Radiation curable vinyl primer systems and ink-absorbing coatings formed therefrom

Abstract

A vinyl primer system is provided. The system includes a first oligomer and a photoinitiator. The first oligomer includes at least one of a polyether (meth) acrylate or a modified polyether (meth) acrylate. The photoinitiator is configured to cure at least the first oligomer upon exposure to UV light, LED light, and / or electron beam. The first oligomer is present in an amount of from 5% to 90% by weight of the vinyl primer system. The vinyl primer system comprises less than 20% by weight of monofunctional (meth) acrylic monomers. The vinyl primer system is configured to provide an ink-absorbing coating on a substrate.

Description

Cross-references to related applications

[0001] This application relates to and claims priority to U.S. Provisional Application Serial No. 63 / 534,391, filed August 24, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This invention relates to vinyl primer systems and methods for preparing the same, to provide an ink-absorbing coating for a substrate, the ink-absorbing coating comprising a photoinitiator and a first oligomer comprising a polyether (meth)acrylate or a modified polyether (meth)acrylate. Background Technology

[0003] Vinyl flooring is increasingly becoming a popular alternative to natural hardwood flooring due to its durability, cost, ease of installation, and engineered, predictable design. Several materials are used in each vinyl flooring panel to make the installed flooring sound-absorbing, durable, comfortable to walk on, and aesthetically pleasing. For example, a vinyl flooring panel may include a base material, several structural layers, and adhesives, decorative, protective, and UV-barrier coatings. Summary of the Invention

[0004] One object of the present invention is to provide a vinyl primer system that has radiation curing and ink absorption (or printability) properties, and can be particularly used in the SPC (stone-plastic composite core) and LVT (luxury vinyl tile) flooring industries.

[0005] Another object of the present invention is to provide a vinyl primer system that provides one or more of the following: improved adhesion to a substrate, improved intercoating adhesion to digital inks on a top surface, and good print quality.

[0006] Another object of the present invention is to provide a vinyl primer system that has radiation curability, preferably UV curability, and can be applied in an environmentally friendly manner in the production of flooring products.

[0007] An additional object of the present invention is to provide a system and method for applying a vinyl primer system to a substrate.

[0008] These and other objects of the invention have been achieved, alone or in combination, by discovering a vinyl primer system and a method for applying it to a substrate, the system comprising a first oligomer comprising at least one of a polyether (meth)acrylate or a modified polyether (meth)acrylate; and a photoinitiator configured to cure at least the first oligomer upon exposure to UV light, LED light, and / or an electron beam, wherein the first oligomer is present in an amount of 5% to 90% by weight of the vinyl primer system, and the vinyl primer system comprises less than 20% by weight of a monofunctional (meth)acrylate monomer; and wherein the vinyl primer system is configured to provide an ink-absorbing coating on a substrate. The vinyl primer system, the ink-absorbing coating prepared therefrom, and the application method will be further described in the following detailed description and the appended claims. Attached Figure Description

[0009] The present invention may take the physical form of certain parts and arrangements of parts, the preferred embodiments of which will be described in detail in the specification and shown in the accompanying drawings which form part of the specification, and wherein:

[0010] Figure 1 Cross-sectional views of some embodiments of a coating system disposed on a substrate and comprising an ink-absorbing primer coating as will be discussed further herein are shown.

[0011] Figures 2 to 9 Perspective views of some embodiments of a method for forming a coating system over a substrate and curing the coating system over the substrate using curing radiation are shown.

[0012] Figure 10 It shows that it can be used with Figures 2 to 9 The flowcharts show some implementation schemes of the methods shown. Detailed Implementation

[0013] The range of values ​​expressed using endpoints includes all values ​​contained within that range (for example, 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0014] To the extent used herein, the terms “comprising,” “having,” “with,” or variations thereof are intended to be inclusive in a manner similar to the term “comprising.” The singular forms “a,” “an,” and “the / that” include multiple referents unless the context clearly indicates otherwise. Furthermore, the terms “a,” “an,” “the / that,” “at least one,” and “one or more” are used interchangeably. Thus, for example, a coating composition containing “a” additive means that the coating composition may contain “one or more” additives. As used throughout this specification and claims, approximate language may be applied to modify quantitative expressions that can be permissibly varied without causing a change in the essential function associated with them. Therefore, values ​​modified by terms such as “about” are not limited to the specified precise values. In some cases, approximate language may correspond to the precision of the instrument used to measure the value. Moreover, unless otherwise specifically stated, the use of the terms “first,” “second,” etc., does not indicate order or importance, but rather the terms “first,” “second,” etc., are used to distinguish one element from another.

[0015] The term "comprising" and its variations are not intended to be limiting when they appear in the specification and claims.

[0016] As used herein, the terms “may” and “may be” indicate a possibility of occurring within a set of conditions; possessing the specified property, characteristic, or function; and / or qualifying another verb by expressing one or more of the performance, capability, or possibility associated with a qualified verb. Thus, the use of “may” and “may be” indicates that the modified term is clearly appropriate, capable, or suitable for the indicated capability, function, or use, while taking into account that in some cases the modified term may sometimes be inappropriate, incapable, or unsuitable. For example, in some cases an event or capability may be anticipated, while in others it may not occur—this distinction is captured by the terms “may” and “may be.”

[0017] As used herein, the term "acrylic acid" includes (meth)acrylic acid, (meth)alkyl acrylate, (meth)acrylamide, (meth)acrylonitrile, and their modified forms, such as (meth)hydroxyalkyl acrylate. Throughout this document, the phrase "(meth)acryloyl" refers to both "methacryloyl" and "acryloyl". For example, (meth)acrylic acid refers to both methacrylic acid and acrylic acid, and methyl methacrylate refers to both methyl methacrylate and methyl acrylate.

[0018] When the term "aliphatic" is used in the context of carbon-carbon double bonds, it includes straight-chain (or open-chain) aliphatic carbon-carbon double bonds and cyclic aliphatic carbon-carbon double bonds, but excludes aromatic carbon-carbon double bonds of aromatic rings.

[0019] The term "aqueous" composition or dispersion as used herein means particles dispersed in an aqueous medium. An "aqueous medium" as used herein refers to a continuous phase comprising at least 50% by weight of water, wherein the remaining composition of the aqueous medium comprises particles and water-miscible compounds, such as, for example, alcohols, glycols, glycol ethers, and glycol esters.

[0020] Unless otherwise specified, the term “(co)polymer” as used herein includes both homopolymers (polymers containing units derived from a single monomer) and copolymers (polymers containing units derived from two or more different monomers).

[0021] As used herein, the term "crosslinking agent" refers to a molecule capable of forming covalent bonds between polymers or between two different regions of the same polymer.

[0022] The term "glass transition temperature" or "Tg" used in this invention can be measured using various conventional techniques, including, for example, differential scanning calorimetry ("DSC") or calculated using the Fox equation. The DSC data and methods described herein conform to ASTM D6604-00.

[0023] When used in the context of coatings applied to a substrate, the term "on" includes both coatings applied directly or indirectly to the substrate. Thus, for example, a coating applied to a primer layer covering a substrate constitutes a coating applied to the substrate.

[0024] The terms "preferred" and "ideally" refer to embodiments of the invention that provide certain benefits in certain circumstances. However, other embodiments may also be preferred in the same or other circumstances. Furthermore, the description of one or more preferred embodiments does not imply that other embodiments are unavailable, and is not intended to exclude other embodiments from the scope of the invention.

[0025] As used in this article, the term “structural unit” (also known as a polymeric unit) for naming monomers refers to the residue of the monomer after polymerization, or the monomer in its polymerized form.

[0026] The term "vinyl polymer" refers to a polymer prepared by addition polymerization of olefinically unsaturated components (e.g., a mixture of olefinically unsaturated monomers and / or oligomers).

[0027] According to an embodiment of the present invention, a vinyl primer system is provided. The vinyl primer system includes a first oligomer and a photoinitiator. The first oligomer includes at least one of polyether (meth)acrylate or modified polyether (meth)acrylate, and is present in an amount of 5% to 90% by weight of the vinyl primer system. The vinyl primer system contains less than 20% by weight of a monofunctional (meth)acrylate monomer. The photoinitiator is configured to cure at least the first oligomer upon exposure to UV light, LED light, and / or an electron beam. The vinyl primer system is configured to provide an ink-absorbing coating on a substrate.

[0028] According to one embodiment of the invention, a system is provided comprising an ink-absorbing primer coating, an ink coating disposed over the ink-absorbing primer coating, and optionally one or more additional coatings disposed over the ink coating. At least one of the ink-absorbing primer coating or the first additional coating of the one or more additional coatings comprises a vinyl primer system. The vinyl primer system comprises a photoinitiator and a first oligomer comprising at least one of a polyether (meth)acrylate or a modified polyether (meth)acrylate. The vinyl primer system comprises 10% to 95% by weight of the first oligomer and, if present, any additional polymerizable or crosslinkable compound. The system is configured to be disposed over a substrate.

[0029] According to one embodiment of the present invention, a method for coating a substrate is provided. The method includes applying a primer composition to the substrate; applying digital ink to the primer composition; applying one or more additional coatings over the substrate and the primer composition and digital ink; and exposing the primer composition, digital ink, and one or more additional coatings to curing radiation to form a cured coating system over the substrate. At least one of the primer system or the first additional coating in the one or more additional coatings includes a photoinitiator and a first oligomer, the first oligomer comprising at least one of polyether (meth)acrylate or modified polyether (meth)acrylate.

[0030] The embodiments of the invention disclosed herein relate to a vinyl primer system. The vinyl primer system comprises a first oligomer and a photoinitiator. The first oligomer comprises a polyether (meth)acrylate or a modified polyether (meth)acrylate. In some embodiments, the vinyl primer system is applied to a substrate, and the coated substrate is suitable for flooring, wall coatings, countertops, and other building material applications. The vinyl primer system can be applied to the substrate by roller coating, spraying, or some other suitable application method. After application to the substrate, the photoinitiator in the vinyl primer system is configured to cure at least the first oligomer upon exposure to curing radiation such as UV light, LED light, electron beams, combinations thereof, or some other suitable radiation. The photoinitiator comprises at least one free radical.

[0031] During curing, the vinyl primer system provides an ink-absorbing coating disposed on the substrate. The ink-absorbing coating is configured to adhere to and protect the substrate, and is also configured to receive and adhere to overlying ink coatings without compromising the quality of the ink coatings. Therefore, the ink-absorbing coating formed by the vinyl primer system can prevent or mitigate ink coating peeling from the substrate, seeping into the vinyl primer system, overspreading on the substrate, etc. Ink coatings can be applied to the ink-absorbing coating by printing to achieve desired complex designs over the substrate. For example, in the flooring industry, ink coatings can be printed onto synthetic substrates to simulate natural materials such as wood, stone, etc. In some other applications, ink coatings can be printed onto substrates to achieve artistic designs, such as painted artificial stone for flooring, backsplashes, countertops, or some other suitable applications. In some embodiments, several ink coatings can be applied to the substrate to distribute various pigments and / or amounts to achieve the desired aesthetic. Similarly, multiple layers of ink-absorbing coatings can be used over the substrate as needed for primer and / or adhesion purposes.

[0032] In a vinyl primer system, the first oligomer is present in an amount of about, for example, preferably 5% to 90% by weight, more preferably 10% to 90% by weight, even more preferably 20% to 80% by weight, and most preferably 30% to 70% by weight. Therefore, in some embodiments, the vinyl primer system is a single resin system comprising the first oligomer. The first oligomer can have different functionalities, such as difunctional, trifunctional, or tetrafunctional. The first oligomer has acrylate functionality, which can be uniform or can vary along the length of the oligomer chain. In some other embodiments, the vinyl primer system comprises the first oligomer and optionally additional polymerizable or crosslinkable compounds. Therefore, in some embodiments, the vinyl primer system comprises about, for example, preferably 10% to 95% by weight, more preferably 30% to 95% by weight, even more preferably 50% to 95% by weight, and most preferably 70% to 90% by weight of the first oligomer and any additional polymerizable or crosslinkable compounds (if present). The additional polymerizable or crosslinkable compound may contain one or more monomers, a second oligomer, or a combination thereof.

[0033] For example, in some embodiments, the additional polymerizable or crosslinkable compound is a second oligomer. The second oligomer can help achieve the desired curing speed, pigment wetting, and other properties. The second oligomer is present, by weight of the vinyl primer system, preferably less than 40% by weight, more preferably less than 30% by weight, even more preferably less than 20% by weight, and most preferably less than 10% by weight. When too much second oligomer is present in the vinyl primer system, the quality of the ink coating printed onto the ink-absorbing coating is poor. When the vinyl primer system contains both a first and a second oligomer, the first and second oligomers together are present, by weight of the vinyl primer system, at about preferably 10% by weight to about 95% by weight, more preferably 10% by weight to 95% by weight, even more preferably 30% by weight to 95% by weight, even more preferably 50% by weight to 95% by weight, and most preferably 70% by weight to 90% by weight. In some embodiments, the second oligomer may comprise epoxy (meth)acrylate, polyester (meth)acrylate, or urethane (meth)acrylate. The second oligomer can have different functionalities, preferably two or more.

[0034] In some embodiments, the polymerizable or crosslinkable compound comprises one or more monomers, which may be monofunctional, difunctional, or trifunctional acrylate monomers, or more preferably difunctional or trifunctional acrylate monomers. To maintain the print quality of the ink coating on the ink-absorbing coating, the vinyl primer system may contain preferably less than 20% by weight, more preferably less than 18% by weight, even more preferably less than 16% by weight, even more preferably less than 14% by weight, even more preferably less than 12% by weight, and most preferably less than 10% by weight of a monofunctional (meth)acrylate monomer.

[0035] The vinyl primer system may also contain other additives, such as pigments, fillers, diluents, extenders, wetting agents, leveling agents, dispersants, antisettling agents, defoamers, rheology modifiers, etc., to achieve desired properties, such as viscosity, wettability, curing speed, adhesion, aesthetics, film thickness, etc. The amount of each optional component is preferably sufficient to achieve its intended purpose, but should not reach a level that adversely affects the vinyl primer system or the ink-absorbing coating obtained therefrom. In some embodiments, the vinyl primer system contains about, for example, preferably 0% to 50% by weight, more preferably 1% to about 35% by weight, even more preferably 1% to about 25% by weight, and most preferably 5% to 15% by weight of pigment. In some embodiments, the vinyl primer system contains about, for example, preferably 0% to 50% by weight, more preferably 1% to about 35% by weight, even more preferably 0% to 12% by weight, and most preferably 5% to 15% by weight of extender. Before application to the substrate, the desired viscosity of the vinyl primer system can be, for example, between 200 and 1500 centipoise at 77 degrees Celsius, as measured according to ASTM D 2196-86. Viscosity measurements can also be performed using other suitable viscosity testing methods. In some embodiments, one or more ink-absorbing coatings can be applied over the substrate.

[0036] Now go to Figure 1 This document describes some embodiments of a system 100 comprising various coatings over a substrate. System 100 may include an ink-absorbing coating 104 disposed over a substrate 102. The ink-absorbing coating 104, comprising a vinyl primer system disclosed herein, is disposed over the substrate 102. In some embodiments, the ink-absorbing coating 104 is disposed directly on the substrate 102 and serves as a primer to adhere to the substrate 102 and receive an overlay. For example, system 100 also includes an ink coating 106 disposed over the ink-absorbing coating 104. The ink coating 106 may comprise several layers. Upon curing, each layer of the ink-absorbing coating 104 may have a dry film thickness in, for example, preferably between 3 micrometers and 40 micrometers, more preferably between 5 micrometers and 30 micrometers, and most preferably between 10 micrometers and 20 micrometers. In some embodiments, each layer of the ink-absorbing coating 104 is sanded after curing and before the application of another coating. In some such embodiments, the aforementioned values ​​for the dry film thickness of each layer of the ink-absorbing coating 104 are the dry film thickness before sanding.

[0037] In addition, system 100 may optionally include one or more additional coatings 108 disposed over substrate 102. In some embodiments, one or more additional coatings 108 may include, for example, a first layer 108a disposed over ink coating 106; a second layer 108b disposed over the first layer 108a; and a third layer 108c disposed over the second layer 108b. These additional coatings 108 may be a sealing layer, a protective abrasion layer, a UV protective layer, an adhesive layer, and / or some other suitable layer. In some embodiments, at least one of the additional coatings 108 comprises a vinyl primer system, and therefore may comprise the same composition as the ink-absorbing coating 104. When the vinyl primer system is applied over ink coating 106, the vinyl primer system may facilitate adhesion between ink coating 106 and any additional overlays (e.g., 108a-c). Therefore, in some embodiments, system 100 may include one or more layers of ink-absorbing coating 104 disposed below ink coating 106, and may also include one or more layers of ink-absorbing coating 104 disposed above ink coating 106. Alternatively, system 100 may include one or more ink-absorbing coatings 104 of a different type than those of the present invention, wherein one or more layers of the vinyl primer composition of the present invention are disposed over the ink coating as inter-coating adhesion layers. Thus, each layer of ink-absorbing coating 104 in system 100 can serve as a primer layer, an ink-absorbing layer, and / or an inter-coating adhesion layer. The ink-absorbing coating 104 disposed over the ink coating 106 may be in direct contact with the ink coating 106, or may be spaced apart from the ink coating 106 by inserting additional coatings. It should be understood that in some embodiments, more or fewer than three additional coatings 108 may be disposed over the ink-absorbing coating 104.

[0038] Figures 2 to 8 Some embodiments of a method for applying an ink-absorbing coating to a substrate are shown.

[0039] like Figure 2 As shown, a substrate 102 is provided. In some embodiments, the substrate 102 may include, for example, engineered wood, polymer composites, synthetic vinyl, fiberglass, particleboard, metal, paper, or combinations thereof. It should be understood that the substrate 102 may include a series of layers and materials; for example, in some embodiments, the substrate 102 may include layers of resin, wood fiber, and fiberglass. In some embodiments, the substrate 102 may be cleaned or pretreated before any coating is applied to it. For example, the substrate 102 may be cleaned with acetone or sanded before applying a coating.

[0040] like Figure 3As shown, a primer composition 304 comprising a vinyl primer system is formed over a substrate 102. The primer composition 304 can be applied to the substrate 102 by spraying, rolling, or some other suitable application process. In some embodiments, the substrate 102 can be arranged on a conveyor belt, and the primer composition 304 can be continuously applied as the substrate 102 is exposed to the coating application equipment. In some such embodiments, the substrate 102 can travel through the coating application equipment at a rate, for example, between about 10 feet per minute and about 120 feet per minute. In some embodiments, the amount of primer composition 304 applied to the substrate 102 can be, for example, between about 0.6 grams per square foot and about 2.0 grams per square foot.

[0041] like Figure 4 As shown, the primer composition ( Figure 3 The ink-absorbing coating 104 is formed over the substrate 102 by exposing the primer composition (304) to curing radiation 402. Upon initial exposure to curing radiation 402, the ink-absorbing coating 104 may be partially or fully cured. In some embodiments, the primer composition (304) is applied in the same process line. Figure 3 Immediately after applying 304, apply the primer composition ( Figure 3 304) is exposed to curing radiation 402. In some other embodiments, in different process lines and / or in the primer composition ( Figure 3 After other layers are formed on top of 304, the primer composition ( Figure 3 304) is exposed to curing radiation 402. For example, in some other embodiments of this kind, the method can be derived from... Figure 3 Go to Figure 5 Thus skipping Figure 4 The steps.

[0042] Figure 4The curing radiation 402 shown can be any desired curing radiation, including but not limited to UV light, LED light, electron beams, or combinations thereof. Curing radiation 402 is configured to activate a photoinitiator to initiate crosslinking of the first oligomer and any additional polymerizable or crosslinkable compounds in the vinyl primer system. Therefore, in some embodiments, the photoinitiator is selected based on the available curing radiation and / or the polymerizable components of the vinyl primer system. Alternatively, the curing radiation can be selected based on the photoinitiator and / or polymerizable components of the vinyl primer system. In some embodiments, the ink-absorbing coating 104 is only partially cured before the additional coating is applied to it. Such partial curing allows the ink-absorbing coating 104 to better receive and adhere to the overlayer, which also reduces peeling. Additionally, in the case of partial curing, the system can still be handled during manufacturing and / or storage without damaging the ink-absorbing coating 104 and / or the substrate 102. The ink-absorbing coating 104 can then be fully cured in subsequent manufacturing steps. In some other embodiments, the ink-absorbing coating 104 is allowed to fully cure before the additional coating is applied to it. In some such embodiments, a fully cured ink-absorbing coating 104 may be less susceptible to damage during manufacturing and / or storage compared to a partially cured ink-absorbing coating 104. In some embodiments, adhesion can be tested using ASTM D3359.

[0043] In some embodiments, the curing radiation 402 may include various types of UV light. For example, the curing radiation 402 may use UVA light, UVB light, UVC light, and / or UVV light. UVC light has the shortest wavelength and the highest energy, while UVV light has the longest wavelength and the lowest energy. In some embodiments, a mercury lamp may be used to project UV light onto the ink-absorbing coating 104. For example, the curing radiation 402 may emit at least one of the following curing power settings: 180 mW / m 2 With 605mW / m 2 UVA light in the range between; 155mW / m 2 With 595mW / m 2 UVB light within the range of 50mW / m 2 With 195mW / m 2 UVC light within the range of 170mW / m 2 With 595mW / m 2UV light at power levels within the range between [specific values]; or combinations thereof. The intensity of the mercury lamp, the distance between the mercury lamp and the ink-absorbing coating 104, the thickness of the ink-absorbing coating 104, and the duration of exposure of the ink-absorbing coating 104 to UV light are all parameters that affect the curing stage of the ink-absorbing coating 104. For example, the ink-absorbing coating 104 may cure to a partially or fully cured level when: the mercury lamp is set to an intensity between approximately 25% and approximately 50%; when the mercury lamp is raised to a height approximately 3 to 5 inches above the standard curing height setting; and when the substrate 102 travels beneath the mercury lamp at a rate of approximately 10 to 65 feet per minute. It should be understood that other parameters and radiation sources can be used to cure the ink-absorbing coating 104 to a sufficient level of partial or full curing to properly adhere to the substrate 102 and the overlay.

[0044] In some embodiments, several layers of ink-absorbing coating 104 may be applied to substrate 102. In some such embodiments, the ink-absorbing coating 104 may optionally be sanded between coatings. If sanding is performed between coatings, the ink-absorbing coating 104 is partially cured prior to sanding. It may also be sanded before any other additional coating is applied over the ink-absorbing coating 104.

[0045] like Figure 5 As shown, an ink coating 106 can be formed over an ink-absorbing coating 104. The ink coating 106 can contain various pigments. Furthermore, the ink coating 106 can be applied to the substrate 102 using a printer (such as an inkjet printer) to achieve specific digital designs. For example, Figure 5 The illustration shows an artificial wood grain pattern, which can be used in flooring or cabinetry applications. In some embodiments, the ink coating 106 has a surface tension in the range of, for example, about 20 mN / m to about 28 mN / m. The surface tension of the ink coating 106 affects the composition and curing stage of the underlying ink-absorbing coating 104. For example, in some embodiments, the amount of extender in the vinyl primer system can be adjusted to achieve favorable intercoating adhesion between the ink-absorbing coating 104 and the ink coating 106.

[0046] like Figure 6 As shown, one or more additional coatings 108, the first layer 108a, is applied over the ink coating 106. Figure 7 As shown, one or more additional coatings 108 are applied as a second layer 108b over a first layer 108a. Figure 8As shown, a third layer 108c of one or more additional coatings 108 is applied over a second layer 108b. Each of the one or more additional coatings 108 can be applied using various application methods. Furthermore, each of the one or more additional coatings 108 can be cured (or partially cured) immediately after application using various curing techniques. The one or more additional coatings 108 are optional; therefore, in some embodiments, the method can be derived from... Figure 5 Go to Figure 9 Thus skipping Figures 6 to 8 The steps in the process.

[0047] like Figure 9 As shown, in some embodiments, system 100 may be re-exposed to curing radiation 402 to cure one or more layers of system 100 disposed above substrate 102. In some embodiments, Figure 9 The curing radiation 402 can be combined with Figure 4 The curing radiation 402 is the same, while in other embodiments, Figure 9 The curing radiation 402 can be combined with Figure 4 The curing radiation 402 has different settings and / or different types of radiation. No radiation is used in it. Figure 4 In the implementation scheme of curing radiation 402, Figure 9 The curing radiation 402 may be the initial curing of the ink-absorbing coating 104 in system 100. During curing, system 100 may be durable for future handling, packaging, shipping, and installation. In some other embodiments, system 100 may already be cured, therefore, the method may not include... Figure 9 The steps are shown.

[0048] Figure 10 A flowchart 1000 illustrates some embodiments of a method for applying an ink coating to an ink-absorbing coating. In some embodiments, Figure 10 The steps in flowchart 1000 correspond to Figures 2 to 9 The method shown.

[0049] In step 1002, the primer composition is applied to the substrate.

[0050] In step 1004, a digital ink coating is applied to the primer composition.

[0051] In step 1006, one or more additional coatings are applied over the digital ink coating and primer composition.

[0052] In step 1008, the primer composition, digital ink coating, and one or more additional coatings are exposed to curing radiation to form a cured coating system over the substrate.

[0053] The following embodiments are provided to illustrate the present invention and its advantages, but should not be construed as limiting the scope of the invention.

[0054] The vinyl primer system comprises a first oligomer, which comprises at least one of a polyether (meth)acrylate or a modified polyether (meth)acrylate. Thus, in some embodiments, the first oligomer comprises both a polyether (meth)acrylate and a modified polyether (meth)acrylate. Non-limiting examples of the first oligomer include amine-modified polyether acrylates.

[0055] In some embodiments, the vinyl primer system comprises one or more additional oligomers. In some such embodiments, the second oligomer may comprise a difunctional epoxy acrylate, a trifunctional polyester acrylate, a polyester acrylate, a trifunctional polyurethane acrylate, an aliphatic polyester polyurethane acrylate, a combination thereof, or some other suitable monomer. In some embodiments, epoxy acrylate oligomers are preferred due to their curing speed.

[0056] In some embodiments, the vinyl primer system includes additional polymerizable or crosslinkable compounds, which may include one or more monomers. In some such embodiments, the one or more monomers may include n-butyl methacrylate copolymers, difunctional acrylate monomers, combinations thereof, or some other suitable monomers. In some embodiments, the monomers are added as diluents.

[0057] In some embodiments, the vinyl primer system comprises a variety of additives. Non-limiting examples of these additives include: antisettling agents, dispersants and wetting agents, micronizing extenders, fillers such as calcium carbonate, adhesion promoters such as trifunctional esters or polybutadiene homopolymers, acrylic flow agents, and hardeners such as sucrose benzoate resins. In some embodiments, trifunctional esters are preferred because they offer favorable adhesion to both the substrate and the ink coating. In some embodiments, extenders increase the surface roughness of the ink-absorbing coating to promote adhesion without affecting the quality of the ink coating.

[0058] In some embodiments, the vinyl primer system is dispersed in a solvent and is solvent-based. In other embodiments, the vinyl primer system is dispersed in water (e.g., aqueous) and / or in a mixture of water and solvent (e.g., aqueous). Non-limiting examples of organic solvents suitable for the water-based and / or solvent-based coating compositions of the present invention include aliphatic hydrocarbons (e.g., solvent oils, kerosene, VM&P naphtha solvent, etc.); aromatic hydrocarbons (e.g., benzene, toluene, xylene, naphtha solvents 100, 150, 200 series products, etc.); alcohols (e.g., ethanol, n-propanol, isopropanol, n-butanol, isobutanol, etc.); ketones (e.g., acetone, 2-butanone, cyclohexanone, methyl aryl ketone, ethyl aryl ketone, methyl isopentyl ketone, etc.); esters (e.g., ethyl acetate, butyl acetate, etc.); glycols (e.g., butyl ethylene glycol); glycol ethers (e.g., ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monobutyl ether, propylene glycol monomethyl ether, etc.); glycol ether esters (e.g., butyl ethylene glycol acetate, methoxypropyl acetate, etc.); and mixtures thereof.

[0059] The following are some non-limiting examples of embodiments of the present invention:

[0060] Implementation Scheme 1. A vinyl primer system, comprising:

[0061] A first oligomer, the first oligomer comprising at least one of a polyether (meth)acrylate or a modified polyether (meth)acrylate; and

[0062] A photoinitiator configured to cure at least the first oligomer upon exposure to UV light, LED light, and / or an electron beam.

[0063] The first oligomer is present in an amount of 5% to 90% by weight of the vinyl primer system, and the vinyl primer system contains less than 20% by weight of a monofunctional (meth)acrylic monomer; and

[0064] The vinyl primer system is configured to provide an ink-absorbing coating on a substrate.

[0065] Implementation Scheme 2. The vinyl primer system according to Implementation Scheme 1 further comprises:

[0066] A polymerizable or crosslinkable compound comprising one or more monomers, a second oligomer, or a combination thereof.

[0067] Implementation Scheme 3. The vinyl primer system according to Implementation Scheme 2, wherein the polymerizable or crosslinkable compound is the second oligomer, wherein the second oligomer is an epoxy (meth)acrylate, a polyester (meth)acrylate, a urethane (meth)acrylate, or a combination thereof.

[0068] Implementation Scheme 4. The vinyl primer system according to Implementation Scheme 3, wherein the second oligomer is present in the vinyl primer system in an amount of less than 40% by weight.

[0069] Implementation Scheme 5. The vinyl primer system according to any one of Implementation Schemes 2 to 4, wherein the polymerizable or crosslinkable compound is the second oligomer, wherein the second oligomer has a different functionality of 2 or higher.

[0070] Implementation Scheme 6. A vinyl primer system according to any one of Implementation Schemes 1 to 5, wherein the first oligomer has acrylate functionality, the acrylate functionality being uniform or variable along the oligomer chain, and wherein the first oligomer has 2 or more functionalities.

[0071] Implementation Scheme 7. The vinyl primer system according to any one of Implementation Schemes 1 to 6, wherein the ink-absorbing coating is configured to have a thickness between 3 micrometers and 40 micrometers.

[0072] Implementation Scheme 8. A vinyl primer system according to any one of Implementation Schemes 1 to 7, wherein the vinyl primer system comprises 10% to 95% by weight of the first oligomer and, if present, any additional polymerizable or crosslinkable compound.

[0073] Implementation Scheme 9. The vinyl primer system according to any one of Implementation Schemes 1 to 8 further comprises 1% to 50% by weight of pigment.

[0074] Implementation Scheme 10. The vinyl primer system according to any one of Implementation Schemes 1 to 9 further comprises 1% to 35% by weight of an extender.

[0075] Implementation Scheme 11. The vinyl primer system according to any one of Implementation Schemes 1 to 10 further comprises additives, such as defoamers, leveling agents, dispersants, antisettling agents and / or rheology modifiers.

[0076] Implementation Scheme 12. The vinyl primer system according to any one of Implementation Schemes 1 to 11, wherein the viscosity of the vinyl primer system is between 200 centipoise and 1500 centipoise at 77 degrees Celsius.

[0077] Implementation Scheme 13. A system comprising:

[0078] Ink-absorbing primer coating;

[0079] An ink coating disposed above the ink-absorbing primer coating; and

[0080] Optionally, one or more additional coatings are disposed above the ink coating.

[0081] The ink-absorbing primer coating or at least one of the first additional coatings of the one or more additional coatings comprises a vinyl primer system, the vinyl primer system comprising:

[0082] A first oligomer, the first oligomer comprising at least one of a polyether (meth)acrylate or a modified polyether (meth)acrylate; and

[0083] A photoinitiator, the photoinitiator being configured to cure at least the first oligomer upon exposure to curing radiation.

[0084] The vinyl primer system comprises 10% to 95% by weight of the first oligomer and, if present, any additional polymerizable or crosslinkable compounds, and

[0085] The system is configured to be disposed on a substrate.

[0086] Implementation Scheme 14. The system according to Implementation Scheme 13, wherein the curing radiation is UV light, LED light, electron beam, or a combination thereof.

[0087] Implementation Scheme 15. The system according to any one of Implementation Scheme 13 or 14, wherein the ink-absorbing primer coating comprises one or more layers, and each layer of the ink-absorbing primer coating has a dry film thickness of 3 micrometers to 40 micrometers.

[0088] Implementation Scheme 16. The system according to any one of Implementation Schemes 13 to 15, wherein the ink-absorbing primer coating comprises at least one additional oligomer different from the first oligomer.

[0089] Implementation Scheme 17. The system according to any one of Implementation Schemes 13 to 16, wherein the substrate is a synthetic vinyl flooring, engineered wood, polymer composite material, metal, wood, paper, or a combination thereof.

[0090] Implementation Scheme 18. The system according to any one of Implementation Schemes 13 to 17, wherein the ink-absorbing primer coating comprises a monomeric diluent.

[0091] Implementation Scheme 19. A method for coating a substrate, comprising:

[0092] Apply a primer composition to the substrate;

[0093] Apply digital ink to the primer composition;

[0094] Optionally, one or more additional coatings may be applied over the substrate, the primer composition, and the digital ink; and

[0095] The primer composition, the digital ink, and the one or more additional coatings are exposed to curing radiation to form a cured coating system on the substrate.

[0096] The primer composition or at least one of the first additional coatings in the one or more additional coatings comprises:

[0097] A first oligomer, the first oligomer comprising at least one of a polyether (meth)acrylate or a modified polyether (meth)acrylate; and

[0098] Photoinitiator.

[0099] Implementation Scheme 20. The method according to Implementation Scheme 19, wherein the primer composition comprises 5% to 95% by weight of a first oligomer prior to curing.

[0100] Implementation Scheme 21. The method according to any one of Implementation Schemes 19 or 20, wherein the primer composition comprises 5% to 98% by weight of the first oligomer and, if present, any additional polymerizable or crosslinkable compound.

[0101] Implementation Scheme 22. The method according to any one of Implementation Schemes 19 to 21, wherein the primer composition is applied by roller coating or spraying.

[0102] Implementation Scheme 23. The method according to any one of Implementation Schemes 19 to 22, wherein at least one of the additional coating and the primer composition comprises the first oligomer and the photoinitiator.

[0103] Implementation Scheme 24. The method according to any one of Implementation Schemes 19 to 23, wherein the curing radiation is UV light, LED light, electron beam, or a combination thereof.

[0104] Implementation Scheme 25. The method according to any one of Implementation Schemes 19 to 24, wherein the primer composition or the at least one of the first additional coatings comprises less than 20% by weight of a monofunctional (meth)acrylic monomer.

[0105] Unless otherwise indicated herein or clearly contradicted by the context, all methods described herein may be performed in any suitable order. The use of language (e.g., “such as”) in any examples or descriptions provided herein is intended to illustrate the invention and not to limit its scope. Any statements herein regarding the nature or benefits of the invention or preferred embodiments are not intended to be limiting. The invention includes all modifications and equivalents of the subject matter described herein as permitted by applicable law. Furthermore, unless otherwise indicated herein or clearly contradicted by the context, the invention covers any combination of the foregoing elements in all possible variations. Descriptions of any references or patent claims herein, even if marked “prior,” are not intended to constitute a concession by such references or patents to prior art. Unclaimed language should not be considered to limit the scope of the invention. Any statement or suggestion herein that certain features constitute part of the claimed invention, unless reflected in the appended claims, is not intended to be limiting. The marking of a patent number on any product or the identification of a patent number in connection with any service should not be construed as indicating that all embodiments described herein are incorporated into such product or service.

[0106] While the implementation schemes discussed herein involve the coatings and methods discussed above, these implementation schemes are intended to be illustrative only and are not intended to limit the applicability of these implementation schemes to those discussed only herein.

[0107] The above description illustrates only several possible embodiments of various aspects of the invention, and equivalent changes and / or modifications will occur to those skilled in the art upon reading and understanding this specification and the accompanying drawings. Furthermore, while a particular feature of the invention has been disclosed with respect to only one of several embodiments, this feature may be combined with one or more other features of other embodiments, as may be desired and advantageous for any given or particular application.

[0108] Based on the foregoing teachings, additional modifications and variations of the invention are possible. Therefore, it should be understood that, within the scope of the appended claims, the invention may be practiced in ways other than those specifically described herein.

Claims

1. A vinyl primer system comprising: A first oligomer, the first oligomer comprising at least one of a polyether (meth)acrylate or a modified polyether (meth)acrylate; and A photoinitiator configured to cure at least the first oligomer upon exposure to UV light, LED light, and / or an electron beam. The first oligomer is present in an amount of 5% to 90% by weight of the vinyl primer system, and the vinyl primer system contains less than 20% by weight of a monofunctional (meth)acrylic monomer; and The vinyl primer system is configured to provide an ink-absorbing coating on a substrate.

2. The vinyl primer system according to claim 1, further comprising: A polymerizable or crosslinkable compound comprising one or more monomers, a second oligomer, or a combination thereof.

3. The vinyl primer system according to claim 2, wherein the polymerizable or crosslinkable compound is the second oligomer, wherein the second oligomer is an epoxy (meth)acrylate, a polyester (meth)acrylate, a urethane (meth)acrylate, or a combination thereof.

4. The vinyl primer system of claim 3, wherein the second oligomer is present in the vinyl primer system in an amount of less than 40% by weight.

5. The vinyl primer system of claim 2, wherein the polymerizable or crosslinkable compound is the second oligomer, wherein the second oligomer has a different functionality of 2 or higher.

6. The vinyl primer system of claim 1, wherein the first oligomer has acrylate functionality, the acrylate functionality being uniform or variable along the oligomer chain, and wherein the first oligomer has 2 or more functionalities.

7. The vinyl primer system of claim 1, wherein the ink-absorbing coating is configured to have a thickness between 3 micrometers and 40 micrometers.

8. The vinyl primer system of claim 1, wherein the vinyl primer system comprises 10% to 95% by weight of the first oligomer and, if present, any additional polymerizable or crosslinkable compound.

9. The vinyl primer system according to claim 1, further comprising 1% to 50% by weight of pigment.

10. The vinyl primer system according to claim 1, further comprising 1% to 35% by weight of an extender.

11. The vinyl primer system according to claim 1 further comprises additives, such as defoamers, leveling agents, dispersants, antisettling agents and / or rheology modifiers.

12. The vinyl primer system according to claim 1, wherein the viscosity of the vinyl primer system is between 200 centipoise and 1500 centipoise at 77 degrees Celsius.

13. A system comprising: Ink-absorbing primer coating; An ink coating disposed above the ink-absorbing primer coating; as well as Optionally, one or more additional coatings are disposed above the ink coating. The ink-absorbing primer coating or at least one of the first additional coatings of the one or more additional coatings comprises a vinyl primer system, the vinyl primer system comprising: The first oligomer comprises at least one of polyether (meth)acrylate or modified polyether (meth)acrylate; as well as A photoinitiator, the photoinitiator being configured to cure at least the first oligomer upon exposure to curing radiation. The vinyl primer system comprises 10% to 95% by weight of the first oligomer and, if present, any additional polymerizable or crosslinkable compounds, and The system is configured to be disposed on a substrate.

14. The system of claim 13, wherein the curing radiation is UV light, LED light, electron beam, or a combination thereof.

15. The system of claim 13, wherein the ink-absorbing primer coating comprises one or more layers, and each layer of the ink-absorbing primer coating has a dry film thickness of 3 micrometers to 40 micrometers.

16. The system of claim 13, wherein the ink-absorbing primer coating comprises at least one additional oligomer different from the first oligomer.

17. The system of claim 13, wherein the substrate is a synthetic vinyl flooring, engineered wood, polymer composite material, metal, wood, paper, or a combination thereof.

18. The system of claim 13, wherein the ink-absorbing primer coating comprises a monomeric diluent.

19. A method of coating a substrate, comprising: Apply a primer composition to the substrate; Apply digital ink to the primer composition; Optionally, one or more additional coatings may be applied over the substrate, the primer composition, and the digital ink; as well as The primer composition, the digital ink, and the one or more additional coatings are exposed to curing radiation to form a cured coating system on the substrate. The primer composition or at least one of the first additional coatings in the one or more additional coatings comprises: A first oligomer, the first oligomer comprising at least one of a polyether (meth)acrylate or a modified polyether (meth)acrylate; and Photoinitiator.

20. The method of claim 19, wherein the primer composition comprises 5% to 95% by weight of the first oligomer prior to curing.

21. The method of claim 19, wherein the primer composition comprises 5% to 98% by weight of the first oligomer and, if present, any additional polymerizable or crosslinkable compound.

22. The method of claim 19, wherein the primer composition is applied by roller coating or spraying.

23. The method of claim 19, wherein at least one of the additional coating and the primer composition comprises the first oligomer and the photoinitiator.

24. The method of claim 19, wherein the curing radiation is UV light, LED light, electron beam, or a combination thereof.

25. The method of claim 19, wherein the primer composition or the at least one of the first additional coating comprises less than 20% by weight of a monofunctional (meth)acrylic monomer.

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