PET wear layer/sol gel top coat layer composites

Abstract

Composite wear layers that include a polyethylene terephthalate wear layer adhered to an organic/inorganic (O/I) top coat layer, and surface coverings and surface covering components including the composite wear layers, are disclosed. The organic/inorganic top coat layer is formed from a top coat formulation that comprises a coupling agent that includes an organic polymerizable moiety such as epoxy, acrylate and the like, as well as an inorganic polymerizable moiety such as a silanol. The wear layer is typically in the range of about 1-20 mils thickness, and the top coat layer is typically in the range of 2 microns to 0.5 mils thickness. The composite wear layers can be included in surface coverings or surface covering components, such as floor and wall coverings. An adhesion promoter/binder can be used to better adhere the polyethylene terephthalate wear layer to the organic/inorganic top coat layer.

1 . A composite wear layer comprising: 
 a) a polyethylene terephthalate wear layer;    b) an organic/inorganic top coat layer, wherein the organic/inorganic top coat layer is formed from a composition comprising a coupling agent, an organic polymerizable monomer or oligomer and an inorganic polymerizable monomer, wherein the coupling agent is a molecule comprising an organic polymerizable moiety and an inorganic polymerizable moiety, wherein the organic polymerizable moiety of the coupling agent and the organic polymerizable monomer or oligomer are selected from the group consisting of (meth)acrylate, epoxy, isocyanate, vinyl ether, allyl, vinyl and acetylenic, wherein the organic polymerizable moiety of the coupling agent is capable of reacting with the organic polymerizable monomer or oligomer; and    c) a first adhesion promoter between the wear layer and the top coat layer.    
     
     
         2 - 7 . (canceled)  
     
     
         8 . The composite wear layer of  claim 1 , wherein the wear layer comprises a polyethylene terephthalate copolymer.  
     
     
         9 . The composite wear layer of  claim 1 , wherein the organic/inorganic top coat was formed from a top coat formulation comprising a colloidal inorganic sol.  
     
     
         10 - 12 . (canceled)  
     
     
         13 . The composite wear layer of  claim 1 , wherein the inorganic polymerizable moiety is selected from the group consisting of hydrolyzable Al, Zr, Si, Ti or B alkoxides and mixtures thereof.  
     
     
         14 - 18 . (canceled)  
     
     
         19 . A surface covering or surface covering component comprising the composite wear layer of  claim 1  and a substrate.  
     
     
         20 . The surface covering or surface covering component of  claim 19 , wherein the surface covering or surface covering component is a floor covering or floor covering component.  
     
     
         21 . The surface covering or surface covering component of  claim 20 , wherein the floor covering is a resilient tile.  
     
     
         22 . The surface covering or surface covering component of  claim 20 , wherein the floor covering is a resilient sheet product and wherein the resilient sheet product comprises a foam or foamable layer.  
     
     
         23 - 25 . (canceled)  
     
     
         26 . The surface covering or surface covering component of  claim 19 , wherein a second adhesion promoter is between the wear layer and the flooring substrate.  
     
     
         27 . (canceled)  
     
     
         28 . The surface covering or surface covering component of  claim 26 , wherein the second adhesion promoter is different from the first adhesion promoter.  
     
     
         29 - 32 . (canceled)  
     
     
         33 . A process of manufacturing a floor covering or floor covering component, comprising: 
 a) laminating a polyethylene terephthalate film to a flooring substrate,    b) applying a first adhesion promoter to an exposed surface of the polyethylene terephthalate film, and    c) applying an organic/inorganic top coat formulation to the exposed surface of the adhesion promoter, wherein the organic/inorganic top coat layer is formed from a composition comprising a coupling agent, an organic polymerizable monomer or oligomer and an inorganic polymerizable monomer, wherein the coupling agent is a molecule comprising an organic polymerizable moiety and an inorganic polymerizable moiety, wherein the organic polymerizable moiety of the coupling agent and the organic polymerizable monomer or oligomer are selected from the group consisting of (meth)acrylate, epoxy, isocyanate, vinyl ether, allyl, vinyl and acetylenic, wherein the organic polymerizable moiety of the coupling agent is capable of reacting with the organic polymerizable monomer or oligomer.    
     
     
         34 - 35 . (canceled)  
     
     
         36 . The process of  claim 33 , wherein a second adhesion promoter is between the wear layer and the flooring substrate.  
     
     
         37 . (canceled)  
     
     
         38 . The process of  claim 36 , wherein the second adhesion promoter is different from the first adhesion promoter.  
     
     
         39 . The process of  claim 33 , wherein the polyethylene terephthalate film comprises a copolymer of polyethylene terephthalate.  
     
     
         40 . A process of manufacturing a floor covering or floor covering component, comprising: 
 a) applying, an organic/inorganic top coat formulation to a polyethylene terephthalate film, wherein the organic/inorganic top coat layer is formed from a composition comprising a coupling agent, an organic polymerizable monomer or oligomer and an inorganic polymerizable monomer, wherein the coupling agent is a molecule comprising an organic polymerizable moiety and an inorganic polymerizable moiety, wherein the organic polymerizable moiety of the coupling agent and the organic polymerizable monomer or oligomer are selected from the group consisting of (meth)acrylate, epoxy, isocyanate, vinyl ether, allyl, vinyl and acetylenic, wherein the organic polymerizable moiety of the coupling agent is capable of reacting with the organic polymerizable monomer or oligomer, and    b) laminating the composite wear layer to a flooring substrate such that the polyethylene terephthalate film is overlying the flooring substrate and the organic/inorganic top coat is exposed.    
     
     
         41 . The process of  claim 40 , wherein the polyethylene terephthalate film further comprises an adhesion promoter and the top coat formulation is applied to the adhesion promoter.  
     
     
         42 . (canceled)  
     
     
         43 . The process of  claim 40 , wherein a second adhesion promoter is between the wear layer and the flooring substrate.  
     
     
         44 . (canceled)  
     
     
         45 . The process of  claim 43 , wherein the second adhesion promoter is different from the first adhesion promoter.  
     
     
         46 . The process of  claim 40 , wherein the polyethylene terephthalate film comprises a copolymer of polyethylene terephthalate.  
     
     
         47 . The surface covering or surface covering component of  claim 19 , wherein the polyethylene terephthalate wear layer comprises a copolymer of polyethylene terephthalate.