Coating for inhibiting stain formation in floor covering

Details Coating for inhibiting stain formation in floor covering Coating for inhibiting stain formation in floor covering

1999-08-31

2002-12-03

Nakarani, D. S. (Department: 1773)

Stock material or miscellaneous articles

Composite

Of addition polymer from unsaturated monomers

C106S286700, C428S512000, C428S514000, C428S537100, C428S537500, C427S316000, C427S317000, C427S325000, C427S326000, C427S395000, C427S396000, C427S397000, C427S408000, C427S411000, C427S419500, C427S419800, C524S080000, C524S428000, C524S435000, C524S572000, C524S558000

Reexamination Certificate

active

06489037

ABSTRACT:

FIELD OF THE INVENTION
This invention relates to liquid formulations that can be applied to the surface of a wood-based flooring panel and dried to form a coated product that is suitable for use as a substrate for decorative floor covering. The coating on the panel dramatically inhibits the staining action that occurs when a decorative vinyl floor covering is installed directly over a wooden substrate. The coating system described inhibits the staining action that occurs when oriented strandboard (OSB) underlayment is used in conjunction with vinyl floor sheathing, while simultaneously providing a substrate surface that has exceptional compatibility with the adhesives and patching materials that are commonly used during the process of installing vinyl floor coverings. The coating formulations are stable and resistant to phase separation and settling over storage periods in excess of two months, and they can be used in high-volume commercial coating operations in compliance with current U.S. environmental regulations.
BACKGROUND OF THE INVENTION
Decorative vinyl floor coverings are commonly installed in residential dwellings in North America. Manufacturers of vinyl floor coverings include Armstrong World Industries (Lancaster, Pa.), Mannington (Salem, N.J.), Congoleum Corporation (Mercerville, N.J.), and Tarkett Incorporated (Whitehall, Pa.). Contemporary floor covering materials are described in U.S. Pat. No. 5,308,694. Although there are a number of elaborate vinyl floor covering construction designs, most are comprised of a three-layered structure. The bottom layer generally consists of a plasticized polymeric film, felt or paper. The middle layer is the decorative portion and it often consists of polyvinyl chloride along with plasticizing agents, dyes and/or pigments, stabilizers and/or other components. In many cases this decorative layer has a cellular structure, which is achieved by decomposing a blowing agent, most commonly azodicarbonamide, during the manufacturing process. In some cases a colored design is gravure-printed on the topside of the middle layer. A discontinuous pattern of foam inhibitor can also be deposited on the topside of the middle layer in order to yield a highly textured floor covering. The upper layer is known as the “wear layer” and it often consists of a plasticized polyvinyl chloride or polyurethane film.
Most types of vinyl floor covering are thin and very conformable. Thus, they must be installed directly over a smooth, flat substrate. Residential sub-floors consisting of ¾″ OSB or plywood sub-floor panels mounted over 2″×10″ joists are frequently abused during the home building process, and have surfaces which are often too rough and irregular to be used as a vinyl floor covering substrate. It is common practice to install a thin, smooth panel, known as an “underlayment panel”, over the rough sub-floor just prior to installation of the vinyl floor covering.
FIG. 1
shows a representative floor construction (
10
) in which a layer of vinyl floor covering (
20
) is adhered to a layer of underlayment panels (
30
), which are stapled or nailed to ¾″ thick sub-floor panels (
40
), which span and are nailed to 2″×10″ supporting joists (
50
). Typical underlayment panels are sanded and comprised of plywood, particleboard, oriented strand board (OSB), or cement/fiber board. Plywood underlayments that are commonly used in North America include those derived from lauan veneer and manufactured in Indonesia and Malaysia. A plywood underlayment, known as MULTIPLY, is composed of aspen veneer and is manufactured by MacMillan Bloedel Ltd. (Vancouver, BC). Another plywood underlayment, known as TECHPLY, is composed of Russian birch veneer and is distributed in North America by the Plywood & Doors Mfrs. Corporation (Union, N.J.). A sanded ⅜″ thick fiberboard, known as FIBERFLOR, is manufactured by MacMillan Bloedel Ltd. (Vancouver, BC). A coated ¼″ thick OSB underlayment panel known as THE INSTALLER'S EDGE is manufactured and sold by the Weyerhaeuser Co. (Tacoma, Wash.). A ⅜″ thick cement/fiber board, known as FIBERBOND, is sold as underlayment by the Louisiana-Pacific Corporation (Portland, Oreg.).
All of these commercial underlayment panels have structural properties that are sufficient for an underlayment application. The panels must also have a smooth, flat, dimensionally stable, hard surface for the duration of their use in a floor system. The typical installation practice includes fastening the underlayment panels to the sub-floor by use of staples or nails; patching the seams; removing any debris from the surface of the panels; and adhering the vinyl floor covering to the underlayment by use of aqueous latex adhesives. Thus, the panels should have a solid, uniform color and appearance in order to aid in the visualization of fastener placement and surface debris when cleaning the panels. The panels must not corrode or degrade metallic fasteners. The panels must be fully compatible with conventional patching compounds and adhesives that are used during the floor covering installation process. The panels must not stain or otherwise adversely interact with the vinyl floor covering that is placed directly on top of them. Underlayment panel attributes that are particularly important and relevant to this invention include 1) compatibility with the commonly used aqueous latex adhesives and patching compounds and 2) an ability to resist staining vinyl floor coverings.
Compatibility with aqueous latex adhesives. The surface of the installed, underlayment must be receptive and functionally compatible with a large number of water-based adhesives that are used to attach the vinyl floor covering to the underlayment. Most of the adhesives are primarily comprised of aqueous acrylic or styrene-butadiene lattices, which are designed to absorb into the underlayment. Thus, the underlayment must have a surface, which will allow some penetration of a water-based adhesive.
One type of vinyl floor covering, known as “fully-adhered”, requires the application of adhesive across the entire underlayment surface. In this case the adhesive must be spread by use of a trowel with repeated stroking actions. Applied adhesive on one part of a floor must remain in a liquid state for a period of time sufficient for the installer to spread the adhesive across the entire floor. Thus, the adhesive must interact with the underlayment panels in a manner that results in a sufficiently long “open-time”. Interactions between the adhesive and the underlayment surface must not cause the adhesive to prematurely solidify. Simultaneously, bond strength must develop between the vinyl floor covering and the underlayment panel within a reasonably short time period after the vinyl floor covering has been placed in intimate contact with the adhesive on top of the underlayment. This bond strength must increase to a level that secures the vinyl floor covering to the underlayment subsequent to installation. Therefore, interactions between the applied adhesive and the underlayment surface must not impede or interfere with bond strength development.
A second type of vinyl floor covering, known as “perimeter-attached”, requires application of an adhesive only at the perimeter of the floor. The perimeter-attached vinyl floor covering is laid onto the floor and positioned into the applied adhesive. In this application it is important that a strong bond quickly develop between the vinyl floor covering and the underlayment along the perimeter of the floor. Immediately after installation a volatile component in the vinyl floor covering will begin to evaporate and the floor covering will simultaneously shrink. As shrinkage occurs a strong shear stress is developed along the perimeter bond. It is vital that the bond strength along the perimeter of the floor-to-vinyl interface be sufficiently high to prevent delamination during this shrinking process.
Ability to bond with aqueous patching compounds. Patching compo

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