US2828219A - Floor and wall covering - Google Patents

Floor and wall covering Download PDF

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Publication number
US2828219A
US2828219A US525400A US52540055A US2828219A US 2828219 A US2828219 A US 2828219A US 525400 A US525400 A US 525400A US 52540055 A US52540055 A US 52540055A US 2828219 A US2828219 A US 2828219A
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US
United States
Prior art keywords
coating
polyethylene
tile
molecular weight
floor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US525400A
Inventor
Russell W Heiges
William R Reed
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Armstrong World Industries Inc
Original Assignee
Armstrong Cork Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Armstrong Cork Co filed Critical Armstrong Cork Co
Priority to US525400A priority Critical patent/US2828219A/en
Application granted granted Critical
Publication of US2828219A publication Critical patent/US2828219A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/06—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wood
    • B05D7/08—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wood using synthetic lacquers or varnishes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2501/00—Varnish or unspecified clear coat
    • B05D2501/10—Wax
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2507/00—Polyolefins
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/3167—Of cork
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31801—Of wax or waxy material

Definitions

  • This invention relates to a floor and wall tile having applied thereto a soil-resistant, wear-resistant coating. More particularly, this invention relates to an irregular floor and wall tile such as cork tile having applied thereto a polyethylene type protective coating to render the surface resistant to dirt and wear.
  • the polyethylene is not completely compatible with the wax'constituents, resulting in a composition which has the disadvantage of showing white scratches on the surface under normal tralfic. These scratches are diflicult to remove. Crystallization of the wax also contributes to the white scratching condition.
  • the present invention has been developed in which the coating is applied in a plurality of layers.
  • the first layer is a coating composition having a low viscosity which will satisfactorily fill all of the imperfections appearing on the surface of the cork tile, and the other layer or layers are a low viscosity polyethylene type which renders the surface wear-resistant and soil-resistant.
  • the top layer or film is all of the same composition, the problem of incompatibility is not present and the white scratch marks do not occur.
  • Polyethylene is of such nature that the problem of crystallizationdoes not occur.
  • Low molecular weight polyethylene (molecular weight ranging between 1,000 and 3,000) 1 /2 a first or cover coat; however, any of the low melt vis-' cosity products can be used satisfactorily for this purpose.
  • the above coating composition is applied as a hot melt application at a regular two-roll coating device.
  • the coating composition forms a pool between the applicator roll and a second roll.
  • the sheet of material to which the hot melt is to be applied is passed between the applicator roll and a back-up roll in such manner that the film of wax adhering to the applicator roll is transferred therefrom onto the surface of the sheet of material passing through the device.
  • the sheet then passes through an ironing roll heated to a temperature of approximately 380 R, which irons the coating composition firmly onto the surface of the tile and smooths out any ridges or grape Vining appearing on the surface. This forms a tile having a relatively smooth coating applied thereto, filling all of the small imperfections in the surface of the cork tile.
  • the drawing illustrates a piece of cork tile 2 comprised of compressed cork particles 3.
  • a dual coating of wax in which the first layer 4 applied directly to the surface of the cork particles 3 is a blend containing a major portion of hydrocarbon wax and a minor portion of a polyethylene polymer having a relatively high molecular weight, and the surface coating 5 is a polyethylene polymer having a relatively low molecular weight.
  • the top or wear coating comprises a film of polyethylene of a relatively low molecular weight ranging between 1,000 to 3,000.
  • This coating of polyethylene is applied from a hot melt of the polyethylene placed in the two-roll applicator in the same manner as expressed for the first coating.
  • the polyethylene coating is also ironed onto the surface.
  • the system outlined above results in a cork tile having a relatively'low viscosity first coat which fills all the imperfections and which has applied thereover a coat of a relatively hard polyethylene wax, forming a smooth wearand soil-resistant surface on the product.
  • the invention may be carried out by substituting a polyethylene coating for the first coating to be applied to the cork tile.
  • a polyethylene material of a relatively low molecular weight such as that falling Within the range of 1,000 to 3,000, be used to cover the imperfections in the tile.
  • This first coating of polyethylene should be rather thin so as to fiow into the imperfections.
  • This coating is ironed onto the surface of the cork tile in the same manner as described earlier.
  • the additional second coat of polyethylene is then applied thereover in the manner expressed above. Either of the systems outlined herein produces a finish which is relatively hard, wear-- resistant, and soil-resistant, and has the high gloss desirable in a product of this type.
  • A-cork composition floor and wall covering having a wear-resistant finish comprising a film of a blend containing a majorportion of hydrocarbon wax and a minor portion of a polyethylene polymer having a molecular weight in excess of 10,000 and a surface coating of a References Cited in the file of this patent polyethylene polymer having a relatively low molecular UNITED STATES PATENTS weight falling Within the range of 1,000 to 3,000. 1
  • a cork composition floor and wall covering hav- 1'824885 Hammond Septing a Wear-resistant finish comprising a film of a blend 5 2290794 Alvarado July 21, 1942 containing about 70% of hydrocarbon wax and about 2698309 Clark et 1954 7% of a polyethylene polymer having a molecular weight FOREIGN PATENTS in excess of 10,000 and a surface coating of a polyethylene 566,745 Great Britain Jam 11, 1945 polymer having a relativelylow molecular weight falling within the range of 1,000 to 3,000. 10

Description

March 25,1958 w, HEIGES ETAL' 2,828,219
FLOOR AND WALL COVERING 'Filed July 29. 1955 LOW MOLECULAR WEIGHT HYDROCARBON wAx PLUS POLYETHYLENE POLYMER HIGH MOLECULAR WEIGHT POLYE THYLENE POLYMER COMPRESSED CORK PARTICLE INVENTQR RUSSELL, w HEIGES WILLJAM BER-EEO.
Unite A 2,828,219 Patented Mar. 25;, 1
FLOGR AND WALL COVERING Russell W. Heiges, and William R. Reed, Pittsburgh, Pa., assignors to Armstrong Cork Company, Lancaster, Pa., a corporation of Pennsylvania Application July 29, 1955, Serial No. 525,400
2 Claims. (Cl. 117-72) This invention relates to a floor and wall tile having applied thereto a soil-resistant, wear-resistant coating. More particularly, this invention relates to an irregular floor and wall tile such as cork tile having applied thereto a polyethylene type protective coating to render the surface resistant to dirt and wear.
In coating floor and wall tile, such as cork tile, with a wear-resistant coating composition, it has been necessary to select a composition which will fill all of the small imperfections in the surface of the tile which are common to products formed from natural ,cork. In order to satisfactorily fill all of these imperfections, it has been necessary that the coating composition have a low viscosity. As a general rule, compositions having low viscosity, even though they satisfactorily fill the imperfections in the surface of the tile, do not have the wear resistance and soil resistance necessary to serve as a satisfactory coating composition. In order to overcome this difficulty, finishes have been prepared from blends of well-known waxes and polyethylene to form a coating composition with low melt viscosity and good wear and soil resistance. However,
the polyethylene is not completely compatible with the wax'constituents, resulting in a composition which has the disadvantage of showing white scratches on the surface under normal tralfic. These scratches are diflicult to remove. Crystallization of the wax also contributes to the white scratching condition.
In order to overcome the disadvantages of the prior art compositions, the present invention has been developed in which the coating is applied in a plurality of layers. The first layer is a coating composition having a low viscosity which will satisfactorily fill all of the imperfections appearing on the surface of the cork tile, and the other layer or layers are a low viscosity polyethylene type which renders the surface wear-resistant and soil-resistant. Inasmuch as the top layer or film is all of the same composition, the problem of incompatibility is not present and the white scratch marks do not occur. Polyethylene is of such nature that the problem of crystallizationdoes not occur.
In preparing the low viscosity coating composition for the first coating, the following formulation has been found satisfactory and is presented here by way of example.
Parts by weight Low molecular weight polyethylene (molecular weight ranging between 1,000 and 3,000) 1 /2 a first or cover coat; however, any of the low melt vis-' cosity products can be used satisfactorily for this purpose.
The above coating composition is applied as a hot melt application at a regular two-roll coating device. The coating composition forms a pool between the applicator roll and a second roll. The sheet of material to which the hot melt is to be applied is passed between the applicator roll and a back-up roll in such manner that the film of wax adhering to the applicator roll is transferred therefrom onto the surface of the sheet of material passing through the device. The sheet then passes through an ironing roll heated to a temperature of approximately 380 R, which irons the coating composition firmly onto the surface of the tile and smooths out any ridges or grape Vining appearing on the surface. This forms a tile having a relatively smooth coating applied thereto, filling all of the small imperfections in the surface of the cork tile.
The drawing illustrates a piece of cork tile 2 comprised of compressed cork particles 3. To this cork tile sheet there is applied a dual coating of wax in which the first layer 4 applied directly to the surface of the cork particles 3 is a blend containing a major portion of hydrocarbon wax and a minor portion of a polyethylene polymer having a relatively high molecular weight, and the surface coating 5 is a polyethylene polymer having a relatively low molecular weight.
The top or wear coating comprises a film of polyethylene of a relatively low molecular weight ranging between 1,000 to 3,000. This coating of polyethylene is applied from a hot melt of the polyethylene placed in the two-roll applicator in the same manner as expressed for the first coating. The polyethylene coating is also ironed onto the surface. The system outlined above results in a cork tile having a relatively'low viscosity first coat which fills all the imperfections and which has applied thereover a coat of a relatively hard polyethylene wax, forming a smooth wearand soil-resistant surface on the product.
The invention may be carried out by substituting a polyethylene coating for the first coating to be applied to the cork tile. When using this modification, it is recommended that a polyethylene material of a relatively low molecular weight, such as that falling Within the range of 1,000 to 3,000, be used to cover the imperfections in the tile. This first coating of polyethylene should be rather thin so as to fiow into the imperfections. This coating is ironed onto the surface of the cork tile in the same manner as described earlier. The additional second coat of polyethylene is then applied thereover in the manner expressed above. Either of the systems outlined herein produces a finish which is relatively hard, wear-- resistant, and soil-resistant, and has the high gloss desirable in a product of this type.
It will be obvious from the foregoing that we have developed a floor and wall covering having applied thereto a finish which adequately fills all the imperfections in the surface of the tile and presents a smooth hard glossy wearand soil-resistant surface which is easy to maintain.
We claim:
1. A-cork composition floor and wall covering having a wear-resistant finish comprising a film of a blend containing a majorportion of hydrocarbon wax and a minor portion of a polyethylene polymer having a molecular weight in excess of 10,000 and a surface coating of a References Cited in the file of this patent polyethylene polymer having a relatively low molecular UNITED STATES PATENTS weight falling Within the range of 1,000 to 3,000. 1
2. A cork composition floor and wall covering hav- 1'824885 Hammond Septing a Wear-resistant finish comprising a film of a blend 5 2290794 Alvarado July 21, 1942 containing about 70% of hydrocarbon wax and about 2698309 Clark et 1954 7% of a polyethylene polymer having a molecular weight FOREIGN PATENTS in excess of 10,000 and a surface coating of a polyethylene 566,745 Great Britain Jam 11, 1945 polymer having a relativelylow molecular weight falling within the range of 1,000 to 3,000. 10

Claims (1)

1. A CORK COMPOSITION FLOOR AND WALL COVERING HAVING A WEAR-RESISTANT FINISH COMPRISING A FILM OF A BLEND CONTAINING A MAJOR PORTION OF HYDROCARBON WAX AND A MINOR PORTION OF A POLYETHYLENE POLYMER HAVING A MOLECULAR WEIGHT IN EXCESS OF 10,000 AND A SURFACE COATING OF A POLYETHYLENE POLYMER HAVING A RELATIVELY LOW MOLECULAR WEIGHT FALLING WITHIN THE RANGE OF 1,000 TO 3,000.
US525400A 1955-07-29 1955-07-29 Floor and wall covering Expired - Lifetime US2828219A (en)

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2969340A (en) * 1958-05-09 1961-01-24 Gulf Research Development Co Process of preventing the separation of polyethylene and wax comprising the addition of water
US2988528A (en) * 1958-02-03 1961-06-13 Sun Oil Co Wax compositions
US3050429A (en) * 1962-08-21 Polyethylene inhibitor for propellant
US3112681A (en) * 1959-08-03 1963-12-03 Exxon Research Engineering Co Paving with polymer-bonded aggregates
US3117101A (en) * 1958-07-28 1964-01-07 Sinclair Research Inc Wax coating compositions
US4567087A (en) * 1983-06-28 1986-01-28 Nevamar Corporation Scuff resistance in abrasion-resistant laminates
US4738887A (en) * 1986-01-09 1988-04-19 Govertsen Lloyd G Wax applicator buffer
US5782444A (en) * 1996-04-26 1998-07-21 Interface, Inc. Cabinet skate
WO1998044217A1 (en) * 1997-04-01 1998-10-08 Baomu Co., Ltd. A method of making fabric floor plate and wall plate
US5833196A (en) * 1995-04-17 1998-11-10 Keith; George A. Desk top mat
US5989380A (en) * 1997-01-08 1999-11-23 Frischer; Paul Process of dry printing a paper-like non-woven wall covering material
US6212838B1 (en) * 1997-09-29 2001-04-10 Kabushikikaisha Edagumi Floor material and flooring using the floor material
US20040161588A1 (en) * 2001-05-29 2004-08-19 Hanns-Joerg Mauk Resilient floor covering with regenerative, dirt-repellent surface
EP2500155A3 (en) * 2011-01-20 2015-10-07 TPS TechnoPartner Samtronic GmbH Polymer bound sheet and method for its manufacture
US20160076259A1 (en) * 2011-07-27 2016-03-17 Armstrong World Industries, Inc. Sound reducing tongue and groove member sound reducing fabrication process and sound reducing blend

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1824885A (en) * 1926-08-24 1931-09-29 Western Waxed Paper Company Wax paper
US2290794A (en) * 1938-09-08 1942-07-21 Du Pont Aqueous dispersions of ethylene polymers
GB566745A (en) * 1943-06-25 1945-01-11 Gladstone Walter Worrall Improvements in or relating to the coating of the interiors of hollow articles with polythene compositions
US2698309A (en) * 1952-04-16 1954-12-28 Standard Oil Dev Co Paper coating wax

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1824885A (en) * 1926-08-24 1931-09-29 Western Waxed Paper Company Wax paper
US2290794A (en) * 1938-09-08 1942-07-21 Du Pont Aqueous dispersions of ethylene polymers
GB566745A (en) * 1943-06-25 1945-01-11 Gladstone Walter Worrall Improvements in or relating to the coating of the interiors of hollow articles with polythene compositions
US2698309A (en) * 1952-04-16 1954-12-28 Standard Oil Dev Co Paper coating wax

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3050429A (en) * 1962-08-21 Polyethylene inhibitor for propellant
US2988528A (en) * 1958-02-03 1961-06-13 Sun Oil Co Wax compositions
US2969340A (en) * 1958-05-09 1961-01-24 Gulf Research Development Co Process of preventing the separation of polyethylene and wax comprising the addition of water
US3117101A (en) * 1958-07-28 1964-01-07 Sinclair Research Inc Wax coating compositions
US3112681A (en) * 1959-08-03 1963-12-03 Exxon Research Engineering Co Paving with polymer-bonded aggregates
US4567087A (en) * 1983-06-28 1986-01-28 Nevamar Corporation Scuff resistance in abrasion-resistant laminates
US4738887A (en) * 1986-01-09 1988-04-19 Govertsen Lloyd G Wax applicator buffer
US5833196A (en) * 1995-04-17 1998-11-10 Keith; George A. Desk top mat
US5782444A (en) * 1996-04-26 1998-07-21 Interface, Inc. Cabinet skate
US5989380A (en) * 1997-01-08 1999-11-23 Frischer; Paul Process of dry printing a paper-like non-woven wall covering material
WO1998044217A1 (en) * 1997-04-01 1998-10-08 Baomu Co., Ltd. A method of making fabric floor plate and wall plate
US6212838B1 (en) * 1997-09-29 2001-04-10 Kabushikikaisha Edagumi Floor material and flooring using the floor material
US20040161588A1 (en) * 2001-05-29 2004-08-19 Hanns-Joerg Mauk Resilient floor covering with regenerative, dirt-repellent surface
US7186453B2 (en) * 2001-05-29 2007-03-06 Awi Licensing Company Resilient floor covering with regenerative, dirt-repellent surface
EP2500155A3 (en) * 2011-01-20 2015-10-07 TPS TechnoPartner Samtronic GmbH Polymer bound sheet and method for its manufacture
US20160076259A1 (en) * 2011-07-27 2016-03-17 Armstrong World Industries, Inc. Sound reducing tongue and groove member sound reducing fabrication process and sound reducing blend

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