Coating processes – Applying superposed diverse coating or coating a coated base – Synthetic resin coating
Reexamination Certificate
1999-09-07
2001-06-19
Beck, Shrive (Department: 1762)
Coating processes
Applying superposed diverse coating or coating a coated base
Synthetic resin coating
C427S412000, C427S508000, C427S513000, C427S407100, C428S455000, C428S456000
Reexamination Certificate
active
06248405
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to materials containing polyreaction products, planar structures based on renewable raw materials which contain these materials particularly in the coating layer and cover coat, respectively, and methods of the production of said planar structures.
Linoleum as an elastic floor covering based on renewable raw materials has long been known. Due to its natural components linoleum has achieved a high value regarding construction-biological and ecological areas. Nevertheless, the production of linoleum coverings requires a thermal treatment in the last method step, the so-called “ripening time”, which takes several weeks.
DE-A-41 35 664 teaches coating masses which are based on renewable raw materials and serve to coat planar textile structures or release paper. The coating masses consist of a combination of epoxidation products of esters of unsaturated fatty acids and partial esters of polycarboxylic acids with polyether polyols as well as with a hydrophobing agent. These coating masses are used to produce floor coverings. However, the fact that the uppermost layer of coatings produced in this manner is very rough and non-transparent and exhibits a coloration caused by the thermal cross-linking is a disadvantage. Furthermore, the coatings of the back require a complicated production with rather expensive separating paper and have no foam and, therefore, are not comfortable when walked on. Furthermore, it turns out that the surface of these coverings is not sufficiently stain-repellent and not fully hardened.
BACKGROUND OF THE INVENTION
WO-96/15203 teaches coatable and, respectively, spreadable coating masses for the production of planar structures based on renewable raw materials. However, the production of these planar structures, particularly the coating layer and the wear layer, respectively, is carried out by thermal cross-linking of the coating masses, which results in yellowing of the coating layer.
SUMMARY OF THE INVENTION
Thus, the problem underlying the present invention is to provide novel planar structures based on renewable raw materials which do not require the time-intensive ripening time of linoleum coverings and substantially do not show yellowing of the coating layer and wear layer, respectively. Furthermore, these planar structures should have excellent material properties.
DETAILED DESCRIPTION OF THE INVENTION
This problem is solved by the embodiments characterized in the claims. In particular, there is provided a material containing polyreaction products wherein the polyreaction products are obtainable by reacting of at least one di- or polycarboxylic acid or their derivatives or of a mixture thereof with at least one epoxidation product of a carboxylic acid ester or with a mixture of these epoxidation products and simultaneously or subsequent curing of the reaction product, wherein the reaction and/or curing is substantially carried out by
(a) UV radiation in presence of at least one UV initiator and/or
(b) electron radiation optionally in presence of at least one UV initiator and/or
(c) IR radiation.
UV initiators used in the present invention may be radical or cationic UV initiators, or a mixture of said types of UV initiators. Preferred examples of radical UV initiators are benzophenone, benzophenone derivatives, phosphine oxides, &agr;-morpholino ketones, quinone, quinone derivatives or &agr;-hydroxy ketones, or mixtures thereof. Preferred examples of cationic UV initiators are triarylsulfonium salts which may be of one type or a mixture of different triarylsulfonium salts, or diaryliodonium salts, or mixtures thereof. Said UV initiators are present, for example, in an amount up to 8% by weight, preferably 0.1 to 3% by weight, based on the amount of the material containing polyreaction products.
In one embodiment of the present invention, besides the UV initiator, at least one photosensitizer may be present, such as e.g. compounds based on anthracene, perylene or thioxanthene-9-one, which is able to activate the UV initiator and to enhance the effectiveness thereof, thereby reducing the concentration of the UV initiator. UV radiation employed in the present invention is, generally, within the usual range, i.e. 200 nm to 380 nm. IR radiation employed in the present invention is, generally, within the usual range, for example, 760 nm to 0.5 mm.
The di- or polycarboxylic acids or their derivatives preferably contain at least one double bond per molecule.
The dicarboxylic acid used can preferably be maleic acid, itaconic acid, fumaric acid, succinic acid, methylsuccinic acid, malic acid or furandicarboxylic acid, or a mixture thereof containing at least two of these acids. The polycarboxylic acid used can preferably be acids with three or more carboxylic acid groups such as e.g. citric acid and aconitic acid.
Anhydrides or partial esters or derivatives having at least one free carboxylic acid group can be used as derivatives of di- or polycarboxylic acids. The alcohol component of the partial esters is not subject to any particular limitation; however, polyols such as dipropylene glycol, propane diols, butane diols, hexane diols, hexane triols, glycerin or pentaerythrite, or a mixture thereof containing at least two of these polyols are preferably used as alcohol component.
In an especially preferred embodiment, as a cross-linking agent, a mixture of a partial ester of maleic acid anhydride and dipropylene glycol is used together with citric acid, wherein the portion of citric acid is up to 50% by weight, more preferably up to 25% by weight, based on the total amount of the cross-linking agent.
The epoxidation product preferably contains more than one epoxy group per molecule. The following can be used with preference as epoxidation product of a carboxylic acid ester: Epoxidized linseed oil, epoxidized soybean oil, epoxidized castor oil, epoxidized rape-seed oil or vernonia oil, or a mixture thereof containing at least two of these epoxidized products. The previously defined alcohols of partial esters such as e.g. dipropylene glycol, propane diols, butane diols, hexane diols, hexane triols or pentaerythrite, or a mixture thereof containing at least two of these polyols can also be used as the alcohol component of these carboxylic acid esters. The carboxylic acid component is not subject to any particular limitation.
Furthermore, the material containing polyreaction products may contain further at least one additive selected from the group consisting of fillers, pigments for designing and patterning, respectively, expanding agents and/or foaming agents, hydrophobing agents and auxiliary substances.
The fillers are preferably wood dust, chalk, cork dust, barium sulfate, silicic acid, kaolin, lignin, cellulose, talcum, glass, textile fibers or glass fibers or plant fibers, cellulose fibers, polyester fibers or e.g. colored granulates and chips, respectively, made of the inventive material containing polyreaction products, or a mixture thereof containing at least two of these substances. Wood dust, chalk, cellulose, lignin or cork dust, or a mixture thereof containing at least two of these substances are especially preferred as filler.
The following can be used by way of example as auxiliary substances: Tall oils, synthetic or natural resins such as e.g. balsamic resin, copals, hydrocarbon resins and/or siccatives such as e.g. compounds of the metals Al, Li, Ca, Fe, Mg, Mn, Pb, Zn, Zr, Ce or Co, or a combination thereof containing at least two of these compounds.
The invention is further directed to a planar structure composed of at least one support layer (I) and of at least one coating layer (II) which comprises the material containing polyreaction products as defined above, optionally an back layer (III) arranged under the support layer (I) and made of a chemically or mechanically foamed foam layer, optionally an compact or priming layer (IV) arranged between the support layer (I) and the coating layer (II) and/or between the support layer (I) and the back layer (III), optionally an chemically foamed foam la
Ess Milko
Jung Bernhard
Kastl Bernd
Beck Shrive
DLW Aktiengesellschaft
Kolb Jennifer
Womble Carlyle Sandridge & Rice PLLC
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