Embossable coating

• US 4,474,920 A
• Filed: 09/27/1982
• Issued: 10/02/1984
• Est. Priority Date: 04/08/1981
• Status: Expired due to Fees

• Current Assignee: Celotex Corporation
• Original Assignee: Celotex Corporation
• Inventors: Einhaus, Bernard J., Kyminas, Stanley C., Hinds, Stephen G.
• Primary Examiner(s): Schofer, Joseph L.
• Assistant Examiner(s): REDDICK, MARIE L
• Application Number:
  US06/424,660
• Time in Patent Office: 736 Days
• Field of Search: 524/386, 524/459, 524/490, 524/528, 524/563
• US Class Current: 524/386
• CPC Class Codes: B05D 3/12 by mechanical means
• CPC Class Codes: B44C 1/20 Applying plastic materials and superficially modelling the surface of these materials
• CPC Class Codes: B44C 1/24 Pressing or stamping ornamental designs on surfaces

Abstract

A method for producing a decorative design on a substrate by applying to the substrate an embossable coating comprising a filler, a binder, a release agent, a moisture control agent, and a liquid; drying the applied coating to remove a major portion of the liquid therefrom, sufficient liquid being retained to make the coating pliable and readily impressible by an embossing means; and subjecting the pliable coating to pressure contact with the embossing means, which is at ambient or an elevated temperature, to impress a decorative design into the coating; and the embossed coated substrate produced by the method.

Claims

1. An embossable coating composition for application to a surface of a substrate at a rate of 25 to 150 grams per square foot of said surface comprising a filler selected from the group consisting of talc and filler mixtures comprising a major proportion of talc, a film-forming binder adapted to bind the filler particles together and to adhere said filler to said substrate, a moisture control agent wherein said moisture control agent is a member selected from the group consisting of propylene glycol, ethylene glycol, diethylene glycol, hexylene glycol, glycerol and combinations there of a release agent, and a liquid,

wherein the quantity of said moisture control agent is sufficient to promote controlled moisture evaporation from said composition, whereby said composition is capable of (a) being dried to remove a major portion of said liquid therefrom but to leave sufficient liquid in said composition to render said composition pliable and readily impressible by an embossing means, and (b) being subjected, when said composition is in said pliable and readily impressible condition, to pressure contact with said embossing means to thereby emboss said composition;

and

wherein the quantity of said release agent is sufficient to render said embossed composition cleanly separable from said embossing means.

2. The composition of claim 1 wherein:

(a) said filler is a finely-divided inorganic material having an average particle size less than 200 microns and selected from the group consisting of talc, and mixtures of talc with calcium carbonate, silica, clay, calcium metasilicate, asbestos, perlite, and titanium dioxide,

and

(b) said binder is a polymer of a member selected from the group consisting of vinyl monomers, polyene monomers, vinylidene monomers, and combinations thereof.

3. The composition of claim 1 wherein said binder is polyvinyl acetate.

4. The composition of claim 1 wherein the weight ratio of said filler to said binder is 2:

1 to 10;

1.

5. The composition of claim 1 wherein said liquid is water.

6. The composition of claim 5 which has a viscosity of 750 to 5000 centipoises at 25°

C.

7. The composition of claim 5 which has a viscosity of 1000 to 2000 centipoises at 25°

C.

8. The composition of claim 5 wherein said moisture control agent is propylene glycol.

9. The composition of claims 1 or 8 wherein said moisture control agent comprises 3 to 10 weight percent of said composition.

10. The composition of claim 5 wherein said release agent is a member selected from the group consisting of polyethylene, a wax, a fluorocarbon, a metallic stearate, and combinations thereof.

11. The composition of claim 5 wherein said release agent is a polyethylene dispersion.

12. The composition of claims 10 or 11 wherein said release agent comprises 0.25 to 2.5 weight percent of said composition.

13. The composition of claims 5, 6, 1 9, 10 or 11 wherein said filler is a member selected from the group consisting of talc, and mixtures of talc with diatomaceous earth, calcium carbonate, clay, crystalline silica, and perlite.

14. The composition of claim 13 wherein said binder is a polyvinyl acetate latex.

15. The composition of claim 5 wherein:

(a) said filler is a finely divided inorganic material having an average particle size less than 200 microns,

(b) said binder is a polymer of a member selected from the group consisting of a vinyl monomer, a polyene monomer, a vinylidene monomer, and combinations thereof,

is a member selected from the group consisting of propylene glycol, ethylene glycol, diethylene glycol, hexylene glycol, glycerol, and combinations thereof, and

(c) said release agent is a member selected from the group consisting of polyethylene, a wax, a fluorocarbon, a metallic stearate, and combinations thereof; and

wherein said composition has a viscosity of 750 to 5000 centipoises at 25°

C. and the weight ratio of said filler to said binder is 2;

1 to 10;

1.

16. The composition of claim 15 wherein:

(a) said filler is a mixture of talc and diatomaceous earth, the weight ratio of said talc to diatomaceous earth being 10;

1 to 7;

1,

(b) said binder is a polyvinyl acetate latex, the filler to binder weight ratio being 5;

1 to 7;

1, and

(c) said moisture control agent is propylene glycol.

17. The composition of claim 15 wherein:

(a) said filler is a mixture of talc and diatomaceous earth, the weight ratio of said talc to diatomaceous earth being 10;

1 to 7;

1,

(b) said binder is a polyvinyl acetate latex, the filler to binder weight ratio being 5;

1 to 7;

1, and

(c) said release agent is a polyethylene dispersion.

18. The composition of claim 15 wherein:

(a) said filler is a mixture of fine perlite and talc in a weight ratio of 1;

8,

(b) said binder is a polyvinyl acetate latex, the filler to binder weight ratio being 5;

1 to 7;

1, and

(c) said moisture control agent is propylene glycol and said release agent is a polyethylene dispersion.

19. The composition of claim 15 wherein:

(a) said filler is a member selected from the group consisting of talc, and mixtures of talc with diatomaceous earth, calcium carbonate, clay, crystalline silica, and perlite , and

(b) said binder is a polyvinyl acetate latex.

20. The composition of claim 19 wherein said moisture control agent is propylene glycol and said release agent is a polyethylene dispersion.

21. The composition of claim 20 wherein said filler is a mixture of talc and diatomaceous earth, the weight ratio of said talc to diatomaceous earth being 10:

1 to 7;

1, and the filler to binder weight ratio being 5;

1 to 7;

1.

22. The composition of claim 21 wherein:

(a) said moisture control agent comprises 3 to 10 weight percent of said composition, and

(b) said release agent comprises 0.25 to 2.5 weight percent of said composition.