Embossed and wiped decorative surface coverings

• US 5,102,716 A
• Filed: 10/29/1990
• Issued: 04/07/1992
• Est. Priority Date: 08/12/1988
• Status: Expired due to Term

• Current Assignee: AWI Licensing Company
• Original Assignee: Armstrong World Industries Incorporated
• Inventors: Balmer, Richard H., Dees, Martin Jr., Drout, Frank G.
• Primary Examiner(s): Robinson, Ellis P.
• Assistant Examiner(s): Loney, Donald J.
• Application Number:
  US07/605,079
• Time in Patent Office: 526 Days
• Field of Search: 428/33, 428/131, 428/133, 428/137, 428/46, 428/47, 428/119, 428/161, 428/167, 428/120, 428/168, 428/172, 428/173, 428/515, 428/542.2, 428/134, 428/141, 428/142, 428/156 , 428/158, 428/424.6, 428/203, 428/163, 428/306.6, 428/308.4, 428/318.4, 428/520, 428/204
• US Class Current: 428/158
• CPC Class Codes: B44C 1/20 Applying plastic materials and superficially modelling the surface of these materials
• CPC Class Codes: D06N 7/0007 characterised by their relief structure
• CPC Class Codes: D06N 7/0057 Layers obtained by sintering or glueing the granules together
• CPC Class Codes: Y10T 428/24182 Inward from edge of web or sheet
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component
• CPC Class Codes: Y10T 428/24521 with component conforming to contour of nonplanar surface
• CPC Class Codes: Y10T 428/24537 Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/24868 Translucent outer layer
• CPC Class Codes: Y10T 428/24876 Intermediate layer contains particulate material [e.g., pigment, etc.]
• CPC Class Codes: Y10T 428/249955 Void-containing component partially impregnated with adjacent component
• CPC Class Codes: Y10T 428/249958 Void-containing component is synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/3158 Halide monomer type [polyvinyl chloride, etc.]
• CPC Class Codes: Y10T 428/31909 Next to second addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31928 Ester, halide or nitrile of addition polymer

Abstract

A surface covering product is disclosed which includes a layer of fused embossed PVC material on a substrate and a layer of transparent or translucent plastic material substantially covering the fused PVC layer and filling the embossed area of depression in the PVC layer. The surface covering product is made by applying the plastic material to the embossed surface of the PVC material and wiping off at least a portion of the plastic material. In one embodiment, a film of plastic material of substantial or minimal thickness remains on the fused PVC material. In another embodiment, the plastic material is completely wiped off the undepressed area of the fused granular material. The PVC material is preferably a granular material such as a stencil vinyl fine material. In one embodiment, the plastic material is a layer of minimal thickness substantially covering the stencil vinyl fine material.

Claims

1. A decorative surface covering product comprising:

(a) a first layer of fused PVC material, and

(b) a second layer of cured transparent or translucent plastic material substantially covering said first layer, said second layer having an element extending into said first layer.

2. The decorative surface covering product of claim 1 wherein the PVC material is a granular material prior to being fused.

3. The decorative surface covering product of claim 2 wherein the granular material is selected from the group consisting of dryblend, stencil vinyl fines, and chips of fused PVC.

4. The decorative surface covering product of claim 2 wherein the granular material appears through the second layer as particles of differing colors.

5. The decorative surface covering product of claim 1 wherein the second layer includes a plurality of discrete elements extending into the first layer.

6. The decorative surface covering product of claim 5 wherein in the surface of the second layer opposite the discrete elements projects above the plane of the surface of the second layer which is opposite the areas between the discrete elements.

7. The decorative surface covering product of claim 5 wherein the surface of the second layer opposite the areas between the discrete elements projects above the plane of the surface of the second layer opposite the discrete elements.

8. The decorative surface covering product of claim 5 wherein the plastic material is transparent and the discrete protruding elements are arranged in a dot pattern design providing the decorative surface of the covering product with a lenticular effect.

9. The decorative surface covering product of claim 5 wherein the portion of the second layer between the elements has minimal thickness.

10. The decorative surface covering product of claim 1 wherein the plastic material is translucent and includes a plurality of discrete elements extending completely into the first layer, the discrete elements being arranged in a dot pattern design providing the decorative surface of the covering product with a discrete colored dot pattern of a contrasting shade of color to the color of the decorative surface of the covering product not above a discrete protruding elements.

11. The decorative surface covering product of claim 1 wherein the second layer includes a plurality of discrete elements having a cross-sectional shape selected from the group consisting of circular, rectangular, regular polygonal and cross-bar.

12. The decorative surface covering product of claim 11 wherein the cross-sectional area of the elements is substantially constant.

13. The decorative surface covering product of claim 1 wherein the depth of the element is about 80% to 90% of the thickness of the first layer.

14. The decorative surface covering product of claim 1 wherein the element is about 0.015 to 0.045 inches in depth.

15. The decorative surface covering product of claim 1 wherein the cross-sectional area of the element at its interface with the surface of the second layer adjacent the first layer is about 10 to 50% of the surface area of the decorative surface covering product.

16. The decorative surface covering product of claim 1 wherein the plastic material contains solid particles.

17. The decorative surface covering product of claim 1 wherein the plastic material is a plastisol.

18. The decorative surface covering product of claim 1 wherein the plastic material is translucent.

19. The decorative surface covering product of claim 1 wherein the surface of the second layer opposite the element extending into the first layer is an exposed wear surface.