PITTS BRADY (US)
| US20110124796A1 | 2011-05-26 | |||
| US20100144225A1 | 2010-06-10 | |||
| US20080250571A1 | 2008-10-16 | |||
| US20070178239A1 | 2007-08-02 | |||
| EP2736977A1 | 2014-06-04 |
| CLAIMS The following is claimed: 1. A water repellant wax composition for reducing creaking and water permeability of a floor plank, the composition comprising a wax fraction containing a wax and a fluoropolymer fraction containing a fluoropolymer comprising structural units derived from an acrylate ester represented by the general formula (I): wherein X is hydrogen, methyl, fluoro, chloro, bromo, iodo, CFX 2 (wherein X1 and X2 are each hydrogen, fluoro, chloro, bromo, or iodo), cyano, straight-chain or branched fluoroalkyl having 1-21 carbon atoms, substituted or unsubstituted benzyl, or substituted or unsubstituted phenyl; Y is an aliphatic group having 1 to 10 carbon atoms; and Rf is a straight-chain or branched fluoroalkyl or fluoroalkenyl group having 1-6 carbon atoms. 2. An interlocking floor plank, comprising: a tongue, a groove on the opposite side of the plank from the tongue, and a layer of the water repellant wax composition of claim 1 on at least one of the tongue and the groove. 3. The floor plank of claim 2, the plank comprising an upper wear layer, a pattern layer below the wear layer, a core layer below the pattern layer, and a balancing layer below the core layer, in which the tongue and groove are part of the core layer. 4. The floor plank of claim 3, wherein the wear layer comprises melamine impregnated with aluminum oxide particles. 5. The floor plank of any one of claims 3-4, wherein the core layer is constructed from high density fiberboard. 6. The floor plank of any one of claims 2-3, in which the plank swells by less than 10% when exposed to water according to the LANASEAL swell test. 7. The floor plank of any one of claims 2-6, in which the plank swells by less than 5% when exposed to water according to the LANASEAL swell test. 8. The floor plank of any one of claims 2-7, in which the plank swells by about 0% when exposed to water according to the test LANASEAL swell test. 9. The floor plank of any one of claims 2-8, in which the plank swells by less than 15% when exposed to a detergent solution according to the LANASEAL swell test. 10. The floor plank of any one of claims 2-9, in which the plank swells by less than 10% when exposed to a detergent solution according to the LANASEAL swell test. 11. The floor plank of any one of claims 2-10, in which the plank swells by about 5% or less when exposed to a detergent solution according to the LANASEAL swell test. 12. The floor plank of any one of claims 2-11, in which the plank swells by about 0% when exposed to a detergent solution according to the LANASEAL swell test. 13. A method of making a water repellant wax composition for reducing creaking and water permeability of a floor plank, comprising blending: a wax fraction containing a wax, and a fluoropolymer fraction containing a fluoropolymer, said fluoropolymer comprising structural units derived from an acrylate ester represented by the general formula (I): o x II I Rf— Y— O— C— C=C¾ wherein X is hydrogen, methyl, fluoro, chloro, bromo, iodo, CFX 2 (wherein X1 and X2 are each hydrogen, fluoro, chloro, bromo, or iodo), cyano, straight-chain or branched fluoroalkyl having 1-21 carbon atoms, substituted or unsubstituted benzyl, or substituted or unsubstituted phenyl; Y is an aliphatic group having 1 to 10 carbon atoms; and Rf is a straight-chain or branched fluoroalkyl or fluoroalkenyl group having 1-6 carbon atoms. 14. The method of claim 13, wherein the fluoropolymer is a solid when blended with the wax. 15. The method of any one of claims 13-14, wherein blending occurs at a temperature of 50° C or higher. 16. The method of any one of claims 13-15, wherein blending occurs at a temperature of 60° C or higher. 17. The method of any one of claims 13-16, wherein blending occurs at a temperature of 70° C or higher. 18. The method of any one of claims 13-17, wherein blending occurs at a temperature of 80° C or higher. 19. The method of any one of claims 13-18, wherein blending occurs at a temperature of 90° C or higher. 20. A water repellant wax composition for reducing creaking and water permeability of a floor plank that is the product of any one of the methods of claims 13-19. 21. Any one of the above, in which the fluoropolymer makes up at least about 10% w/w of the water repellant wax composition. 22. Any one of the above, in which the fluoropolymer makes up at least about 10-50% w/w of the water repellant wax composition. 23. Any one of the above, in which the fluoropolymer makes up about 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80% of the water repellant wax composition. 24. Any one of the above, in which the fluoropolymer makes up about 25% and the wax makes up about 75% of the water repellant wax composition. 25. Any one of the above, wherein the wax is a hydrocarbon wax. 26. Any one of the above, wherein the wax is a petroleum wax. 27. Any one of the above, wherein the wax is an animal wax. 28. Any one of the above, wherein the wax is a vegetable wax. 29. Any one of the above, wherein the wax is a petroleum wax selected from the group consisting of a paraffin wax and a microcrystalline wax. 30. Any one of the above, wherein the wax is selected from the group consisting of: beeswax, carnauba wax, and soy wax. 31. Any one of the above, wherein the melting point of the fluoropolymer is greater than or equal to the melting point of the wax. 32. Any one of the above, wherein the wax has a melting point at about 37-40° C. 33. Any one of the above, wherein the fluoropolymer has a melting point at about 40-45° C. 34. Any one of the above, wherein the wax has a melting point at about 37-40° C and the fluoropolymer has a melting point at about 40-45° C. 35. Any one of the above, wherein the wax fraction contains at least 50% w/w of the wax. 36. Any one of the above, wherein the wax fraction contains at least 75% w/w of the wax. 37. Any one of the above, wherein the wax fraction contains at least 90% w/w of the wax. 38. Any one of the above, wherein the wax fraction consists of the wax. 39. Any one of the above, wherein the fluoropolymer fraction contains at least 50% w/w of the fluoropolymer. 40. Any one of the above, wherein the fluoropolymer fraction contains at least 75% w/w of the fluoropolymer. 41. Any one of the above, wherein the fluoropolymer fraction contains at least 90% w/w of the fluoropolymer. 42. Any one of the above, wherein the fluoropolymer fraction consists of the fluoropolymer. 43. Any one of the above, wherein the fluoropolymer fraction consists of the fluoropolymer and the wax fraction consists of the wax. 44. Any one of the above, wherein the wax composition displays a contact angle of at least 60° with 2% w/v AATCC Standard Reference Liquid Detergent. 45. Any one of the above, wherein the wax composition displays a contact angle of at least 60° with 50% v/v isopropanol. 46. Any one of the above, wherein the wax composition displays a resistance to a 50% v/v propanol solution according to the blotter paper test when applied at 64 mg inch"1. 47. Any one of the above, wherein the wax composition displays a resistance to 2% w/v AATCC Standard Reference Liquid Detergent according to the blotter paper test when applied at 64 mg inch"1. 48. Any one of the above, wherein the wax composition displays a resistance to a 50% v/v propanol solution according to the blotter paper test when applied at 128 mg inch"1. 49. Any one of the above, wherein the wax composition displays a resistance to 2% w/v AATCC Standard Reference Liquid Detergent according to the blotter paper test when applied at 128 mg inch"1. |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application cites the priority of US 62/369,602, filed on 1 August 2016 (currently pending). The foregoing application is incorporated herein by reference in its entirety.
BACKGROUND
Interlocking planks, such as planks of laminate flooring, are constructed with tongue- and-groove features that allow the planks to be easily assembled to form the needed surface. These features also provide a degree of give and flexibility to the surface, increasing its durability and lifespan. However, when assembled the planks are noisy when they flex relative to one another, resulting for example in a squeaky floor. Such surfaces are generally cleaned with water or solutions of water and soap or detergents, and such aqueous cleaning substances can infiltrate between the planks. Especially in the case of laminate flooring, this infiltration can result in swelling of the planks, which can permanently disfigure the floor.
These problems have been addressed in the past by applying a thin layer of hydrocarbon-based wax to the tongue and groove of the plank. The wax mainly serves to lubricate the planks relative to one another, so that they do not make noise when they flex relative to one another. Such planks fit together quite tightly, so only a very thin layer of wax can be applied. Unfortunately, the layer of wax is too thin to provide much resistance to aqueous liquids (defined as water, a water-based solution, and a water-based suspension) such as water, detergent solutions, and aqueous emulsions. Aqueous liquid resistance for such plank surfaces is typically achieved by coating the top of the surface (such as a floor surface) with a thick layer of wax. However, this external coating can quickly wear off with use, and must be renewed frequently.
Therefore, there is a need in the art for a means to prevent the infiltration of aqueous liquids between planks, such as laminated floor planks, that is more lasting than external waxing. SUMMARY
The problems outlined above, as well as others, are addressed by an interlocking floor plank, comprising a layer of wax containing a fluoropolymer additive; and by a wax composition that repels aqueous liquids. The fluoropolymer additive has several advantages, such as miscibility with commercially available waxes and a melting j temperature equal to or greater than many such waxes. Methods of making and using the plank and wax are also provided.
In a first aspect an interlocking floor plank is provided comprising a tongue, a groove, and a layer of wax composition on at least one of the tongue and the groove, the layer of wax composition comprising a fluoropolymer comprising structural units derived from an acrylate ester represented by the general formula (I): o x
Rf— Y— O— C II— C I =C¾ wherein X is hydrogen, methyl, fluoro, chloro, bromo, iodo, CFX X X 2 (wherein X 1 and X 2 are each hydrogen, fluoro, chloro, bromo, or iodo), cyano, straight-chain or branched fluoroalkyl having 1-21 carbon atoms, substituted or unsubstituted benzyl, or substituted or unsubstituted phenyl; Y is an aliphatic group having 1 to 10 carbon atoms or the like; and Rf is a straight-chain or branched fluoroalkyl or fluoroalkenyl group having 1 to 6 carbon atoms. In a second aspect, a water repellant wax composition for reducing creaking and permeability of a floor plank is provided, the composition comprising a wax and a fluoropolymer comprising structural units derived from an acrylate ester represented by the general formula (I) as provided above.
In a third aspect, a method of making a water repellant wax composition for reducing creaking and permeability of a floor plank is provided, comprising blending a hydrocarbon-based wax with a solid fluoropolymer, said fluoropolymer comprising structural units derived from an acrylate ester represented by the general formula (I) as provided above.
The above presents a simplified summary in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview.
It is not intended to identify key or critical elements or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. The general construction of laminate planks.
FIG. 2. An illustration of the mechanism of liquid infiltration and swelling.
FIG. 3. Swelling due to liquid infiltration using 50% fluoropolymer composition.
FIGS. 4A-4B. Swelling due to liquid infiltration (water v. aqueous detergent solution) using 10, 25, and 40% fluoropolymer compositions. FIG. 4A shows swelling of the boards initially after all of the liquid has evaporated. FIG. 4B shows swelling after 24 hours.
FIGS 5A-E. Blotter paper sprayed with LANASEAL 37C with or without fluoropolymer then exposed to water (left droplet) and 2% detergent solution (right droplet). Two layer weights are shown. FIGS. 6A-E, Blotter paper sprayed with paraffin wax with or without fluoropolymer then exposed to water (left droplet) and 2% detergent solution (right droplet). Two layer weights are shown.
FIGS. 7A-E. Blotter paper sprayed with beeswax with or without fluoropolymer then exposed to water (left droplet) and 2% detergent solution (right droplet). Two layer weights are shown.
FIGS. 8A-E. Blotter paper sprayed with carnauba wax with or without fluoropolymer then exposed to water (left droplet) and 2% detergent solution (right droplet). Two layer weights are shown.
FIGS. 9A-E. Blotter paper sprayed with soy wax with or without fluoropolymer then exposed to water (left droplet) and 2% detergent solution (right droplet). Two layer weights are shown.
FIG. 10. Contact angles of three aqueous liquids on surfaces treated with either 100% wax or a blend of 75% wax and 25% fluoropolymer, in which the wax is LANASEAL 37C. The wax composition was applied at both 64 mg inch "2 and 128 mg inch "2 . The bars represent deionized water on 100% wax, 2% detergent solution on 100% wax, 50% isopropanol solution on 100% wax, deionized water on 75% wax/25% FP, 2% detergent solution on 75% wax/25% FP, and 50% isopropanol solution on 75% wax/25% FP.
FIG. 11. Contact angles of three aqueous liquids on surfaces treated with either 100% wax or a blend of 75% wax and 25% fluoropolymer, in which the wax is paraffin wax. The wax composition was applied at both 64 mg inch "2 and 128 mg inch "2 . The bars represent deionized water on 100% wax, 2% detergent solution on 100% wax, 50% isopropanol solution on 100% wax, deionized water on 75% wax/25% FP, 2% detergent solution] on 75% wax/25% FP, and 50% isopropanol solution on 75% wax/25% FP. FIG. 12. Contact angles of three aqueous liquids on surfaces treated with either 100% wax or a blend of 75% wax and 25% fluoropolymer, in which the wax is beeswax. The wax composition was applied at both 64 mg inch "2 and 128 mg inch 2 . The bars represent deionized water on 100% wax, 2% detergent solution on 100% wax, 50% isopropanol solution on 100% wax, deionized water on 75% wax/25% FP, 2% detergent solution on 75% wax/25% FP, and 50% isopropanol solution on 75% wax/25% FP.
FIG. 13. Contact angles of three aqueous liquids on surfaces treated with either 100% wax or a blend of 75% wax and 25% fluoropolymer, in which the wax is palm wax (carnauba). The wax composition was applied at both 64 mg inch "2 and 128 mg inch "2 . The bars represent deionized water on 100% wax, 2% detergent solution on 100% wax, 50% isopropanol solution on 100% wax, deionized water on 75% wax/25% FP, 2% detergent solution on 75% wax/25% FP, and 50% isopropanol solution on 75% wax/25% FP.
FIG. 14. Contact angles of three aqueous liquids on surfaces treated with either 100% wax or a blend of 75% wax and 25% fluoropolymer, in which the wax is soy wax. The wax composition was applied at both 64 mg inch "2 and 128 mg inch "2 . The bars represent deionized water on 100% wax, 2% detergent solution on 100% wax, 50% isopropanol solution on 100% wax, deionized water on 75% wax/25% FP, 2% detergent solution on 75% wax/25% FP, and 50% isopropanol solution on 75% wax/25% FP.
DETAILED DESCRIPTION
A. DEFINITIONS
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art of this disclosure. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well known functions or constructions may not be described in detail for brevity or clarity.
It will be understood that when a feature or element is referred to as being "on" another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being "directly on" another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being "connected", "attached" or "coupled" to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being "directly connected", "directly attached" or "directly coupled" to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
Spatially relative terms, such as "under", "below", "lower", "over", "upper" and the like, may be used herein for ease of description to describe one element or feature's relationship to another when the plank is positioned in the horizontal position, as it would be when part of a floor. The terms "first," "second," and the like are used herein to describe various features or elements, but these features or elements should not be limited by these terms. These terms are only used to distinguish one feature or element from another feature or element. Thus, a first feature or element discussed below could be termed a second feature or element, and similarly, a second feature or element discussed below could be termed a first feature or element without departing from the teachings of the present disclosure.
With reference to the use of the words "comprise" or "comprises" or "comprising" in the foregoing description and/or in the following claims, those words are used on the basis and clear understanding that they are to be interpreted inclusively, rather than exclusively, and that each of those words is to be so interpreted in construing the foregoing description and the following claims.
The term "consisting essentially of" means that, in addition to the recited elements, what is claimed may also contain other elements (steps, structures, ingredients, components, etc.) that do not adversely affect the operability of what is claimed for its intended purpose as stated in this disclosure. This term excludes such other elements that adversely affect the operability of what is claimed for its intended purpose as stated in this disclosure, even if such other elements might not adversely affect the operability of what is claimed for some other purpose.
The terms "about" or "approximately" mean within a range of reasonable error around a central value. Such reasonable error may for example stem from the precision of an instrument or method used to measure the value. The error could also stem from the precision of a method of making a component of a device. Specific examples of such limits of reasonable error are ± 20%, 10%, 5%, 2.5%, and 1%. Unless specified otherwise, all numerical values in the specification may be approximate or exact. B. FLUOROPOLYMER
The fluoropolymer that is useful for enhancing resistance to liquid infiltration is a fluorinated acrylate ester. A general embodiment of the fluoropolymer has the general formula (I): o x
Rf— Y— O— C II— C I =C¾ wherein X is hydrogen, methyl, fluoro, chloro, bromo, iodo, CFX 3 ^ 2 (wherein X 1 and X 2 are each hydrogen, fluoro, chloro, bromo, or iodo), cyano, straight-chain or branched fluoroalkyi having 1-21 carbon atoms, substituted or unsubstituted benzyl, or substituted or unsubstituted phenyl; Y is an aliphatic group having 1 to 10 carbon atoms or the like; and Rf is a straight-chain or branched fluoroalkyi or fluoroalkenyl group having 1 to 6 carbon atoms.
In the fluorine-containing acrylate ester, X is preferably a hydrogen atom or a methyl group. In the formula (I), the Rf group is preferably a perfluoroalkyl or perfluoroalkenyl group. The carbon number of the fluoroalkyi or fluoroalkenyl group is from 1 to 6, for example, from 1 to 4.
Examples of the fluoroalkyi group include -CF3, -CF 2 CF3, -CF 2 CF 2 CF 3 , -CF(CF 3 )2, - CF 2 CF 2 CF 2 CF 3 , -CF 2 CF(CF 3 ) 2 , -C(CF 3 ) 3 , -(CF2) 4 CF 3 , -(CF 2 ) 2 CF(CF 3 ) 2 , -CF2C(CF 3 ) 3 , - CF(CF 3 )CF 2 CF 2 CF 3 , -(CF 2 ) 5 CF 3 , and -(CF 2 ) 3 CF(CF 3 ) 2 . Examples of the fluoroalkenyl group include CF=CF 2 , F 2 CF=CF 2 , -(CF 2 ) 2 CF=CF 2 , -CF 2 C(CF 3 )=CF 2 , -CF(CF 3 )CF=CF 2 , -(CF2) 3 CF=CF 2 , -(CF 3 ) 2 CF=CF 2 , -(CF 2 ) 2 C(CF 3 )=CF 2 , (CF 2 ) 4 CF=CF 2 , -(CF 2 ) 4 CF=CF 2 , and -(CF 2 ) 3 C(CF 3 )=CF 2 .
Y is an aliphatic group having 1 to 10 carbon atoms, an aromatic or cycloaliphatic group having 6 to 10 carbon atoms, a -CH 2 CH 2 N(R 1 )S0 2 - group (in which R 1 is an alkyl group having 1 to 4 carbon atoms) or a ^ -CH2CH(OY 1 )CH2- group (in which Y 1 is a hydrogen atom or an acetyl group). The aliphatic group is preferably an alkylene group (having particularly 1 to 4, for example, 1 or 2 carbon atoms) The aromatic or cycloaliphatic group may be substituted or unsubstituted.
Examples of the fluorine-containing acrylate ester include acrylate esters of the formulas:
R 1
Rf— S0 2 — NR 2 OCOCR 3 =CH 2
(1)
Rf (CH 2 ) n OCOCR 3 =CH 2
(2)
R 1
Rf— CO N 1 R 2 2 OCOCR 3 =CH 2
(3)
OH
Rf— CH 2 CHCH 2 OCOCR 3 =CH 2
(4)
Rf— 0— Ar— CH 2 OCOCR 3 =CH 2
(5) wherein Rf is a perfluoroalkyi group having 1 to 6 carbon atoms,
R 1 is hydrogen or an alkyl group having 1 to 10 carbon atoms, R 2 is an alkylene group having 1 to 10 carbon atoms, R 3 is a hydrogen atom or a methyl group,
Ar is an aryl group optionally having a substituent group, and n is an integer of 1 to 10.
Specific examples of the fluorine-containing polymerizable compound include:
CF 3 (CF 2 ) 5 (CH 2 )OCOCH=CH 2 , CF3(CF2) 5 (CH 2 )OCOC(CH 3 )=CH 2 ,
(CF 3 ) 2 CF(CF 2 ) 3 (CH 2 ) 2 OCOCH=CH 2 ,
CF 3 CF 2 (CH 2 ) 2 OCOCH=CH 2 ,
CF 3 (CF 2 ) 3 S0 2 N(CH 3 )(CH 2 ) 2 OCOCH=CH 2 ,
CF 3 (CF 2 )3S0 2 N(C 2 H5)(CH2) 2 OCOC(CH 3 )=CH 2/
(CF 3 ) 2 CF(CF 2 )3CH2CH(OCOCH3)CH 2 OCOC(CH3)=CH 2; and
(CF3)2CF(CF2)3CH 2 CH(OH)CH 2 OCOCH=CH-2.
The fluorine-containing polymer may contain a chlorine-containing polymerizable compound as repeating units. The chlorine-containing polymerizable compound is a compound having both a chlorine atom and a carbon-carbon double bond. Examples of the chlorine-containing polymerizable compound are vinyl chloride, vinylidene chloride, alpha- chloroacrylate (for example, an alkyl (having 1 to 30 carbon atoms) ester) and 3-chloro-2- hydroxypropyl methacrylate.
The fluorine-free polymerizable compound may be, for example, a fluorine-free alkyl (meth)acrylate.
The fluorine-free alkyl (meth)acrylate is generally a compound of the formula: X 1 -- CX 2 =CH 2 (i) wherein X 1 is an alkyl carboxylate group (the alkyl group has 1 to 18 carbon atoms), and X 2 is a hydrogen atom or a methyl group.
The fluorine-containing polymer may in some embodiments not contain the fluorine- free alkyl (meth)acrylate.
The other copolymerizable compound may be various. Examples of the other copolymerizable compound include: (1) acrylic acid and methacrylic acid, and methyl, ethyl, butyl, isobutyl, t-butyl, propyl, 2-ethylhexyl, hexyl, decyl, lauryl, stearyl, isobornyl, -β-hydroxyethyl, glycidyl,: phenyl, benzyl and 4-cyanophenyl esters thereof;
(2) vinyl esters of fatty acids such as acetic acid, propionic acid, caprylic acid, lauric acid and stearic acid;
(3) styrene compounds such as styrene, a-methylstyrene and p-methylstyrene;
(4) vinyl and vinylidene halide compounds (excluding chlorides) such as vinyl fluoride, vinyl bromide and vinylidene fluoride;
(5) fatty acid allyl esters such as allyl heptanoate, allyl caprylate and allyl caproate; (6) vinyl alkyl ketones such as vinyl methyl ketone and vinyl ethyl ketone;
(7) acryl amides such as N-methylacrylamide and N-methylolmethacrylamide; and
(8) dienes such as 2,3-dichloro-l,3-butadiene and isoprene.
In the fluorine-containing polymer which is the copolymer, the amount of the fluorine-containing polymerizable compound may be at least 10% by weight, for example, from 20 to 80% by weight, particularly from 30 to 60% by weight. In the chlorine-containing polymer, the amount of the chlorine-containing polymerizable compound is at most 50% by weight, for example, from 0 to 30% by weight, particularly from 0.5 to 25% by weight.
The molecular weight of the fluorine-containing polymer may be generally from 1,000 to 1,000,000, particularly from 3,000 to 50,000 (for example, in terms of polystyrene measured by GPC).
C. WAX COMPOSITION
A water repellant wax composition for reducing creaking and water permeability of a floor plank is provided, the composition comprising a wax and the fluoropolymer described above. The wax component may be any wax that would be deemed suitable by one of ordinary skill in the art for this purpose. Hydrocarbon waxes are one exemplary class of waxes useful for lubricating planks; petroleum waxes (such as but not limited to paraffin wax, microcrystalline wax, and petroleum jelly) are a more specific class of example. In a specific embodiment of the water repellant wax composition, the wax is LANASEAL 37C (available from Lenmar Chemical Corp., Dalton, Georgia, USA). Comparable commercially available products may also be used.
The fluoropolymer is present in the composition in an amount sufficient to significantly reduce the infiltration of liquids between planks when the planks are assembled using the composition. In this context "significantly reduce" refers to a measurable reduction compared to the use of the wax portion of the wax composition alone. This may be measured, for example, by the amount of swelling caused by liquid infiltration between two planks, as in the tests performed in the example below. One example of such a measurable reduction is a 50% reduction in swelling compared to the wax component alone. It may also be measured by the amount of swelling caused by liquid infiltration between two planks without reference to the amount of swelling seen with the wax alone, as in the tests performed in the example below. For example, the amount may be sufficient to limit the swell of the plank to below about 15, 10, or 5%. Alternatively, the amount may be sufficient to limit the swell to about 0%. The liquid in question is an aqueous liquid, such as water, a detergent solution, and a soap solution. In a specific example, the detergent is AATCC Standard Reference Liquid Detergent (as per AATCC Monograph M2, published in AATCC Technical Manual/2014, and Developed in 2003 by AATCC Committee RA88; revised 2005; numbered in 2011) at 2% w/v.
In some embodiments of the wax composition, the fluoropolymer is present at about 10-50% w/w. In some specific embodiments, the amount of fluoropolymer is one of about 10, 25, 40, 50% (w/w), at least one of these values, or any range between these values. In a particular embodiment the fluoropolymer is present at about 25% w/w and the wax is present at about 75% w/w.
The wax composition may be made by any suitable method. An advantage of the fluoropolymer of this disclosure is that its melting point is close to the melting point of commercial waxes like LANASEAL 37C. The composition may be made by a method comprising blending the wax with the fluoropolymer. The amounts of fluoropolymer and wax can be varied to achieve the desired blend ratio. Blending may be facilitated by exposing the mixture to heat using an oven, drum heater, or other suitable apparatus. In some embodiments of the production process, the heat is sufficient to at least partially melt each component. In a specific embodiment of the method the blend is exposed to a temperature of at least about 50° C. In further embodiments, the blend is exposed to a temperature of at least about 60, 70, 80, or 90° C. Blending can be achieved using a mechanical stirrer or other suitable apparatus. Either component may be solid or liquid prior to blending.
The wax composition may also be made by adding the fluoropolymer in solid form to the wax in liquid or semi-solid form. This can be achieved in various ways, including by selecting a fluoropolymer with a melting point at least as high as that of the wax. In a specific embodiment the fluoropolymer has a melting point of about 40-45° C and the wax has a melting point of about 37-40° C. The use of solid particulate fluoropolymer; has the advantage of simpler handing and less preparation compared to solutions and emulsions.
A wax composition for reducing creaking and water permeability of a floor plank, that repels aqueous liquids, is provided that is the product of any of the above methods. D. INTERLOCKING FLOOR PLANK An interlocking floor plank 100 is provided, comprising a tongue 110, a groove 120, and a layer 130 of wax composition on at least one of the tongue 110 and the groove 120, the layer 130 of wax composition comprising any of the fluoropolymers provided above. The layer 130 of wax composition may also be any of the wax compositions described above.
The tongue 110 and the groove 120 are located on opposite sides of the plank 100, typically separated by a top surface 140 and a parallel bottom surface 150. Flooring planks are generally rectangular in shape (i.e., right rectangular prism) with the tongue 110 and groove 120 positioned on the right and left sides. In this disclosure such rectangular planks 100 are referred to as having a length that is greater than the width, the width being greater than the depth. The top and bottom sides have length and width, the right and left sides have length and depth, and the front and back sides have depth and width. Of course, the plank 100 may be of any other suitable shape, as could be designed for various purposes by one of ordinary skill in the art. Such other shapes include without limitation a parallelepiped, square cuboid, triangular prism, rhomboid prism, and hexagonal prism. Some embodiments of the plank have a tongue and groove on one side each, but could be engineered to have more than one tongue 110 or more than one groove 120 depending on the shape.
In some embodiments of the interlocking floor plank 100, the plank 100 is laminated flooring. In addition to the tongue 110 and groove 120, a laminate flooring plank 100 may comprise one or more of a wear layer 160 on top of the plank 100, a pattern layer 170 below the wear layer 160, a core layer 180 below the pattern layer 170, and a balancing layer 190 below the core layer 180. The wear layer's 160 purpose is to provide abrasion resistance. Commonly the wear layer 160 comprises melamine impregnated with aluminum oxide particles. The pattern layer 170 generally is a decorative image, for example an image imitating a wood or stone surface. The core layer 180 is the bulk of the structure that imparts mechanical strength and thickness, as well as some sound insulation. Typically a core layer 180 is constructed from high density fiberboard. The balancing layer 190 is generally a rigid waterproof layer. Some laminate planks 100 comprise an underlayer 200 that blocks moisture and dampens sound. The tongue 110 and groove 120 are generally part of the core layer 180, which is typically the thickest and strongest layer. Therefore, some embodiments of the floor plank 100 comprise at least the core layer 180.
The wax composition is applied to the tongue 110 or groove 120 of the plank 100. The wax composition is applied as a liquid, which will usually require an application temperature at which both the wax and the fluoropolymer are at least partially melted. For example, when the wax is LANASEAL 37C, the application temperature may be at least about 50° C. The wax composition can be applied by any suitable method, for example by brush, roller, or spray (such as a pneumatic spray).
E. EXAMPLE 1
Tests were conducted to determine whether a mixture of LANASEAL 37C and a fluoropolymer comprising structural units derived from an acrylate ester (hereinafter "fluoropolymer") confers resistance to water and detergent infiltration between laminate planks. The specific fluoropolymer is sometimes referred to in these examples as S-2234.
Small samples of edge-treated boards (50% fluoropolymer in LANASEAL 37C (w/w)) were measured for initial thickness and "click-locked" together. A ring of plumber's putty (approximately 4-6 inches in diameter) was used to make a dam over the seam of the boards. Either water (10 mL) or a detergent solution (10 mL, AATCC Standard Reference Liquid Detergent at 2% w/v) was added to the area inside the plumber's putty ring. When no liquid remained inside the ring, the putty was removed and the thickness of the boards was measured ("initial/' see FIG. 4A). The thickness was measured again after 24h (see FIG. 4B). The measurements were used to calculate the edge swell (just after the liquid was gone) and recovery (24h after the liquid was gone). Control samples included a positive control (LANASEAL 37C treatment without fluoropolymer) and a negative control (no edge treatment). This test was then repeated with the blend ratios varied from 10% to 40% (w/w, fluoropolymer/ LANASEAL 37C). This specific testing protocol may be referred to as "the LANASEAL swell test/' and any reference using this term should be construed to refer to the protocol above.
The results are summarized in FIGS. 3-4. FIG. 3 shows the percent swelling for the controls and the boards that were treated with 50% fluoropolymer/LANASEAL 37C. The swelling was reduced in the fluoropolymer-LANASEAL 37C boards in comparison to the negative control. This was true for both the water treated boards and the boards treated with aqueous detergent. FIGS. 4A-4B compare boards treated with various percentages of fluoropolymer-LANASEAL 37C. The boards were measured for swelling immediately after the evaporation of the liquid (FIG. 4A). None of the samples at the 10, 25, and 40% levels showed any swelling when exposed to water alone (including the positive control), indicating that the untreated boards were resistant to water-induced swelling under the test conditions. However, when exposed to the detergent solution, the fluoropolymer/LANASEAL 37C outperformed the LANASEAL 37C alone at all concentrations. The boards were also measured for swelling 24 hours after exposure (FIG. 4B), with substantially the same result. It is not clear why the LANASEAL 37C-treated planksiswelled after water exposure in the experiment presented in FIG. 3 but not in the experiment presented in FIGS. 4A and 4B. F. EXAMPLE 2
Tests were conducted to determine whether waxes other than LANASEAL 37C could effectively be used in combination with the fluoropolymer used in Example 1. Fluoropolymer was added to several waxes to test miscibility and compatibility. The ability of each mixture to repel water and detergent was tested at two coating weight targets (see Tables below).
TABLE 1: LANASEAL 37C TABLE 2: PARAFFIN WAX
TABLE 4: CARNUBA WAX
Carnauba Wax 100%
0.125 grams/in 2
S-223 4 0%
Target = 0.128 grams/in 2 Actual
Carnauba Wax 75%
0.149 grams/in 2
S-2234 25%
Using a hobby air brush set, the compositions were sprayed in molten state on blotter paper using a 1" (2.54 cm) diameter template. The blotter paper was used to observe penetration of water and detergent solution through the wax. The liquids used for testing were water with red dye and a 2% detergent solution (lower surface tension) with red dye. The droplets were applied to the surface of the wax in a controlled environment (22° C, 50% relative humidity). The blotter paper was observed to determine if there was penetration of the liquids through the wax. This specific testing protocol may be referred to as "the blotter paper test," and any reference using this term should be construed to refer to the protocol above.
The results are shown in FIGS. 4-8. Each wax used repelled water even in the absence of fluoropolymer. However, none of the waxes repelled the detergent solution in the absence of fluoropolymer (FIGS. 5A, 5C, 6A, 6C, 7 A, 7C, 8A, 8C, 9A, and 9C). With the addition of 25% w/w fluoropolymer, the wax/fluoropolymer composition effectively repelled the detergent solution at both 64 mg/in 2 (per 6.45 cm) and 128 mg/in 2 (per 6.45 cm) (FIGS. 5B, 5D, 6B, 6D, 7B, 7D, 8B, 8D, 9B, and 9D). These results demonstrate that a variety of natural and synthetic waxes can be used in the composition.
G. EXAMPLE 3
Tests were conducted to measure the contact angle of three aqueous liquids on mixtures of S-2234 in various waxes and on the waxes alone as controls. The fluoropolymer was added to several waxes (LANASEAL 37C, paraffin wax, beeswax, palm wax (carnauba), and soy wax) to test miscibility/compatibility and to test performance at two coating weight targets (64 mg inch 2 and 128 mg inch "2 ). Using a hobby air brush set, molten waxes were spray applied with and without fluoropolymer on blotter paper using a 1 inch (2.54 cm) diameter template. The contact angles of deionized water, 50% v/v isopropyl alcohol, and 2% detergent solution (as described above) were measured on the various waxes at 0% fluoropolymer and 25% fluoropolymer at coating weights of 64 mg inch "2 and 128 mg inch 2 . Static contact angle measurement was conducted in a controlled humidity and temperature environment set at 22° C and 50% relative humidity. The contact angles were measured with a KSV CAM 200 (Biolin Scientific, Gothenburg, Sweden) instrument and data analyzed using Attension Theta software (Biolin Scientific, Gothenburg, Sweden). Droplets were placed on sample using an Eppendorf pipette with a droplet size ranging from 2-5 μί.
Results are shown in FIGS. 10-14. In each of the five waxes tested, the addition of the fluoropolymer increased contact angles of the detergent solution and the isopropanol solution. Effects were similar at 64 mg inch 2 and 128 mg inch "2 . Contact angles between wax controls and the detergent solution and the isopropanol solution were about zero (completely wetted). The wax controls and the wax/fluoropolymer compositions both showed very high contact angles with deionized water. These results demonstrate significant improvements in resistance to lower surface tension liquids such as detergent and isopropanol solutions with the addition of the fluoropolymer.
H. CONCLUSIONS
It is to be understood that any given elements of the disclosed embodiments of the invention may be embodied in a single structure, a single step, a single substance, or the like. Similarly, a given element of the disclosed embodiment may be embodied in multiple structures, steps, substances, or the like. The foregoing description illustrates and describes the processes, machines, manufactures, compositions of matter, and other teachings of the present disclosure. Additionally, the disclosure shows and describes only certain embodiments of the processes, machines, manufactures, compositions of matter, and other teachings disclosed, but, as mentioned above, it is to be understood that the teachings of the present disclosure are capable of use in various other combinations, modifications, and environmentsiand are capable of changes or modifications within the scope of the teachings as expressed herein, commensurate with the skill and/or knowledge of a person having ordinary skill in the relevant art. The embodiments described hereinabove are further intended to explain certain best modes known of practicing the processes, machines, manufactures, compositions of matter, and other teachings of the present disclosure and to enable others skilled in the art to utilize the teachings of the present disclosure in such, or other, embodiments and with the various modifications required by the particular applications or uses. Accordingly, the processes, machines, manufactures, compositions of matter, and other teachings of the present disclosure are not intended to limit the exact embodiments and examples disclosed herein. Any section headings herein are provided only for consistency with the suggestions of 37 C.F.R. § 1.77 or otherwise to provide organizational queues. These headings shall not limit or characterize the invention(s) set forth herein.