PVC-free foamed flooring and wall coverings
AssigneeThe Dow Chemical Company
InventorsJohan A. Thoen, Kyung W. Suh, James G. Kennedy, Creston D. Shmidt
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Abstract
The present invention pertains to a multilayer foamed flooring and wall product. The inventive product is a resilient cushion foam flooring and wall product that is free of polyvinyl chloride (PVC), plasticizers and heavy metal stabilizer. The product is made of a multilayer top layer which is integrated with a latex or polyolefin polymer foam back layer. The product has particular utility in the heterogeneous flooring market and can be prepared using ordinary PVC melt processing equipment.
Claims22
A multilayer resilient cushion foam floor or wall covering comprising a top layer, wherein the top layer includes:
- (a) a transparent upper wear layer comprised of at least one melt processed polyolefin polymer or at least one solvent dispersed polyolefin polymer or both,
- (b) a solvent dispersed or melt processed print layer comprised of at least one polyolefin polymer and interposed below the transparent upper wear layer, and
- (c) an optional melt processed polyolefin polymer or textile intermediate reinforcement layer interposed below the print layer,
- wherein the transparent upper wear layer and the print layer have a combined thickness of from about 50 to about 800 microns and the optional intermediate layer has a thickness of from about 5 to about 500 microns,
- wherein the top layer is integrated with a foamed backing layer comprised of a latex composition, a melt processed polyolefin composition of at least one polyolefin polymer, or a solvent dispersed polyolefin composition of at least one polyolefin polymer, and
- wherein at least one layer selected from the group cosisting of the transparent upper wear layer, the print layer, the optional intermediate reinforcement layer, when present, and the foam backing layer comprises a substantially linear ethylene polymer characterized as having
- (i) a melt flow ratio, I.sub.10 /I.sub.2 .gtoreq.5.63,
- (ii) a molecular weight distribution, M.sub.w /M.sub.n, as determined by gel permeation chromatography and defined by the equation:
- (M.sub.w /M.sub.n).ltoreq.(I.sub.10 /I.sub.2)-4.63,
- (iii) a gas extrusion rheology such that the critical shear rate at onset of surface melt fracture for the substantially linear ethylene polymer is at least 50 percent greater than the critical shear rate at the onset of surface melt fracture for a linear ethylene polymer, wherein the substantially linear ethylene polymer and the linear ethylene polymer comprise the same comonomer or comonomers, the linear ethylene polymer has an I.sub.2 M.sub.w /M.sub.n and density within ten percent of the substantially linear ethylene polymer and wherein the respective critical shear rates of the substantially linear ethylene polymer and the linear ethylene polymer are measured at the same melt temperature using a gas extrusion rheometer,
- (iv) a single differential scanning calorimetry, DSC, melting peak between -30 and 150.degree. C., and
- (v) a short chain branching distribution index greater than about 50 percent, or
- a homogeneously branched linear ethylene polymer characterized as having a molecular weight distribution less than 3 and a short chain branching distribution index equal to or greater than 50 percent.
Dependencies are inferred from the claim text.