# US 12,109,828 B2 · Decorative floor covering production method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,109,828 B2 - Document ID: US12109828B2 - Status: Granted - Kind: B2 - Application number: 17/778,966 - Filed: 2020-12-07 - Published: 2022-12-29 - Granted: 2024-10-08 - Earliest claimed: 2019-12-12 - Assignees: Tarkett GDL - Applicants: Tarkett Gdl - Inventors: Igor Brankov - Web page: https://patentgrep.com/patent/US12109828B2 ## CPC - B41M 3/006: {Patterns of chemical products used for a specific purpose, e.g. pesticides, perfumes, adhesive patterns; use of microencapsulated material; Printing on smoking articles} - B29C 48/08: flexible, e.g. films - B29C 48/21: the layers being joined at their surfaces - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 7/14: applied in spaced arrangements, e.g. in stripes - B32B 27/08: of synthetic resin - B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF} - B32B 37/12: characterised by using adhesives - B32B 37/1292: {selectively, e.g. in stripes, in patterns (B32B37/0076 takes precedence)} - B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)} - B32B 38/145: {Printing} - B41M 7/0081: {using electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams} - E04F 15/105: {of organic plastics with or without reinforcements or filling materials} - B29K 2027/06: PVC, i.e. polyvinylchloride - B29K 2995/0087: Wear resistance - B29L 2031/722: {Decorative or ornamental articles} - B32B 2037/1253: {curable adhesive} - B32B 2250/02: 2 layers - B32B 2250/03: 3 layers - B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer - B32B 2255/26: Polymeric coating - B32B 2307/4026: within the layer by addition of a colorant, e.g. pigments, dyes - B32B 2307/554: Wear resistance - B32B 2327/06: PVC, i.e. polyvinylchloride - B32B 2471/00: Floor coverings (B32B2419/04 takes precedence) - E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)} - 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) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - 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) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A method for producing a decorative floor covering comprises digitally printing an adhesive on a printing substrate thus generating an adhesive layer forming an at least one-dimensionally patterned decorative motif. The adhesive is a radiation-curable composition, preferably essentially free from non-reactive solvents and/or from photoinitiator. The printing substrate includes one of a core structure and a wear layer. After the printing of the adhesive, the adhesive layer on the printing substrate is contacted with the other one of the core structure and the wear layer. The core structure and the wear layer are then attached to each other by electron-beam curing the adhesive layer between them. ## Claims ### Claim 1 A method for producing a decorative floor covering, comprising: digitally printing an adhesive on a printing substrate thus generating an adhesive layer forming an at least one-dimensionally patterned decorative motif, the adhesive being a radiation-curable composition, the printing substrate including one of a core structure and a wear layer; contacting the adhesive layer on the printing substrate with the other one of said core structure and said wear layer; attaching the printing substrate and the other one of said core structure and said wear layer to each other by electron-beam curing said adhesive layer. ### Claim 2 (depends on 1) The method as claimed in claim 1, wherein the printing substrate includes said core structure and wherein the other one of said core structure and said wear layer is the wear layer. ### Claim 3 (depends on 1) The method as claimed in claim 1, wherein the printing substrate includes said wear layer and wherein the other one of said core structure and said wear layer is the core structure. ### Claim 4 (depends on 1) The method as claimed claim 1, comprising forming the core structure, the formation of the core structure comprising at least one of: a. extrusion of a single plastic layer, the plastic layer being compatible with said adhesive; b. coextrusion of at least two adjacent plastic layers, at least one of at least two adjacent plastic layers being compatible with said adhesive; c. extrusion of a plastic layer or coextrusion of at least two plastic layers, followed by application of a plastisol coating thereon, the plastisol coating being compatible, after curing, with said adhesive; and d. extrusion of a plastic layer or coextrusion of at least two plastic layers, followed by application of a primer layer thereon, the primer layer being compatible with said adhesive. ### Claim 5 (depends on 1) The method as claimed in claim 1, comprising fixation of the at least one-dimensionally patterned decorative motif by incompletely precuring the adhesive layer before the printing substrate is contacted with the other one of said core structure and said wear layer. ### Claim 6 (depends on 1) The method as claimed in claim 1, wherein the adhesive is substantially free from photoinitiator. ### Claim 7 (depends on 1) The method as claimed in claim 1, wherein the decorative motif is at least two-dimensionally patterned. ### Claim 8 (depends on 1) The method as claimed in claim 1, wherein the digital printing of the adhesive, the contacting of the adhesive layer with the other one of said core structure and said wear layer and the attaching of the printing substrate and the other one of said core structure and said wear layer to each other are carried out at temperatures not exceeding 100° C. ### Claim 9 (depends on 1) The method as claimed in claim 1, wherein the at least one-dimensional patterning is effected by digitally printing said adhesive in different colours. ### Claim 10 (depends on 1) The method as claimed in claim 1, wherein the core structure comprises one or more layers of rigid PVC material. ### Claim 11 (depends on 1) The method as claimed in claim 1, wherein the adhesive comprises or consists of at least one of radiation-curable polyurethane and acrylate glue. ### Claim 12 (depends on 1) The method as claimed in claim 1, wherein said digital printing of the adhesive includes the printing of registration marks. ### Claim 13 (depends on 1) The method as claimed in claim 1, further comprising digitally printing a three-dimensional transparent or at least translucent relief on a face of said wear layer turned away from the core structure. ### Claim 14 (depends on 13) The method as claimed in claim 13, wherein said core structure and said wear layer remain continuous at least up to where the digital printing of said three-dimensional relief is effected. ### Claim 15 (depends on 13) The method as claimed in claim 13, wherein an intermediate product formed by attaching the printing substrate and the other one of said core structure and said wear layer to each other is cut upstream of where the digital printing of said three-dimensional relief is effected. ### Claim 16 (depends on 15) The method as claimed in claim 15, wherein the cutting is carried out with a water jet or a guillotine. ### Claim 17 A method of producing a decorative floor covering, comprising: providing a wear layer; providing an adhesive, the adhesive being a radiation-curable composition; forming a core structure, the formation of the core structure comprising at least one of: a. extrusion of a single plastic layer, the plastic layer being compatible with said adhesive; b. coextrusion of at least two adjacent plastic layers, at least one of at least two adjacent plastic layers being compatible with said adhesive; c. extrusion of a plastic layer or coextrusion of at least two plastic layers, followed by application of a plastisol coating thereon, the plastisol coating being compatible, after curing, with said adhesive; and d. extrusion of a plastic layer or coextrusion of at least two plastic layers, followed by application of a primer layer thereon, the primer layer being compatible with said adhesive; digitally printing the adhesive on a printing substrate thus generating an adhesive layer forming an at least one-dimensionally patterned decorative motif, the adhesive being a radiation-curable composition, the printing substrate including one of the core structure and the wear layer; contacting the adhesive layer on the printing substrate with the other one of said core structure and said wear layer; and attaching the printing substrate and the other one of said core structure and said wear layer to each other by electron-beam curing said adhesive layer. ### Claim 18 (depends on 17) The method as claimed in claim 17, wherein the adhesive comprises at least one of radiation-curable polyurethane and acrylate glue, and wherein the adhesive is substantially free from photoinitiator. ### Claim 19 (depends on 18) The method as claimed in claim 18, wherein the decorative motif is at least two-dimensionally patterned and wherein the at least two-dimensional patterning is effected by digitally printing said adhesive in different colors. ### Claim 20 (depends on 18) The method as claimed in claim 18, wherein the digital printing of the adhesive, the contacting of the adhesive layer with the other one of said core structure and said wear layer and the attaching of the printing substrate and the other one of said core structure and said wear layer to each other are carried out at temperatures not exceeding 100° C., and wherein said core structure and said wear layer are maintained continuous at least up to where the digital printing of said three-dimensional relief is effected.