Method of seam coating flooring

Abstract

The seam of a surface covering product, having an exposed surface which is the reaction product of a protective coating composition including an aminoplast and a polyol, is coated with a seam coating composition including a cyanoacrylate monomer and a plasticizer. The preferred monomer is methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate or methoxy ethyl 2-cyanoacrylate. The preferred plasticizer is dibutyl phthalate. The seam coating should have a viscosity of about 100 CPS. An accelerator may be applied to the uncured seam coating.

Description

FIELD OF THE INVENTION

The invention relates to a method of seam coating resilient sheet flooring. In particular, the invention is directed to a method of seam coating a resilient sheet flooring having a highly crosslinked wear surface, and more specifically, a wear surface which is the reaction product of a composition comprising a polyol and aminoplast.

BACKGROUND OF THE INVENTION

A highly crosslinked wear surface formed by the reaction of a composition comprising a polyol and an aminoplast has been developed which has excellent scratch and stain resistance. However, since the surface of the highly crosslinked wear layer has only a trace amount of reactive functional groups, it has been extremely difficult to discover a composition which will adhere to the wear layer and which can be used as a seam coating.

As known in the art, when two sections of resilient sheet flooring are laid with two edges abutting, a seam is formed. Unless the seam is coated with a sealing composition, dirt tends to accumulate in the seam, and due to the slight difference in surface height between the two sections of resilient flooring at the seam, traffic will tend to snag the higher surface. A seam coating eliminates the crevice at the abutment and smooths the transition between the two elevations at the abutment.

Numerous seam coating compositions are known. Further a cyanoacrylate adhesive with dibutyl phthalate plasticizer is disclosed in European patent application Ser. No. 239,890. The invention of the European Application is an opaque cyanoacrylate adhesive or coating composition which comprises a monomeric ester of 2-cyanoacrylic acid and 5 to 50% by weight, based on the monomeric ester, of a semi-compatible plasticizer. The European application compares the opaque adhesive of the European invention with a non-opaque coating of cyanoacrylate with a fully compatible dibutyl phthalate plasticizer.

Since typical seam coatings would not adhere to the polyol/aminoplast wear layer, the surface was analyzed by the present inventors to determine if there were any functional groups present which could be used to gain adhesion. Only trace amounts of N--H, C--O, C.dbd.O and C--Cl were detected. Attempts to attack or soften the wear layer surface with solvents was also evaluated. The solvents were covered with watch glasses to retard evaporation. Of the nine solvents tested, only methylene chloride, tetrahydrofuran and methyl ethyl ketone softened and/or shriveled the surface of the wear layer within a twenty minute time period. However, if any of the above solvents were allowed to evaporate to dryness without restrictions, they had no effect on the surface of the wear layer.

Typical acrylic, nitrocellulose and vinyl lacquers utilizing these most active solvents were evaluated. The wear layer acted as a release coating and the lacquers failed to gain adhesion.

Many resinous systems including cyanoacrylates, alkyds, lacquers, epoxies, polyurethanes, and crosslinkable lattices were evaluated. The surface of the wear layer was pretreated with such agents as acids, alkali and corona discharge without improving the bonding characteristics.

One objective of the present invention is to provide a method of seam coating the surface of a wear layer comprising the reaction product of an aminoplast and a polyol.

A further object is to provide a seam coating composition which will adhere to the aminoplast/polyol wear layer and have excellent stain and scratch resistance as well as an appearance similar to the surface of the aminoplast/polyol wear surface.

These and other advantages of the present invention will become apparent from the detailed description of the preferred embodiments which follows.

SUMMARY OF THE INVENTION

It has been found that of the numerous adhesives and coating compositions for resilient floor coverings, only a coating composition comprising cyanoacrylate monomer will adhere to the surface of an aminoplast/polyol wear layer and has the desired stain and scratch resistance and appearance.

DETAILED DESCRIPTION OF THE INVENTION

U.S. Pat. No. 4,781,987, issued Nov. 1, 1988, in the names of Bolgiano et al. and U.S. application Ser. No. 945,831, filed Dec. 23, 1986 in the name of Witman disclose highly crosslinked protective coatings or wear layers comprising an aminoplast, preferably melamine, and a polyol. Both of these references are incorporated herein by reference. The compositions of the Bolgiano et al. patent and Witman application yield a protective coating for resilient flooring which has superior stain and scratch resistance. However, the surface of the wear layer has only trace amounts of N--H, C--O, C.dbd.O and C--Cl functional groups and no NH.sub.2 or OH functional groups. Therefore, it has been difficult to discover a seam coating composition which will adhere to the aminoplast/polyol wear layer.

Attempts were made to soften the surface of the wear layer with a number of solvents. The solvents were covered with watch glasses to retard evaporation. Table 1 sets forth the substance and the results of the test.

TABLE 1______________________________________Solvent Surface Treatment Time for SurfaceSolvent Softening and/or Shriveling______________________________________Methylene Chloride 4 minutesTetrahydrofuran 12 minutesMethyl ethyl ketone 22 minutesMethyl isobutyl ketone 7 hours, slight blisteringIsopropanol 7 hours, noneEthanol 7 hours, noneIsopropyl acetate 7 hours, noneButyl cellosolve acetate 7 hours, noneToluol 7 hours, none______________________________________

When the above solvents are allowed to evaporate to dryness without the watch glass, they have no effect on the wear layer surface. Typical acrylic nitrocellulose and vinyl lacquers utilizing the most active solvents were evaluated by applying the lacquer to the wear layer and allowing it to air dry at room temperature. Other seam coating candidates including highly crosslinked polyurethanes were also tested. The results of these tests are set forth in Table 2.

TABLE 2__________________________________________________________________________Solvent Solvent Adhesion and/Based Lacquers Type System or Remarks__________________________________________________________________________Acryloid .RTM. A21.sup.1 Methyl methacrylate MEK.sup.2 Poor - good(25%) iodine resistanceAcryloid A21/ Methyl methacrylate/ MEK Poor - CS-1Acryloid CS-1.sup.1 tackifier lowered glossAcryloid A21/ Methyl methacrylate/ MeCl.sub.2.sup.3 PoorSanticizer 160 (2.5%).sup.8 plasticizerAcryloid B67.sup.1 Isobutyl VM&P Good after 2 methacrylate naphtha days, poor after 7 daysAcryloid B67 Isobutyl MEK Poor - easily(Crumbs).sup.1 methacrylate marredAcryloid B67/ Isobutyl methacrylate MEK Poor - easilyAcryloid DMSS.sup.1 marredAcryloid B84.sup.1 Methyl Toluene/ Poor - poor methacrylate Sec. iodine resistance ButanolAcryloid B48S Methyl Toluene Poor - poor(45%).sup.1 methacrylate iodine resis.Acryloid B-99.sup.1 Methyl Toluene/ Poor - brittle methacrylate xylene good iodine resistanceAcryloid XR-34.sup.1 -- -- PoorAcryloid B44.sup.1 /VAGH.sup.4 /DOP.sup.5 Acrylic/PVC.sup.6 / MeCl.sub.2 /Toluol 2/1 Poor3/2/1/ (25%) PlasticizerNitrocellulose RS.sup.7 -- -- PoorNitrocellulose SS.sup.7 -- Ethanol Poor1/2 sec (40%)Butvar .RTM. 90.sup.8 (20%) Polyvinyl butyral n-butanol/ Poor MIBK 1/1Butvar .RTM. 98.sup.8 (15%) Polyvinyl butyral Toluene/ Poor ethanol 6/4Ethyl Cellulose N7 (15%) -- Toluol/n Poor - alcohol butanol redissolvesEvlacite .RTM. 2045.sup.9 Isobutyl MEK Poor(15%) methacrylateEvlacite 2041.sup.9 Isobutyl MEK Poor methacrylateElvacite 2041.sup.9 / Isobutyl MEK/THF.sup.10 / PoorVMCH.sup.4 (11%) methacrylate/PVC DMF.sup.11 20/4/1Elvacite 2041.sup.9 / Isobutyl MEK/THF/DMF PoorFirestone 6336.sup.12 (11%) methacrylate/PVC 20/4/1Carboset .RTM. XL-44.sup.13 Alkali soluble MEK (also NH.sub.4 OH) Poor(10%) acrylicsCarboset .RTM. 525.sup.13 Alkali soluble MEK Poor(10%) acrylicsVAGH.sup.4 (20%) PVC/PVAC.sup.14 /OH.sup.15 MEK/MeCl.sub.2 Poor 1/1VAGH.sup.4 (25%) PVC/PVAC/OH cyclohexanone PoorVYES.sup.4 (40%) PVC/PVAC/OH MIBK.sup.16 /toluene Good - 1/1 easily marred, poor U.V.Mirabond .RTM..sup.17 Polyurethane Xylene PoorMirabond .RTM..sup.17 -- Added MeCl.sub.2 Poor (20%)Securabond Adhesive.sup.17 Polyamide/Epoxy -- PoorVAGH.sup.4 /THF -- THF PoorWhittaker's Adhesive Polyester -- Poor#46960.sup.18Ciba Geigy GY-9513.sup.19 / Epoxy/ -- PoorCiba Geigy HY-2964.sup.19 Aliphatic amine__________________________________________________________________________High Crosslinked Adhesion and/orPolyurethanes Type Remarks__________________________________________________________________________Thermoplastic Polyurethane Poor - soft, rubberyDesmodur W.sup.20 dicyclohexyl Poor - soft, rubberyThermoplastic methyl(4,4')diisocyanate fair-good iodine resis.Desmodur W dicyclohexyl Poor - hard, glossy methyl(4,4')diisocyanateDesmodur N-100.sup.20 hexamethylene Poor - soft, rubbery diisocyanate easily marred oligomer/catalystDesmodur N-3390.sup.20 hexamethylene Poor - soft, rubbery diisocyanate easily marred oligomer/catalystDesmodur N-3390.sup.20 hexamethylene Poor - soft, rubbery diisocyanate easily marred oligomer/catalystDesmodur N-3390/TMDI.sup.21 hexamethylene 1 day good (soft) diisocyanate 5 days poor (hard) oligomer/TMDI/ catalystDesmodur W3398.sup.20 hexamethylene Poor - hard, glossy diisocyanate fair-good iodine resis. oligomer/catalyst__________________________________________________________________________Other Seam Coating Adhesion and/orCandidates Type Remarks__________________________________________________________________________Congo's Seam Coater Two part urethane Poor - poor iodine"Easy Does It" SN-102.sup.22 based on an aliphatic resistance diisocyanateDel Val's Ink Vehicle.sup.23 Polyamide - Poor - yellowed Ethanol/VMP/IPAc.sup.24 60/20/20Magic Appliance Touch-Up -- PoorPaint for Tubs andSinks (White).sup.25Mobay 0402A.sup.20 Aliphatic carboxylated Poor - soft and urethane latex flexibleSpencer Kellogg Aliphatic carboxylated Poor - dull filmDV 5546 urethane latexSpencer Kellogg DV5546 9 Aliphatic carboxylated Gelled on mixingResimene 717.sup.8 1 Methylated Melamine in of PTSAPTSA.sup.27 10% in water 1 CatalystRohm and Haas E 2184.sup.1 Acrylic latex Poor - sl. yellow (dried at 30.degree. C.)CDM-WJ55 2 Epoxy PoorMaincote TL-5.sup.1 1Resimene 717.sup.8 9 Methylated melamine Poor - waterPTSA (10% in water) 1 Catalyst re-soluble after 10 daysHelastic 6545.sup.28 Aliphatic polyurethane Poor - very poorUcarlnk XL 225E.sup.4 dispersion iodine resistance, Carbodiamide easily marredHelastic X915.sup.28 Aliphatic polyurethane Poor - poorXama 7.sup.29 dispersion iodine resistance AziridineRhoplex WL-91.sup.1 Acrylic latex Tg 52.degree. C. Good - good iodineBCA.sup.30 resistance, easily marredDER 331/DER 721.sup.31 Bisphenol A epoxy PoorDEH 58 Amine hardenerButvar B-98.sup.8 (20%) 90 Polyvinyl butyral UnsatisfactoryResimene U-983.sup.8 in 24 Melamineethanol/water, 95/5PTSA (40%) 0.75 CatalystButvar B-98.sup.8 (20%) 90 Polyvinyl butyral UnsatisfactoryResimene 881.sup.8 20 MelaminePTSA (40%) 0.75 CatalystButvar B-98.sup.8 (20%) 90 Polyvinyl butyral UnsatisfactoryResimene 872.sup.8 20 MelaminePTSA (40%) 0.75 CatalystButvar B-98.sup.8 (20%) 90 Polyvinyl butyral UnsatisfactoryResimene U-983.sup.8 3 MelamineResimene 872.sup.8 20 MelaminePTSA (40%) 0.75 CatalystButvar B-98.sup.8 (20%) 90 Polyvinyl butyral UnsatisfactoryResimene U-983.sup.8 10 MelamineResimene 872.sup.8 10 MelaminePTSA (40%) 0.75 CatalystResimene 747.sup.8 20 Methylated melamine UnsatisfactoryRJ-100.sup.8 40 Styrene allyl alcoholToluene/ethanol (1:1) 60PTSA (40%) 0.6 CatalystResimene 747.sup.8 20 Methylated melamine UnsatisfactoryRJ-100.sup.8 40 Styrene allyl alcoholToluene/ethanol (1:1) 60PTSA (40%) 1.2 CatalystResimene 2060.sup.8 50 Melamine UnsatisfactoryToluene/ethanol (2:1) 30PTSA (40%) 5 CatalystResimene 2060.sup.8 50 Melamine UnsatisfactoryToluene/ethanol 30PTSA (40%) 10 CatalystResimene 745.sup. 8 10 Melamine UnsatisfactoryStyrene allyl alcohol 40Toluene/ethanol (2:1) 25PTSA (40%) 5 CatalystResimene 745.sup.8 10 Melamine UnsatisfactoryStyrene allyl alcohol 40Toluene/ethanol (2:1) 25PTSA (40%) 10 CatalystGelva GMS 264.sup.32 Polyvinyl acetate - Unsatisfactory maleate copolymerGelva GMS 269.sup.32 Polyvinyl acetate - Unsatisfactory maleate copolymerGelva GMS 1140.sup.32 Polyvinyl acetate - Unsatisfactory maleate copolymerGelva GMS 1215.sup.32 Polyvinyl acetate - Unsatisfactory maleate copolymerGelva GMS 1430.sup.32 Polyvinyl acetate - Unsatisfactory maleate copolymerGelva GMS 1753.sup.32 Polyvinyl acetate - Unsatisfactory maleate copolymerGelva GMS 1822U.sup.32 Polyvinyl acetate - Unsatisfactory maleate copolymerGelva GMS 1151.sup.32 / Polyvinyl acetate - UnsatisfactoryPAPI isocyanate.sup.33 maleate copolymer/catalystMirabond.sup.17 95 Polyurethane PoorKL3-2001.sup.20 5 Bonding agentMirabond.sup.17 90 Polyurethane PoorKL3-2001.sup.20 10 Bonding agentS-553.sup.17 95 Vinyl sealer PoorKL3-2001.sup.20 5 Bonding agentS-553.sup.17 90 Vinyl sealer PoorKL3-2001.sup.20 10 Bonding agentGelva GMS 1151.sup.32 95 PVAC-maleate copolymer PoorKL3-2001.sup.20 5 Bonding agentGelva GMS 1430.sup.32 95 PVAC-maleate copolymer PoorKL3-2001.sup.20 5 Bonding agentEpon 828.sup.35 50 Epoxy PoorVersamide 1540.sup.34 17.94 Amine hardenerXylene/MIBK.sup.16, 3/1 15Epon 828.sup.35 50 Epoxy PoorVersamide 1540.sup.34 17.94 Amine hardenerKL3-2001.sup.20 3.4 Bonding agentXylene/MIBK, 3/1 15Butvar B-98.sup.8 (20% in 90 Polyvinyl butyral Poor - poortoluene/ethanol, 1/1) iodine resistanceDyno MB-98.sup.36 (97%) 15 MelaminePTSA (40%) 0.75 CatalystButvar B-98.sup.8 (20%) 90 Polyvinyl butyral Poor - poorDyno MB-98.sup.36 (97%) 15 Melamine iodine resistancePTSA (40%) 1.5 CatalystButvar B-98.sup.8 (20%) 90 Polyvinyl butyral Poor - poorDyno MB-98.sup.36 (97%) 15 MelaminePTSA (40%) 3.75 CatalystButvar B-98.sup.8 (20%) 90 Polyvinyl butyral Poor - poorDyno MB-98.sup.36 (97%) 15 Melamine iodine resistancePTSA (40%) 7.5 CatalystDyno MB-98.sup.36 21 Melamine Poor - poorRJ-100.sup.8 (40% in 100 Styrene allyl alcohol iodine resistancetoluene/ethanol, 1/1)PTSA (40%) 0.6 CatalystDyno MB-98.sup.36 21 Melamine Poor - poorRJ-100.sup.8 (40%) 100 Styrene allyl alcohol iodine resistancePTSA (40%) 1.2 CatalystResimene 747.sup.8 20 Methylated melamine Poor - poorRJ-100.sup.8 (40%) 100 Styrene allyl alcohol iodine resistancePTSA (40%) 7.5 CatalystResimene 747.sup.8 20 Methylated melamine Poor - poorRJ-100.sup.8 (40%) 100 Styrene allyl alcohol iodine reistancePTSA (40%) 15 CatalystDyno MB-98.sup.36 20.6 Melamine Poor - poorRJ-100.sup.8 (40%) 100 Styrene allyl alcohol iodine resistancePTSA (40%) 7.5 CatalystDyno MB-98.sup.36 20.6 Melamine Poor - poorRJ-100.sup.8 (40%) 100 Styrene allyl alcohol iodine resistancePTSA (40%) 15 CatalystButvar B-76.sup.8 (14% in MEX) 658.5 Polyvinyl butyral Poor - poorSanticizer 8.sup.8 7.5 Plasticizer iodine resistanceButvar B-76.sup.8 (14%) 658.5 Polyvinyl butyral Poor - poorSanticizer 8.sup.8 7.5 Plasticizer iodine resistanceKL3-2001.sup.20 5.0 Bonding agentButvar B-76.sup.8 (14%) 658.5 Polyvinyl butyral Poor - poorSanticizer 8.sup.8 7.5 Plasticizer iodine resistanceKL3-2001.sup.20 10.0 Bonding agentButvar B-76.sup.8 (14%) 658.5 Polvinyl butyral Poor - poorSanticizer 160.sup.8 7.5 Plasticizer iodine resistanceButvar B-76.sup.8 (14%) 658.5 Polyvinyl butyral Poor - poorSanticizer 160.sup.8 7.5 Plasticizer iodine resistanceKL3-2001.sup.20 5.0 Bonding agentButvar B-76.sup.8 (14%) 658.5 Polyvinyl butyral Poor - poorSanticizer 160.sup.8 7.5 Plasticizer iodine resistanceKL3-2001.sup.20 10.0 Bonding agentAroplaz 6065x50.sup.37 170.0 alkyd resin Poor - poorAroplaz 2477x65 23.1 alkyd resin iodine resistance6% Cobalt naphthenate 0.676% manganese naphthenate 0.33Xylene 28.045% nonvolatile solidsAroplaz 6065x50.sup.37 100 alkyd resin Poor - poor6% Cobalt naphthenate 0.33 iodine resistance6% manganese naphthenate 0.17Xylene 10.6145% nonvolatile solidsAroplaz 6008x50.sup.37 170.0 alkyd resin Poor - poorAroplaz 2477x65.sup.37 23.1 alkyd resin iodine resistance6% Cobalt naphthenate 0.676% manganese naphthenate 0.33Xylene 28.045% nonvolatile solidsAroplaz 6008x50.sup.37 100 alkyd resin Poor - poor6% Cobalt naphthenate 0.33 iodine resistance6% manganese naphthenate 0.17Xylene 10.6145% nonvolatile solidsAroflint 607.sup.38 50 polyester-epoxy PoorAroflint 404xx60.sup.38 83.33 polyester-epoxyDowanol PMA.sup.31 1069.77% nonvolatile solidsAroflint 607.sup.38 50 polyester-epoxy PoorAroflint 252zm160.sup.38 83.33 polyester-epoxyDowanol.sup.31 10__________________________________________________________________________ .sup.1 Sold by Rohm and Haas Company .sup.2 Methyl ethyl ketone .sup.3 Methylene chloride .sup.4 Sold by Union Carbide Corp. .sup.5 Dioctyl phthalate .sup.6 Polyvinyl chloride .sup.7 Sold by Hercules Inc. .sup.8 Sold by Monsanto Chemical Co. .sup. 9 Sold by E. I. Du Pont Le Nemours .sup.10 Tetrahydrofuran .sup.11 Dimethylformamide .sup.12 Sold by Firestone Fire & Rubber Company .sup.13 Sold by B. F. Goodrich Company .sup.14 Polyvinyl acetate .sup.15 Hydroxyl .sup.16 Methyl isobutyl ketone .sup.17 Sold by Armstrong World Industries, Inc. .sup.18 Sold by Whittaker Corp. .sup.19 Sold by Ciba Geigy Corporation .sup.20 Sold by Mobay Chemical Corp. .sup.21 Trimethyl hexamethylene diisocyanate .sup.22 Sold by Congoleum Corp. .sup.23 Sold by Del Val Ink & Color Inc. .sup.24 Isopropyl acetate .sup.25 Sold by Hechinger Co. .sup.26 Sold by Textron Inc. .sup.27 Paratoluenesulfonic acid .sup.28 Sold by Seton Leather Company .sup.29 Sold by AerojetGeneral Corporation .sup.30 Butyl cellosolve acetate sold by Union Carbide Corp. .sup.31 Sold by Dow Chemical Company .sup.32 Sold by Shawinigan Products Corporation .sup.33 Sold by Carwin Company .sup.34 Sold by General Mills, Inc. .sup.35 Sold by Shell Chemical Corporation .sup.36 A melamine low temperature crosslinker .sup.37 Sold by Ashland Oil, Inc. .sup.38 Sold by Spencer Kellogg

Cyanoacrylate monomers were the only resinous system that showed adequate adhesion to the wear layer. Table 3 lists the cyanoacrylates and amine accelerators which were evaluated.

TABLE 3______________________________________Cyanoacrylates Monomers ViscosityDesignation Cyanoacrylate Ester (CPS)______________________________________Loctite .RTM. 401.sup.1 Ethyl 100Loctite .RTM. 403 Methoxy ethyl 1,000Loctite .RTM. 411 Modified ethyl 5,000Loctite .RTM. 414 Ethyl 120Loctite .RTM. 430 Methyl 80Loctite .RTM. 447 Ethyl 600Loctite .RTM. 460 Methoxy ethyl 50Permabond .RTM. 102.sup.2 Ethyl 100Permabond .RTM. 130 Methyl 500Permabond .RTM. 910 Methyl 100Permabond .RTM. 5238-143A Ethyl + 5% DMP.sup.3 --Permabond .RTM. 5238-143B Ethyl + 10% DMP --Hernon's Instantbond 105.sup.4 Methyl 1-5Hernon's Instantbond 110 Methyl 100Hernon's Instantbond 117 Ethyl 1,300-1,700Hernon's Instantbond 123 Ethyl 100-120Hernon's Instantbond 126 "Rubber" modified 2,000Hernon's Instantbond 127 "Rubber" modified 4,000-6,000______________________________________Cyanoacrylate Accelerators and Primers % ActiveDesignation Ingredient Composition Solvent______________________________________Loctite 1.0 Sulfenamide.sup.5 1,1,1-tri-Activator 711 chloroethaneLoctite 0.1 " 1,1,1,-tri-Activator 702 chloroethaneLoctite 0.1 " 1,1,1,-tri-Activator 703 chloroethaneLoctite 1.0 Modified Freon 113/Activator sulfenamide acetone 85/15FMD-146Permabond 1.0 DMPT.sup.6 1,1,1-tri-Q.F.S. chloroethanePermabond 27A 1.0 Modified DMPT 1,1,1-tri- chloroethanePermabond 27B 1.0 Phenyl ethyl 1,1,1-tri- ethanolamine chloroethaneHernon Primer 20 1.0 DMPT trichloro trifluoro ethaneHernon Primer 22 0.5 DMPT trichloro trifluoro ethane______________________________________ .sup.1 Sold by Loctite Corporation .sup.2 Sold by National Starch and Chemical Corp. .sup.3 Dimethyl phthalate .sup.4 Sold by Hernon Mfg. Inc. .sup.5 Sold by Vanderbilt Chemical Corp. under the registered trademark Amax .sup.6 Dimethyl ptoluidine

For the adhesion evaluations, the cyanoacrylates were applied to floor coverings having the aminoplast/polyol wear layer, optionally leveled with an applicator tip and sprayed with various amine accelerators using a hand-operated atomizer. The accelerator was applied ten minutes after the coating composition was applied. Ethyl esters which had a viscosity of approximately 100 CPS were the most promising.

Physical properties of samples prepared at ambient conditions of 75.degree. F. and 34% relative humidity were evaluated. The results are shown in Table 4.

TABLE 4__________________________________________________________________________ Accelerator or Primer Ultra-Violet (% active Household.sup.1 Stain Discoloration TestCyanoacrylate ingredient) Adhesion Resistance - 3 Hours 3 days 5 days__________________________________________________________________________Loctite 401 711 (1.0%) Chipped off 000040 mod.sup.2 mod w/difficulty" 702 (.1%) Good 000020 v.sl.sup.3 v.sl" 703 (0.01%) Good 000020 v.sl v.sl" FMD-146 Good 000000 none none (experimental)Permabond 102 Q.F.S. (1%) Poor 010040 severe severe" 27A (1%) Poor 000040 none none" 27B (1%) Poor 020240 mod modPermabond 143A Q.F.S. (1%) Poor 010240 severe severe" 27A (1%) Poor 010340 none none" 27B (1%) Poor 000340 mod modHernon 123 Primer 20 (1%) Poor 000030 none none" Primer 22 (0.5%) Poor 000030 none noneLoctite 401 None Good 000010 v.sl v.slPermabond 102 None Good 000030 none noneHernon 123 None Good 000040 none none__________________________________________________________________________ .sup.1 Ball Point Pen Ink, Magic Marker, Brown Shoe Polish, Hair Dye, Iodine 3% and Driveway Sealer, respectively. A higher number indicates darker stain. .sup.2 Moderate .sup.3 Very slight

The use of higher concentration accelerators resulted in poor adhesion because the speed of cure was too fast to allow the monomers to wet-out or penetrate the wear layer surface. If the accelerators were applied to the wear layer surface before the cyanoacrylates, the adhesion was poorer for the same reason. Most of the cyanoacrylates showed good household stain resistance in three hour tests except for iodine. The more severe discoloration generally occurred with the higher concentrations of accelerator.

Further physical property tests were run at 75.degree. F. and 66% relative humidity. The results of these tests are set forth in Tables 5 and 6.

TABLE 5______________________________________ Adhesion 180.degree. flex Accelerator Surface 2 daysCyanoacrylate or Primer Frosting Texture old______________________________________Loctite 401 702 (0.1%) v. slight good gloss good v. slight shrivelLoctite 460 702 (0.1%) v. slight good gloss good v. slight shrivelLoctite 430 702 (0.1%) v. slight good gloss good v. slight shrivelPermabond 102 Q.F.S. (1%) slight sl. grainy poorPermabond Q.F.S. (1%) slight gnarled poor143APermabond Q.F.S. (1%) slight sl. grainy good143BInstantbond 123 Primer 20 v. sl good gloss poor (1%)Instantbond 110 Primer 20 v. sl severe good (1%) whitening______________________________________ TABLE 6______________________________________ Adhesion Accelerator General Comments FourCyanoacrylate or Primer One Day Days______________________________________Loctite 460 702 (0.1%) iodine resistance good(methoxy ethyl) poor, grainy surfaceLoctite 430 702 (0.1%) good overall good(methyl)Loctite 401 702 (0.1%) sl. grainy, good good(ethyl) gloss and iodine resistancePermabond 102 Q.F.S. (1%) good iodine poor(ethyl) resistance (pops off)Permabond Q.F.S. (1%) iodine worse than good5238-143A Permabond 102Permabond Q.F.S. (1%) iodine worse than poor5238-143B Permabond (pops off) 5238-143AInstantbond 123 Primer 20 (1%) low frosting, poor(ethyl) no shrivel, (pops off) iodine OK, adhesion goodInstantbond 100 Primer 20 (1%) grainy, no good, but(methyl) frosting brittle when rubbed______________________________________

Again, at lower accelerator concentrations, the cyanoacrylates exhibited good adhesion.

The cyanoacrylate monomers are very volatile and their vapors can escape from the seam coater bead before curing starts and redeposit alongside of it causing a white "frosted" appearance (chlorsis). To combat this, the surface may be sprayed with a very low solids amine accelerator in trichloroethane or Freon solvents. If the concentration or coverage is too low, "frosting" occurs. If the concentration or coverage is too high, the cure is too rapid leading to distorted gnarled surface textures. If no accelerator is used the surface cures with a dull grainy surface depending on the relative humidity. The "frosting" and the cured cyanoacrylates can be removed from wear layer surface with nitroethane.

Floor coverings were installed with an epoxy adhesive under the seams. In coating with seams with cyanoacrylates, the polyamide hardening agent in the epoxy adhesive remaining on the surface and/or its vapors were present. This caused the cyanoacrylate to cure prematurely resulting in poor adhesion and a whitening in the coating itself. When installed with an aqueous adhesive, the problem did not occur.

Stain resistance was determined on two of the polyurethane coatings (Desmodur W and Desmodur W3398), Loctite 401 and the wear layer without a seam coating. The results are set forth in Table 7.

TABLE 7__________________________________________________________________________ Asphalt Antioxidant Household StainSeam Coater Tracking Staining Staining Resistance__________________________________________________________________________Desmodur W 12.4 + 4.3 + 18.8 = 35.5Desmodur W3398 7.5 + 4.7 + 11.7 = 23.9Loctite 401 5.7 + 4.5 + 3.7 = 13.9Wear Layer 6.7 + 6.8 + 1.6 = 15.1__________________________________________________________________________ (A lower number indicates less staining).

The two polyurethane coatings were significantly less stain resistant than either the cyanoacrylate monomer coating or the wear layer itself. The cyanoacrylate monomer coating was similar to the wear layer.

As stated previously, 2-ethyl cyanoacrylate is the preferred monomer for use with the aminoplast/polyol wear layer. If the cyanoacrylate is modified by the addition of a phthalic acid ester, and particularly dibutyl phthalate, the cyanoacrylate may be applied to the seam by brush. Further, the phthalic acid ester modified cyanoacrylate more closely matches the wear appearance properties of the aminoplast/polyol wear layer. The dibutyl phthalate modified 2-ethyl cyanoacrylate is sold by National Starch and Chemical Corporation under the designation Permabond BK#5235-149A.

Claims

1. A method of seam coating a surface covering product having an exposed surface comprising the reaction product of a protective coating composition including an aminoplast and a polyol, the method comprising applying to the seam of the surface covering a seam coating composition comprising cyanoacrylate monomer.

2. The method of claim 1 wherein the cyanoacrylate monomer is selected from the group consisting of methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate, propyl 2-cyanoacrylate, butyl 2-cyanoacrylate, methoxy ethyl 2-cyanoacrylate, methoxy methyl 2-cyanoacrylate, ethoxy methyl 2-cyanoacrylate and ethoxy ethyl 2-cyanoacrylate.

3. The method of claim 2 wherein the cyanoacrylate monomer is selected from the group consisting of methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate and methoxy ethyl 2-cyanoacrylate.

4. The method of claim 1 wherein the seam coating composition comprises at least two cyanoacrylate monomers.

5. The method of claim 1 wherein the seam coating composition further comprises a plasticizer.

6. The method of claim 5 wherein the plasticizer is a phthalic acid ester.

7. The method of claim 6 wherein the phthalic acid ester is about two percent to about thirty percent by weight of the seam coating composition.

8. The method of claim 6 wherein the phthalic acid ester is the esterification product of phthalic acid and an organic group selected from the group consisting of an alkanol comprising two to ten carbon atoms, benzyl alcohol, benzyl alcohol derivatives and mixtures thereof.

9. The method of claim 8 wherein the phthalic acid ester is selected from the group consisting of dibutyl phthalate, dihexyl phthalate, dioctyl phthalate and butyl benzyl phthalate.

10. The method of claim 9 wherein the phthalic acid ester is dibutyl phthalate.

11. The method of claim 1 wherein the seam coating composition is clear after it is cured.

12. The method of claim 1 further comprising applying in accelerator to the uncured seam coating composition.

13. The method of claim 12 wherein the accelerator is an amine.

14. The method of claim 13 wherein the amine is sulfenamide, phenyl(C.sub.1 -C.sub.6)alkyl(C.sub.1 -C.sub.6)alkanol amine or (C.sub.1 -C.sub.8)alkyl-substituted p-toluidine.

15. The method of claim 14 wherein the amine is selected from the group consisting of N-oxydiethylene benzothiazol-2-sulfenamide, phenyl ethyl ethanol amine and dimethyl p-toluidine.

16. The method of claim 1 wherein the aminoplast is a melamine.

17. The method of claim 16 wherein the melamine is alkyl etherified with alkyl groups comprising 1 to 10 carbon atoms.

18. The method of claim 17 wherein the alkyl groups have 1 to 4 carbon atoms.

19. The method of claim 1 wherein the protective coating composition further comprises a vinyl resin.

20. The method of claim 19 wherein the vinyl resin is selected from the group consisting of VAGH, VAGD, VROH and VYES.

21. The method of claim 1 wherein the seam coating is brushable after application on the seam and prior to being cured.

22. The method of claim 1 wherein the seam coating has a viscosity of about 50 to about 300 CPS at the time of application.

23. The method of claim 22 wherein the seam coating has a viscosity of about 100 CPS at the time of application.

24. A flooring system comprising two floor coverings each having an exposed surface comprising the reaction product of a protective coating composition including an aminoplast and a polyol, said floor coverings having abutting edges forming a seam, and a seam coating applied to the seam comprising cyanoacrylate monomer.

25. The flooring system of claim 24 wherein the cyanoacrylate monomer is selected from the group consisting of methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate, propyl 2-cyanoacrylate, butyl 2-cyanoacrylate, methoxy ethyl 2-cyanoacrylate, methoxy methyl 2-cyanoacrylate, ethoxy methyl 2-cyanoacrylate and ethoxy ethyl 2-cyanoacrylate.

26. The flooring system of claim 24 wherein the seam coating further comprises a plasticizer.

27. The flooring system of claim 24 wherein the aminoplast is a melamine.

28. The flooring system of claim 27 wherein the melamine is alkyl etherified with alkyl groups comprising 2 to 10 carbon atoms.

29. The flooring system of claim 24 wherein the protective coating composition further comprises a vinyl resin.