Foamed surface covering with coherent layer
Embodiments of a new foamed surface covering are disclosed, wherein a primary layer of polymeric foam features at least one coherent layer consisting of a water-resistant blend of styrene-maleic anhydride and acrylic resin. The coherent layer facilitates the secured and reusable application of the surface covering after repeated washings.
1. A surface covering for horizontal and vertical surfaces, comprising:
a multilayered composite material comprising: (a) a primary layer of polymeric foam; and (b) at least one layer of coherent resin, wherein the at least one layer of coherent resin includes a water-resistant composition of styrene-maleic anhydride copolymer having a glass transition temperature in the range of −30° C. to −40° C. and acrylic resin, whereby the surface covering can be secured and reapplied to horizontal and vertical surfaces after repeated washings.
2. The surface covering according to claim 1 , wherein the primary layer of polymeric foam further includes a polymeric compound containing a resin selected from the group consisting of latex, polyvinyl chloride, polyurethane and ethylene vinyl acetate.
3. The surface covering according to claim 1 , wherein the primary layer of polymeric foam is composed of a thermally cured polyvinyl chloride (PVC) compound, the compound further comprising a plasticizer, polyvinyl chloride resins, calcium carbonate, a chemical foaming agent, a heat stabilizer, and a pigment.
4. The compound according to claim 3 , wherein the plasticizer is selected from the group consisting of Diisononyl phthalates (DINP), Dioctyl terephthalates (DOTP), Epoxidized Soybean Oils (ESO), or combinations thereof.
5. The compound according to claim 3 , further comprising a copolymeric blend of two dissimilar PVC homopolymer dispersion resins.
6. The surface covering according to claim 1 , wherein the primary layer is between 1.275 mm to 6.35 mm in thickness.
7. The surface covering according to claim 1 , wherein the primary layer of polymeric foam encases an intermediate reinforcing layer of knitted or nonwoven scrim.
8. The surface covering according to claim 7 , wherein the knitted scrim comprises woven yarns selected from the group consisting of natural or synthetic yarns.
9. The surface covering according to claim 8 , wherein the woven construction of the knitted scrim defines a series of apertures.
10. The surface covering according to claim 7 , wherein the nonwoven scrim comprises autogenously bonded polyester fibers.
11. The surface covering according to claim 1 , wherein the primary layer consists of a continuous layer of unsupported polymeric foam.
12. The surface covering according to claim 11 , wherein the continuous layer of unsupported foam includes at least one surface having a plurality of micro-embossed indentations.
13. The surface covering according to claim 12 , wherein the micro-embossed indentations provide an arrangement of concave recesses to enhance the bonding characteristics of the coherent layer.
14. The surface covering according to claim 1 , wherein at least one layer of coherent resin is between 0.5 mm to 1.5 mm in thickness.
15. The surface covering according to claim 1 , wherein the Styrene-Maleic Anhydride copolymer is formed by means of controlled radical polymerization.
16. The surface covering according to claim 1 , wherein the coherent layer of Styrene-Maleic Anhydride copolymer and Acrylic resin impedes the migration of plasticizers.
17. The surface covering according to claim 1 , wherein the coherent layer of Styrene- Maleic Anhydride copolymer and Acrylic resin prevents the adhesion of residual polymeric foam to subjacent surfaces upon removal.
18. The surface covering according to claim 1 , wherein the multilayered composite material does not require an integral release coating to protect the layer of coherent resin.
19. The surface covering according to claim 1 , wherein the multilayered composite material does not require a separable release liner to protect the layer of coherent resin.
20. A surface covering for horizontal and vertical surfaces, comprising:
a multilayered composite material comprising: (a) a primary layer of polymeric foam; (b) an obverse layer of coherent resin; (c) a subjacent layer of coherent resin; and (d) at least one separable release liner, wherein at least one layer of coherent resin includes a water-resistant composition of styrene-maleic anhydride copolymer having a glass transition temperature in the range of −30° C. to −40° C. and acrylic resin, whereby the surface covering can be secured and reapplied to horizontal and vertical surfaces after repeated washings.
21. The surface covering according to claim 20 , wherein the primary layer of polymeric foam further includes a polymeric compound containing a resin selected from the group consisting of latex, polyvinyl chloride, polyurethane and ethylene vinyl acetate.
22. The surface covering according to claim 20 , wherein the primary layer of polymeric foam is composed of a thermally cured polyvinyl chloride (PVC) compound, the compound further comprising a plasticizer, polyvinyl chloride resins, calcium carbonate, a chemical foaming agent, a heat stabilizer, and a pigment.
23. The compound according to claim 22 , wherein the plasticizer is selected from the group consisting of Diisononyl phthalates (DINP), Dioctyl terephthalates (DOTP), Epoxidized Soybean Oils (ESO), or combinations thereof.
24. The compound according to claim 22 , further comprising a copolymeric blend of two dissimilar PVC homopolymer dispersion resins.
25. The surface covering according to claim 20 , wherein the primary layer is between 1.275 mm to 6.35 mm in thickness.
26. The surface covering according to claim 20 , wherein the primary layer of polymeric foam encases an intermediate reinforcing layer of knitted or nonwoven scrim.
27. The surface covering according to claim 26 , wherein the knitted scrim comprises woven yarns selected from the group consisting of natural or synthetic yarns.
28. The surface covering according to claim 27 , wherein the woven construction of the knitted scrim defines a series of apertures.
29. The surface covering according to claim 26 , wherein the nonwoven scrim comprises autogenously bonded polyester fibers.
30. The surface covering according to claim 20 , wherein the primary layer consists of a continuous layer of unsupported polymeric foam.
31. The surface covering according to claim 30 , wherein the continuous layer of unsupported foam includes at least one surface having a plurality of micro-embossed indentations.
32. The surface covering according to claim 31 , wherein the micro-embossed indentations provide an arrangement of concave recesses to enhance the bonding characteristics of the coherent layer.
33. The surface covering according to claim 20 , wherein at least one layer of coherent resin is between 0.5 mm to 1.5 mm in thickness.
34. The surface covering according to claim 20 , wherein the Styrene-Maleic Anhydride copolymer is formed by means of controlled radical polymerization.
35. The surface covering according to claim 20 , wherein the coherent layer of Styrene- Maleic Anhydride copolymer and Acrylic resin impedes the migration of plasticizers.
36. The surface covering according to claim 20 , wherein at least one coherent layer of Styrene-Maleic Anhydride copolymer and Acrylic resin prevents the adhesion of residual polymeric foam to subjacent surfaces upon removal.