US20190315092A1 – October 17, 2019 – POLYURETHANE BASED RIGID FLOORING LAMINATE

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Inventors :

Robert G. Pierson; Henry C. Ashton; Robert L. Gray; Gilles Le Du

Owner :

SCHNELLER LLC

Application Number :

US16455852

Document Number :

US20190315092A1

Priority Date :

June 28, 2019

Filing Date :

June 28, 2019

Date of Grant/ Publication :

October 17, 2019

Class :

B32B7 / 12; B32B27 / 36; B32B27 / 28; B32B27 / 12; B32B27 / 20; B32B27 / 40; B32B27 / 30; B32B27 / 08; B32B27 / 38; B32B5 / 22; B32B27 / 34; B32B5 / 26; B32B5 / 02; B32B27 / 18

Abstract

The laminate according to the invention is a multiple layer structure and contains predominantly urethane-based polymeric materials in the cap and base layers thereof, with no significant amount of PVC. As such, under combustion conditions, the laminate releases substantially no harmful halogen-based bases, such as HCl or other toxic gases, and exhibits toxicity and smoke generation parameters well below acceptable industry standards.

Claim(s)

claim 1: 1 . A laminate structure comprising: a backing layer comprising, by weight, from about 20% to about 80% a fiber reinforcement and from about 80% to about 20% with a thermoset or thermoplastic polymer resin matrix; a base layer comprising an alloy layer made of polyurethane in combination with a terpolymer comprising polyamide, polyester and polyether or a combination thereof; and an adhesive layer disposed on a first surface of the base layer between the backing layer and the base layer; and a cap layer comprising polyurethane, wherein the peel resistance between the combination of the cap layer and base layer and the backing layer is at least about 103 Newtons (N) per 25 millimeters after aging for at least 500 hours.;
claim 2: 13 . A laminate structure comprising: a backing layer comprising, by weight, from about 40% to about 50% polyester, and from about 50% to about 60% by weight fiber reinforcement; a base layer comprising a polyurethane alloy comprising polyurethane in combination with a terpolymer comprising polyamide, polyester and polyether or a combination thereof sub layer containing polyurethane in combination with a copolymer of at least two of polyamide, polyether, polyester, polyether, polyimide, polyphenylene oxide and polystyrene; a first adhesive layer disposed between the backing layer and the base layer, the adhesive layer comprising a thermoplastic polyurethane; a cap layer disposed on a surface of the base layer opposite the backing layer and comprising a polyurethane-based material; and a second adhesive layer disposed between the base layer and the cap layer, wherein the laminate structure having no amount of PVC in any component layer of the laminate, and exhibits abrasion resistance of less than 400 mg according to ISO 9352.;
claim 3: 17 . A laminate structure comprising: a backing layer comprising, by weight from about 20% to about 80% fiber reinforcement and from about 80% to about 20% thermoset or thermoplastic polymer; a base layer comprising polyurethane-based material; and an adhesive layer disposed on a first surface of the base layer between the backing layer and the base layer; and a cap layer comprising polyurethane, wherein the laminate meets the toxicity flaming and non-flaming test protocols pursuant to AITM 2.0007 with respect to HCN, CO, NO 2 , SO 2 /H 2 S, HF, and HCl limits, said limits being less than 150, 1000, 100, 100, 100, and 150 respectively as measured by specific optical density, in addition to Federal Aviation Regulation 25.853 MD with regard to the parameters of vertical burn, drip time and char of the laminate, said limits being less than 15 seconds, 5 seconds and 203 mm respectively.;
claim 4: 18 . A laminate structure comprising: a backing layer comprising, by weight, from about 40% to about 50% polyester, and from about 50% to about 60% by weight fiber reinforcement; a base layer comprising a sub layer containing polyurethane; a first adhesive layer disposed between the backing layer and the base layer, the adhesive layer comprising a thermoplastic polyurethane; and a cap layer disposed on a surface of the base layer opposite the backing layer and comprising a polyurethane-based material, wherein the laminate does not generate harmful halogen gases upon combustion, and produces NBS smoke levels of less than 200 according to the ASTN E662 flaming mode test method and by specific optical density (Ds) @ 4 min. non-flaming mode test method.

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