Method of coating a polyolefin floor tile

A system for applying a polyurethane coating to a polyolefin floor tile, comprising:

• a conveyor for moving the polyolefin floor tile;
• a heater, disposed adjacent to the conveyor, and configured to heat a top surface of the floor tile;
• a plasma generator, disposed adjacent to the conveyor, and configured to expose the top surface of the floor tile to an electric arc plasma;
• an applicator, disposed adjacent to the conveyor and immediately subsequent to the heater and the plasma generator, configured to apply a non-solvent-based, UV-cured, liquid polyurethane to the top surface of the floor tile immediately after the tile has been heated and exposed to the electric arc plasma;
• and
• an ultraviolet light system, disposed adjacent to the conveyor and subsequent to the applicator, configured expose the liquid polyurethane to ultraviolet radiation so as to cure it after it has been applied to the tile.

A system for applying a polyurethane coating to a polyolefin floor tile, comprising:

• means for transporting a polyolefin floor tile for processing a top surface thereof;
• means for heating the top surface of the floor tile to an elevated temperature which is not so high as to melt, warp, or substantially damage the tile;
• means for exposing the top surface of the floor tile to an electric arc plasma so as to increase the dyne level of said top surface;
• means for applying a polyurethane coating to the top surface of the floor tile when the top surface is both heated and at an increased dyne level.

A system for applying a polyurethane coating to a polyolefin floor tile, comprising:

• a conveyor, configured to move the polyolefin floor tile in a downstream direction at a conveying speed;
• a first heater, disposed adjacent to the conveyor, and configured to heat a top surface of the floor tile to an elevated temperature;
• a plasma generator, disposed downstream of the first heater and adjacent to the conveyor, configured to expose the heated top surface of the floor tile to an electric arc plasma;
• a second heater, disposed downstream of the plasma generator and adjacent to the conveyor, configured to maintain the elevated temperature of the top surface of the floor tile;
• a first roller, disposed downstream of the second heater and adjacent to the conveyor, configured to roll a first layer of a first non-solvent-based, UV-cured, liquid polyurethane onto the top surface of the floor tile after the tile has been heated and exposed to the electric arc plasma;
• a first ultraviolet light system, disposed downstream of the first roller and adjacent to the conveyor, configured to cure the liquid polyurethane after it has been applied to the tile;
• a second roller, disposed downstream of the first ultraviolet light system and adjacent to the conveyor, configured to roll a second layer of a second non-solvent-based, UV-cured, liquid polyurethane atop the first layer of a first non-solvent-based, UV-cured, liquid polyurethane;
• and
• a second ultraviolet light system, disposed downstream of the second roller and adjacent to the conveyor, configured to cure the first and second layers of liquid polyurethane.

A method of applying a polyurethane coating to a polyolefin floor tile, comprising the steps of:

• a) heating a top surface of the floor tile to an elevated temperature which is not so high as to melt, warp, or substantially damage the tile;
• b) exposing the top surface of the floor tile to an electric arc plasma so as to increase the dyne level of said top surface;
• and
• c) applying a polyurethane coating to the top surface of the floor tile while the top surface is both heated and at an increased dyne level.

A floor tile, comprising:

• an injection molded thermoplastic floor tile, having a top surface;
• a region of increased energy on the top surface of the floor tile, said region having its energy increased by exposure to both elevated temperature and an electric arc plasma;
• and
• a polyurethane coating applied to the region of increased energy.

A floor tile, comprising:

• an injection molded polyolefin floor tile, having a top surface;
• and
• a polyurethane coating applied to the top surface, said polyurethane coating comprising:
• a first layer of UV-cured, aliphatic polyurethane, bonded to the top surface;
• a second layer of one-part, all-solids, UV-cured, aliphatic polyurethane;
• and
• an additive, included in at least one of the first and second layers of polyurethane, the additive selected from the group consisting of:
• 0-10% silicone;
• 0-10% Polytetrafluoroethylene having a particle size of 0-25 microns;
• 0-40% aluminum oxide having a particle size of 0-50 microns;
• 0-5% iron oxide having a particle size of 0-25 microns;
• 0-10% glass beads having a size of 0-25 microns;
• and pigments.