US4439480A — Radiation cured coating and process therefor

Claim 1

Independent Claim 131 words

Method of forming a pigmented, radiation cured coating on a substrate comprising: (a) applying to the substrate a pigmented first layer between about 0.01 and about 0.1 mm thick of radiation curable material and subjecting such layer to ionizing irradiation or ultraviolet light in an atmosphere containing at least about 5,000 ppm oxygen until the radiation curable material is cured except for its surface; and (b) then applying to selected areas of the surface of the thus partially cured first layer an unpigmented second layer of the same or a different radiation curable material and subjecting the second layer to ionizing irradiation or ultraviolet light in an inert atmosphere containing less than about 1,000 ppm oxygen to thereby completely cure said second layer and complete the cure of the first layer.

Claim 2

Dependent Claim 131 words

Method of forming a pigmented, radiation cured coating on a substrate comprising: (a) applying to the substrate a pigmented first layer between about 0.01 and about 0.1 mm thick of radiation curable material and subjecting such layer to ionizing irradiation or ultraviolet light in an atmosphere containing at least about 5,000 ppm oxygen until the radiation curable material is cured except for its surface; and (b) then applying to selected areas of the surface of the thus partially cured first layer an unpigmented second layer of the same or a different radiation curable material and subjecting the second layer to ionizing irradiation or ultraviolet light in an inert atmosphere containing less than about 1,000 ppm oxygen to thereby completely cure said second layer and complete the cure of the first layer.

Claim 3

Dependent Claim 25 words

Method according to claim 1 wherein radiation curable material of said first and second layers is substantially solvent free and the first layer is opaque.

Claim 4

Dependent Claim 35 words

Method according to claim 1 wherein the coating material used for said layers of material comprises in each case fluid urethane compound containing at least two photo-polymerizable, ethylenically unsaturated groups of the general structure: ##STR4##

Claim 5

Dependent Claim 37 words

Method according to claim 1 wherein each of steps (a) and (b) includes subjecting the radiation curable material to ultraviolet light until a radiation dosage between about 0.2 and 20 megarads has been received by the material.

Claim 6

Dependent Claim 97 words

Method according to claim 1 wherein (a) radiation curable material of said first and second layers is substantially free of non-reactive solvent; (b) the coating material used for said layers of material comprises in each case fluid urethane compound containing at least two photo-polymerizable, ethylenically unsaturated groups of the general structure: ##STR5## where R is either H or CH 3 and (c) each of steps (a) and (b) of claim 1 includes subjecting the radiation curable material to ultraviolet light until a radiation dosage between about 0.2 and about 20 megarads have been received by the material.

Claim 7

Dependent Claim 17 words

Method according to claim 5 wherein the substrate is vinyl tile base material or sheet vinyl material.

Claim 8

Dependent Claim 24 words

Method according to claim 1 wherein the second layer is between about 0.01 and about 0.15 mm thick and the first layer is opaque.

Claim 9

Dependent Claim 10 words

A coated article formed by the method of claim 1.

Claim 10

Dependent Claim 53 words

A coated article comprising a substrate, suitable for use in a floor covering product having two layers of radiation cured coating adhered thereto, the first layer being a pigmented layer between about 0.01 and about 0.1 mm thick and the second layer being an unpigmented layer adhered to and overlying the first layer.

Claim 11

Dependent Claim 53 words

A coated article comprising a substrate, suitable for use in a floor covering product having two layers of radiation cured coating adhered thereto, the first layer being a pigmented layer between about 0.01 and about 0.1 mm thick and the second layer being an unpigmented layer adhered to and overlying the first layer.

Claim 12

Dependent Claim 26 words

A coated article according to claim 9 wherein the second layer is between about 0.01 and about 0.15 mm thick and the first layer is opaque.

Claim 13

Dependent Claim 37 words

The coated article of claim 9 wherein the substrate is embossed in a decorative pattern and wherein the first pigmented layer is thicker in the valleys defined by the embossing than on the tops of the embossing.

Claim 14

Dependent Claim 21 words

The coated article of claim 9, wherein the second layer overlies and adheres to the first layer in selected areas only.

Claim 15

Dependent Claim 26 words

The coated article of claim 9 wherein the composition of the second layer is, except for the lack of pigment, the same as the first layer.

Claim 16

Dependent Claim 26 words

The coated article of claim 9 wherein the composition of the second layer is, in addition to the lack of pigment, different from the first layer.

Claim 17

Dependent Claim 42 words

The coated article of claim 9 wherein the second layer comprises a urethane compound photopolymerized from a fluid coating composition comprising at least two photo-polymerizable ethylenically unsaturated groups of the general structure: ##STR6## where R is either H or CH 3 .

Claim 18

Dependent Claim 18 words

The coated article of claim 9 wherein the substrate is vinyl tile base material or sheet vinyl material.

Claim 19

Dependent Claim 18 words

The coated article of claim 11 wherein the substrate is vinyl tile base material or sheet vinyl material.

Claim 20

Dependent Claim 25 words

The coated article of claim 11 formed by applying the first layer to the substrate by roll coating and the second layer by curtain coating.

Claim 21

Dependent Claim 74 words

Method of forming an article having a pigmented, radiation cured coating comprising: (a) applying to a substrate, suitable for use in a floor covering product, a first layer of pigmented radiation curable material; (b) then applying a second layer of unpigmented radiation curable material over the first layer, which is at least partially uncured prior to such application, and (c) completely curing both the first and second layers with ionizing irradiation or ultraviolet light.

Claim 22

Dependent Claim 74 words

Method of forming an article having a pigmented, radiation cured coating comprising: (a) applying to a substrate, suitable for use in a floor covering product, a first layer of pigmented radiation curable material; (b) then applying a second layer of unpigmented radiation curable material over the first layer, which is at least partially uncured prior to such application, and (c) completely curing both the first and second layers with ionizing irradiation or ultraviolet light.

Claim 23

Dependent Claim 31 words

The method of claim 19 wherein the first layer is between about 0.01 and about 0.1 mm thick and the second layer is between about 0.01 and about 0.15 mm thick.

Claim 24

Dependent Claim 115 words

Method of forming a pigmented, radiation cured coating on a substrate of embossed tile base or sheet material, each suitable for floor covering, comprising: (a) applying to the substrate a thin first layer of pigmented, radiation curable material, said layer being applied onto the substrate so that all of the substrate is covered by the coating and with enough pressure to leave puddles of coating material in the embossed valleys of the substrate, (b) then applying a thin second layer of unpigmented, radiation curable material over the first layer which is at least partially uncured prior to such application, and (c) completely curing both the first and second layers with ionizing irradiation or ultraviolet light.

Claim 25

Dependent Claim 115 words

Method of forming a pigmented, radiation cured coating on a substrate of embossed tile base or sheet material, each suitable for floor covering, comprising: (a) applying to the substrate a thin first layer of pigmented, radiation curable material, said layer being applied onto the substrate so that all of the substrate is covered by the coating and with enough pressure to leave puddles of coating material in the embossed valleys of the substrate, (b) then applying a thin second layer of unpigmented, radiation curable material over the first layer which is at least partially uncured prior to such application, and (c) completely curing both the first and second layers with ionizing irradiation or ultraviolet light.

Claim 26

Dependent Claim 31 words

The method of claim 21 wherein the first layer is between about 0.01 and about 0.1 mm thick and the second layer is between about 0.01 and about 0.15 mm thick.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-03-27	1987-09-26	1988-03-27	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-03-27	1991-09-26	1992-03-27	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-03-27	1995-09-26	1996-03-27	$7700.00	Window Closed / Lapsed

Radiation cured coating and process therefor

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