Decorative surface coverings

• US 5,891,564 A
• Filed: 12/11/1996
• Issued: 04/06/1999
• Est. Priority Date: 06/07/1995
• Status: Expired due to Fees

• Current Assignee: Mannington Mills of Delaware Incorporated
• Original Assignee: Mannington Mills Incorporated (Mannington Commercial Incorporated)
• Inventors: Crispin, Barry C., Shultz, Jeffrey R.
• Primary Examiner(s): Beck, Shrive
• Assistant Examiner(s): PARKER, FREDERICK JOHN
• Application Number:
  US08/762,022
• Time in Patent Office: 846 Days
• Field of Search: 428/324, 428/325, 428/326, 428/327, 428/424.6, 427/194, 427/195, 427/197, 427/198, 427/202, 427/203, 427/359, 427/356, 427/366
• US Class Current: 428/324
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 43/30 Making multilayered or multicoloured articles B29C43/26 takes precedence
• CPC Class Codes: B44C 1/24 Pressing or stamping ornamental designs on surfaces
• CPC Class Codes: D06N 3/0077 Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
• CPC Class Codes: D06N 3/06 with polyvinylchloride or its copolymerisation products surface treatment or foaming for floor coverings D06N7/0007
• CPC Class Codes: D06N 7/001 obtained by mechanical embossing
• CPC Class Codes: D06N 7/0028 characterised by colour effects, e.g. craquelé, reducing gloss terrazzo by sintering D06N7/0057
• CPC Class Codes: E04F 13/002 made of webs, e.g. of fabrics, or wallpaper, used as coverings or linings of a number of similar elements carried by a common web E04F13/0862; paperhanging, tapestry work B44C7/00
• CPC Class Codes: E04F 13/08 composed of a plurality of similar covering or lining elements, E04F13/072 takes precedence; borders, skirtings E04F19/02; of webs or fabrics E04F13/002; fixing strips E04F19/06; separate provisional spacers between adjacent tiles E04F21/0092; implements or means for setting tiles E04F21/18
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: Y10T 428/251 Mica
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material
• CPC Class Codes: Y10T 428/3158 Halide monomer type [polyvinyl chloride, etc.]

Abstract

The present invention discloses surface covering products and methods and an apparatus for making surface covering products. In particular, the method of the present invention includes depositing color particles on a moving carrier to form a base layer. The base layer then comes in contact with a patterned embossing device such as a roll to create a depressed or displaced pattern image on the base layer. Afterwards, accent particles or pellets are sprinkled or applied over the embossed base layer. The embossed base layer is subjected to heat and/or pressure to consolidate the accent and color particles and form a preformed mass. The preformed mass is then pressed to form a fused, texture-created structure. The surface covering products made from the process of the present invention have unique geometric patterns with well-defined grout lines or irregular decorative designs.

Claims

1. A surface covering comprising:

a base material formed from color particles, said base material having a formed and contoured upper surface with a repeating pattern of depressions;

accent particles having a first population density within said depressions; and

additional accent particles having a second population density disposed in at least a portion of said upper surface between said depressions, said second population density of said additional accent particles being lower than said first population density of said accent particles.

2. The surface covering claim 1, wherein said color particles comprise single colored particles.

3. The surface covering of claim 1, wherein said color particles comprise multi-color blends of particles.

4. The surface covering of claim 1, wherein said color particles comprise PVC pellets and at least one color pigment blended with said PVC pellets.

5. The surface covering of claim 1, wherein said accent particles comprise at least one color pigment, a PVC resin, a filler, a plasticizer, and a heat stabilizer.

6. The surface covering of claim 1, wherein said color particles comprise at least one pigment, a paste resin, to enhance flow characteristics, a plasticizer, and a stabilizer.

7. The surface covering of claim 1, wherein said color particles have a particle size range of from about 8 mesh to about 100 mesh.

8. The surface covering of claim 7, wherein said particle size range is from about 16 mesh to about 50 mesh.

9. The surface covering of claim 1, wherein said accent particles are single or multi-color particles, clear PVC particles, metal pigments, mineral pigments, cellulosic particles, glass beads, pearlescent particles or mixtures thereof.

10. The surface covering of claim 9, wherein said accent particles are single or multi-color particles.

11. The surface covering of claim 1, wherein said accent particles have a diameter of from about 0.001 inch to about 0.150 inch.

12. The surface covering of claim 11, wherein said accent particles have a diameter of from about 0.001 inch to about 0.100 inch.

13. The surface covering of claim 1, further comprising a backing material.

14. The surface covering of claim 1, further comprising a clear or colored coating of a thermoplastic resin or UV-curable coating disposed over the surface of said base material and accent particles.

15. The surface covering of claim 14, wherein said clear or colored coating is a urethane top coat.

16. The surface covering of claim 1, wherein said first population density varies within said depressions.

17. The surface covering of claim 1, wherein said first population density is generally uniform within said depressions.

18. The surface covering of claim 1, wherein at least a portion of said depressions contain no accent particles.

19. The surface covering of claim 1, wherein said second population density varies in said upper surface.

20. The surface covering of claim 1, wherein said second population density is generally uniform in said upper surface.

21. The surface covering of claim 1, wherein at least a second portion of said upper surface between said depressions has no accent particles thereon.

22. The surface covering of claim 1, wherein said surface covering is a floor covering.

23. The surface covering of claim 1, wherein said surface covering is, wallpaper, a countertop, or a laminate.