, polyester based plasticizer, epoxy-based plasticizer, sebacate-based plasticizer, azelate-based plasticizer, citrate based plasticizer, glycolate-based plasticizer, ricinolate-based plasticizer, maleate-based plasticizer, fumarate-based plasticizer, benzoate plasticizers, pyromellitate-based plasticizer and itaconate-based plasticizer, and the oily component is selected from the group consisting of phthalic acid esters, adipic acid esters, sebacic acid esters, citric acid esters, azelaic acid esters, lauric acid esters, myristic acid esters, palmitic acid esters, octanoic acid esters, and isononanoic acid esters. ### Claim 2 (depends on 1) The method of claim 1, wherein the surface covering raw material is not subjected to heating, which causes any curing or gelling treatment, after application of the liquid resin layer and before discharging the ink to form the pattern. ### Claim 3 (depends on 1) The method according to claim 1, wherein the ink is discharged no more than one hour after the liquid resin layer is applied to the substrate. ### Claim 4 (depends on 1) The method according to claim 1, wherein the liquid resin layer of the surface covering raw material comprises a resin and a carrier liquid and, optionally, other components selected from a foaming agent, a foaming accelerator, a filler, a dispersant, a defoamer, an antiblocking agent, and a thickener. ### Claim 5 (depends on 1) The method according to claim 1, wherein the liquid resin layer of the surface covering raw material comprises vinyl resin. ### Claim 6 (depends on 5) The method according to claim 5, wherein the vinyl resin includes at least one of PVC, azodicarbonamide, diisononyl phthalate or zinc stearate. ### Claim 7 (depends on 1) The method according to claim 1, wherein the liquid resin layer of the surface covering raw material comprises an acrylic polymer resin or an acrylic copolymer resin, and the liquid resin layer of the surface covering raw material further comprises azodicarbonamide and zinc stearate. ### Claim 8 (depends on 1) The method according to claim 1, wherein the pattern comprises at least one of a visible pattern and a pattern of a foaming inhibiting composition. ### Claim 9 (depends on 1) The method according to claim 1, wherein the oil-based ink comprises at least one of a colorant and a foaming inhibiting component. ### Claim 10 (depends on 9) The method according to claim 9, wherein the oily component is the same as a plasticizer or compatible with a plasticizer in the liquid resin layer of the surface covering raw material. ### Claim 11 (depends on 1) The method according to claim 1, further comprising a coating step, for applying a coating material to the surface covering raw material to provide an additional level of surface protection. ### Claim 12 (depends on 1) The method according to claim 1, wherein the pattern is applied no more than 30 minutes after the liquid resin layer is applied to the substrate. ### Claim 13 (depends on 1) The method of claim 1, wherein the surface covering raw material is subjected to a partial curing treatment or a partial gelling treatment after application of the liquid resin layer before application of the pattern. ### Claim 14 (depends on 1) The method of claim 1, wherein the ink used for the inkjet printing is heated and jetted to the surface covering raw material while a temperature of the surface covering raw material is in a range 25-100° C. ### Claim 15 (depends on 1) The method of claim 1, wherein the inkjet printhead is heated in a range 30° C. to 60° C.