GB1569943A - Decorative sheet-type material containing chips and process for making same - Google Patents
Decorative sheet-type material containing chips and process for making same Download PDFInfo
- Publication number
- GB1569943A GB1569943A GB3207/77A GB320777A GB1569943A GB 1569943 A GB1569943 A GB 1569943A GB 3207/77 A GB3207/77 A GB 3207/77A GB 320777 A GB320777 A GB 320777A GB 1569943 A GB1569943 A GB 1569943A
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- United Kingdom
- Prior art keywords
- chips
- layer
- plastics
- plastics layer
- wet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/005—Processes for producing special ornamental bodies comprising inserts
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
- D06N3/0061—Organic fillers or organic fibrous fillers, e.g. ground leather waste, wood bark, cork powder, vegetable flour; Other organic compounding ingredients; Post-treatment with organic compounds
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N3/06—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
- D06N7/0007—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by their relief structure
- D06N7/0013—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by their relief structure obtained by chemical embossing (chemisches Prägen)
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
- D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
- D06N7/0052—Compounding ingredients, e.g. rigid elements
- D06N7/0055—Particulate material such as cork, rubber particles, reclaimed resin particles, magnetic particles, metal particles, glass beads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/26—Polymeric coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Laminated Bodies (AREA)
Description
(54) DECORATIVE SHEET-TYPE MATERIAL CONTAINING
CHIPS AND PROCESS FOR MAKING SAME
(71) We, GAF CORPORATION, a corporation organized and existing under the laws of the State of Delaware, United States of
America, having its main office at 140 West 51st Street, New York, New York 10020,
United States of America, do hereby declare the invention for which we pray a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to a decorative sheet-type covering material containing chips and to a method for preparing such material.
Decorative sheet-type covering materials such as vinyl floor coverings are well known in the art. The use of plastics layers containing chips in such materials to impart various decorative effects is also well known.
In the manufacturing of such materials containing chips, it is normally desirable that the chips be embedded in a layer of plastics material so that the upper surface of the layer of plastics material in which the chips are embedded is relatively smooth. Such smooth surface facilitates the application of printing or wear layers on top of the plastics layer in which the chips are embedded and is considered desirable even where the surface of the end product is to be textured.
Embedding of chips into the plastics layer in connection with the manufacture of the type of sheet materials described herein has normally been accomplished by sprinkling the chips on the surface of the wet plastics layer and then embedding the chips into the plastics material by the application of pressure such as by the use of conventional planishing rolls. Planishing rolls have also been necessary where the chips have been mixed with the plastics material prior to application to the substrate.
U.S. Patent Specification 3,265,548 discloses the use of an alternative process in which chips having significantly higher densities than the plastics layer are used so that the chips sink to the bottom of the plastics layer. This process is disadvantageous in that the decorative effect of the chips is usually greater when they remain at or near the surface of the plastics layer in which they are embedded. Further, where foamable chips are desired in order to provide a textured surface on the end product, chips which sink below the surface of the plastics layer will not produce as acceptable texturing effects as those which remain at or near the upper surface of the plastics layer in which they are embedded.
An additional alternative process suggested by the prior art is that described in
U.S. Patent Specification 3,682,741 which teaches that chips may be allowed to sink into the plastics layer by heating the plastics material to cause the chips to rapidly sink into the plastics layer. This procedure is disadvantageous in that it has been found difficult to control viscosity of the plastics layer in this manner so as to allow the chips to sink into the plastics material without sinking to the bottom of the plastics layer.
In accordance with one aspect of the invention a decorative sheet-type covering material is provided which comprises a substrate, a cured (as hereinafter defined) plastics layer adhered to the substrate and chips embedded in the upper portion of the plastics layer, the chips having a specific gravity of 105% to 120% of the specific gravity of the plastics layer. In this specification by the term "cured" we meant "set, hardened or dried". The plastic layer containing the chips preferably comprises cured polyvinyl chloride (PVC) plastisol or organosol and the chips are preferably of plasticized vinyl material. The chips do not extend above the upper surface of the plastics layer and are preferably not in contact with the substrate.
A process is also provided for making decorative sheet-type covering material of the type described immediately above. The process comprises forming a layer of wet, curable plastics material adhered to a substrate, distributing chips on the layer of wet plastics material and allowing the chips to settle into the plastics layer sufficiently to form a smooth surface on the plastics layer without the chips sinking to the bottom of the layer, the chips having a specific gravity of 105% to 120% of the specific gravity of the wet plastics layer onto which the chips are distributed. When the chips have been allowed to settle into the plastics layer, the plastics material is then cured as hereinbefore defined.
As mentioned above, the preferred product of the invention is a decorative sheettype covering material comprising a substrate, a cured plastics layer having chips embedded in an upper portion thereof and a wear layer over the plastics layer containing the chips. The chips have a specific gravity of 105% to 120% of the specific gravity of the plastics layer within which they are embedded. Additionally, the chips the surface of the plastics layer in which they are embedded. Additionally ,the chips are preferably not in contact with the substrate.
The substrate used in the product of the invention may include a suitable supporting material such as an asbestos sheet, a nonwoven fibrous web, a woven fibrous web, a plastisol layer, a plastisol layer on felt backing or a layer of felt sealed with a layer of latex. The preferred substrate is felt, most advantageously an impregnated asbestos felt or a resin impregnated cellulose or other organic felt or, with suitable sealing coats, an asphalt saturated organic felt. While felt is preferred, paper sheet, cloth or even metal foil may be used for some purposes such as wall coverings.
The use of a sealing or priming coat is not considered essential but is preferred, especially where a felt base is used. Where used, the sealing or priming coat may be made up of a latex containing an acrylic polymer with or without pigments or filters such as the prime coat described in U.S.
Patent Specification 3,458,337 to Rugg.
The cured plastics layer adhered to the substrate and within which the chips are embedded is as mentioned above preferably a cured PVC plastisol or organosol.
Such PVC plastic may be any of the various
PVC resin materials normally used in connection with coating of decorative sheet materials and may specifically include those described in the above mentioned U.S.
Patent Specification 3,458,337. Plastics material having a specific gravity of 1 to 1.4 is frequently preferred for this purpose.
The chips used in the product of the invention may be formed as described in more detail below and may, if desired, be opaquely or translucently pigmented. The chips may be uniformly distributed throughout the upper portion of the plastics layer or may be distributed in patterns to provide decorative effects on only certain parts of the sheet. The chips which are preferably chips of plastics material are preferably of a gelled or fused plasticized vinyl composition and, if desired, all or a portion of the chips may contain blowing suppressant or blowing agent. The chips may be prepared in a suitable manner such as from extruded thin vinyl sheets, plasticized calendered sheets or sheets cast from plastisols which are then chopped or diced into relatively fine particles.
While size of chips used is not critical, chipped particle sizes averaging from 1/64" to 1/8" or sheets from 1 to 20 mils thickness chopped into particles of about this size range are preferred. Chips may conveniently be prepared using the same basic plastics composition used in forming the plastics layer in which the chips are embedded (except, of course, for such variations in compositions as may be desirable or necessary to obtain desired chip densities in accordance with the invention). Alternatively, chips may also conveniently be prepared using the same basic plastics composition used in forming the wear layer where a wear layer is utilized. The chips may, within the specific gravity limits specified herein, include both filled and unfilled chips. Chips having a specific gravity from 1.25 to 1.45 are preferred.The term "chips" as used herein is intended to include not only chips formed as described above but also other particles of suitable specific gravity. Alternative forms of such particles may include for instance gelled plastics particles made as described in U.S. Patent Specification 3,345,235 to Miller or small plasticized particles such as those formed as described in U.S. Patent 3,856,900 to Erb.
For most applications, especially for use as flooring, the products of the invention will normally include a cured wear layer over the plastics layer containing the chips.
To provide necessary protection on flooring material the wear layer should have a minimum thickness of 4 mils, preferably at least 10 mils and, depending upon the degree of protection desired, may be substantially thicker, such as up to 15 or 20 mils or more. The wear layer may be of any suitable material such as polyurethane or cured
PVC plastisol or organosol. Such materials are well known in the art and are described for instance in the above mentioned U.S.
patent Specification 3,458,337.
If desired, additional plastics coatings and printing may be used in the manner well known in the art. For instance a plain or foamed plastics layer may be included as part of the substrate on which the plastics layer containing the chips is placed and printing may be applied either beneath or above the layer of plastics material containing the chips. In a preferred embodiment of the invention a suitable pattern of printing is located between the plastics layer containing the chips and the wear layer. Preparation of these various optional components as well as the plastics layer containing the chips is described in greater detail below.Compositions, thicknesses and methods used in applying printing, wear layers and other optional components may be as conventionally known in the art including for instance those described in the above mentioned United States Patent
Specification 3,458,337.
The plastics layer in which chips are embedded in accordance with the invention preferably has a thickness significantly greater than the diameter or thickness of the chips embedded therein. In a preferred embodiment chips do not touch the substrate and preferably do not extend much more than 1/2 of the way from the surface of the plastics layer to the substrate. For maximum decorative effect the upper surfaces of the chips are level with or only very slightly below the top surface of the plastics layer. In general the further the tops of the chips sink into the plastics layer the more difficult it is to obtain desired decorative effects through the use of chips.
A major advantage of the product of the present invention is that the chips used in the present invention may be positioned in the upper portion of the plastics layer rather than the bottom portion thereof without the need for planishing during manufacture of the product.
If desired, the plastics layer in which the chips are embedded in accordance with the invention may be a cured foamed plastics layer which may be obtained by suitable means such as those discussed below.
As mentioned above, the basic process of the invention involves the manufacture of a decorative sheet-type covering material of the invention by first forming a layer of wet curable plastics material adhered to a substrate and then distributing chips of the type described above on the wet plastics layer and allowing the chips to settle into the plastics layer sufficiently to form a smooth surface on the layer without the chips sinking to the bottom of the layer. The plastics layer may then be cured in a conventional manner. Also, as mentioned above,
PVC plastisol or organosol having a specific gravity from 1 to 1.4 is the preferred plastics material.While the temperatures at which the chips are allowed to settle into the plastics layer may obviously be varied within fairly wide limits, desired temperatures for such operations will of course be somewhat dependent upon the particular plastics material used. Using the preferred plastics material of the preferred specific gravity mentioned, temperatures of 60 to 1500F may conveniently be used. With the plastics layer maintained within this approximate temperature range, settling times of 0.2 to 2 minutes will be found suitable for allowing the chips to settle into the plastics layer in accordance with the invention.If the specific gravity limitations of the invention are observed, it will be found that surface tension effects will prevent all or at least most of the chips from settling substantially below the surface of the plastics layer, even though the specific gravity of the chips may be well above that of the plastics layer. On the other hand, the reduced viscosity of the plastics material due to the elevated temperatures will enable the chips to sink into the plastics material to the point where the chips do not protrude above the surface of the plastic layer.
As mentioned above, preferred embodiments of the invention involve the use of a separate clear wear layer over the layer of plastics material containing the chips.
Where such wear layer is used, the plastics layer containing the chips is conveniently gelled and the wear layer (and any intermediate printing or other layers) applied to the gelled layer containing the chips before the entire sheet is heated to a temperature sufficient to cure the various plastics layers (including the layer including the chips and the wear layer). If foamable chips are used or a blowing agent is used in the plastics layer containing the chips, the curing temperature should, of course, be sufficiently high to decompose the blowing agent and thereby foam the foamable chips or the plastics layer where such contains blowing agent.
Application of chips to the wet plastisol or other plastics materials forming the plastic layer within which the chips are to be embedded may be by any suitable means such as sifting, screening, stencilling or vibratory feeding. Chips may be applied in any suitable amounts. Amounts sufficient to provide from 106% to 90% coverage with respect to the surface area of the plastics layer are preferred.
Where foamable chips or a foamable plastics layer incorporating chips in accordance with the invention is desired, any suitable blowing agent or catalyst activated blowing agent may be used. Such agents are well known in the art for producing foamed plastisol or organosol layers and include, for instance, those described in the above mentioned U.S. Patent Specification 3,458,337. Such blowing agents include, for instance, azodicarbonamide (ABFA), N, N'dinitrosopentamethylenetetramine, aminoguanidine bicarbonate, p, p'-thiobis (benzene sulphonhydrazide) p, p'-diphenylmethane disulphonhydrazide, benzene m-disulphonhydrazide, benzene sulphonhydrazide, terephthalazide, benzazide and p-tert.-butyl benzazide, phthalazide.Gelling of plastics layers where used may be carried out in accordance with normal practices whereby the plastics material is heated sufficiently to gel but not sufficiently to decompose blowing agents. When the various desired layers have been applied and gelled, the entire sheet may then be heated to a temperature sufficient to cure the plastics material (e.g.
fuse the PVC plastisols or organosols) and also decompose any blowing agent used.
Typical blowing agent systems have decomposition temperatures within a range of 300"F. and 400"F. Typical conditions for gelling without decomposing blowing agents involve exposure to temperatures of, for instance, 250"F for times of 2 to 4 minutes or at higher temperatures for correspondingly shorter periods of time. Similar conditions are also suitable where blowing agent systems are not used.
When practising the present invention it is not necessary as required in prior art processes to smooth the plastics layer containing the settled chips prior to applying printing or a wear layer thereto. When a planishing roll is used, considerable difficulty is frequently experienced in extrusion of a thick, not fully fused coating in the nip of the roll as well as in properly balancing the gelling process between gelling the plastics layer containing the chips too solidly to to allow chip embedding and undergelling with subsequent "mudcracking" of the plastics layer. These problems are, of course, nonexistent in connection with the practice of the present invention since a planishing roll need not be used.
The following Example is illustrative only.
Example
In this example asbestos felt sealed with a latex seal coat was coated with a 23 mil thick layer of a clear plastics coating having the following formulation:
Parts by
Ingredient Weight
PVC homopolymer dispersion resin 80
PVC homopolymer suspension resin 20
Plasticizer 56
Stabilizer 11
Mineral Spirits diluent 2
Surfactant 0.6
Vinyl chips were distributed on the wet plastics layer at the rate of 0.4 lb. /sq. yard to give a chip coverage of 60%. The chips were made by gelling a plastisol composition in a layer of 12 mils thick on release paper for 3 minutes at 2750F, stripping the sheet and chopping the sheet to a mesh size of - 8+20 U.S. standard sieve. About 80% by weight of the chips consisted of a foamable composition while the remaining 20% consisted of a solid vinyl composition.The plastics coating formulation had a specific gravity of 1.20.
The foamable chip composition used in this example was as follows:
Parts by
Ingredient Weight
PVC homopolymer dispersion resin 50
PVC homopolymer suspension resin 50
Plasticizer 60
Pigment (titanium dioxide) 7.5
Pigment (barium sulphate) 18.3
Blowing Agent (ABFA) 2.5
Stabilizer-Catalyst 2.5
Blue Tint 0.05
The specific gravity of the above foamable chip composition was 1.35.
The solid chip composition used in this example was as follows:
Parts by
Ingredient Weight
PVC Homopolymer dispersion resin 54
PVC Homopolymer suspension resin 46
Plasticizer 32
Stabilizer 11
Mineral Spirits 3
Pigment (titanium dioxide) 3.5
The specific gravity of this solid chip composition was 1.265.
After being applied to the wet plastics coating layer, the chips were allowed to settle for two minutes at room temperature and the sheet was then placed in an oven at 300 F for two minutes to gel the sheet without decomposing the blowing agent. In this way a smooth printable surface resulted.
The sheet was then printed with a suitable design and topcoated with a 16 mil thickness layer of the same plastisol formulation used for the plastics layer containing the chips. The sheet was then placed in an oven at 370 F for four minutes to fuse the plastics layers and foam the foamable chips.
WHAT WE CLAIM IS:
1. Decorative sheet-type covering material having a substrate and a cured (as hereinbefore defined), plastics layer adhered to the substrate and having chips embedded in the upper portion of the plastics layer, the chips having a specific gravity of 105% to 120% of the specific gravity of the plastics layer.
2. Decorative sheet-type covering material according to Claim 1, in which the plastics layer comprises cured PVC plastisol or organosol.
3. Decorative sheet-type covering material according to either of Claims 1 or 2,
**WARNING** end of DESC field may overlap start of CLMS **.
Claims (15)
1. Decorative sheet-type covering material having a substrate and a cured (as hereinbefore defined), plastics layer adhered to the substrate and having chips embedded in the upper portion of the plastics layer, the chips having a specific gravity of 105% to 120% of the specific gravity of the plastics layer.
2. Decorative sheet-type covering material according to Claim 1, in which the plastics layer comprises cured PVC plastisol or organosol.
3. Decorative sheet-type covering material according to either of Claims 1 or 2,
in which the chips are of plasticized vinyl material.
4. Decorative sheet-type covering material according to any one of Claims 1 to 3, which also includes a clear, cured plastics wear layer over the plastics layer containing the chips, the wear layer being formed from polyurethane or PVC plastisol or organosol.
5. Decorative sheet-type covering material according to any one of Claims 1 to 4, in which the substrate comprises felt coated with latex.
6. Decorative sheet-type covering material according to any one of Claims 1 to 5, in which the plastics layer has a specific gravity before curing of 1 to 1.4.
7. Decorative sheet-type covering material according to any one of Claims 1 to 5, in which the chips have a specific gravity of 1.25 to 1.45.
8. Decorative sheet-type covering material according to Claim 1 substantially as herein described and exemplified.
9. A process for making a decorative sheet-type covering material comprising:
(a) forming a layer of wet, curable plastics material adhered to a substrate;
(b) distributing chips on the wet layer, the chips having a specific gravity of 105% to 120 of the specific gravity of the wet plastics layer whereby the chips can settle into the plastics layer sufficiently to form a smooth surface on the plastics layer without sinking to the bottom of the plastics layer;
(c) allowing the chips to settle into the plastics layer sufficiently to form a smooth surface on such layer without the chips sinking to the bottom of the layer, and
(d) then curing as hereinbefore defined the plastics layer.
10. The process according to Claim 9, in which the wet, curable plastics material comprises PVC plastisol or organosol and is cured by exposure to elevated temperatures after the chips have been allowed to settle into the wet plastics material.
11. A process according to either of
Claims 9 and 10 in which, following step (c) of Claim 9, but prior to step (d), the wet plastics layer is gelled and a clear wear layer is applied over the surface of the gelled layer, the wear layer comprising polyurethane or PVC plastisol or organosol and the wear layer being cured during step (d).
12. A process according to any one of
Claims 9 to 11, in which the chips are of plasticized vinyl material having a specific gravity of 1.25 to 1.45, the substrate comprises felt coated with latex and the chips are allowed to settle into the wet plastics layer following application thereto for a period of time of 0.2 minute to 2 minutes at a plastics layer temperature of 60"F to 1500F before the wet plastics layer is cured.
13. A process according to any one of
Claims 9 to 11, in which the wet plastics layer has a specific gravity of 1 to 1.4, the substrate comprises felt coated with latex and the chips are allowed to settle into the wet plastics layer following application thereto for a period of time of 0.2 minute to 2 minutes at a plastics layer temperature of 60"F to 1500F before the wet plastics layer is cured.
14. A process according to Claim 9 substantially as herein described and exemplified.
15. A decorative sheet-type covering material which has been obtained by the process claimed in any one of Claims 9 to 14.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US66326576A | 1976-03-03 | 1976-03-03 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB1569943A true GB1569943A (en) | 1980-06-25 |
Family
ID=24661101
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB3207/77A Expired GB1569943A (en) | 1976-03-03 | 1977-01-26 | Decorative sheet-type material containing chips and process for making same |
Country Status (3)
| Country | Link |
|---|---|
| CA (1) | CA1083896A (en) |
| GB (1) | GB1569943A (en) |
| NL (1) | NL7702272A (en) |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2500369A1 (en) * | 1981-02-24 | 1982-08-27 | Armstrong World Ind Inc | NON-SLIP PLASTIC MATERIAL FOR FLOOR COVERINGS AND MANUFACTURING METHOD |
| FR2531009A1 (en) * | 1982-07-29 | 1984-02-03 | Armstrong World Ind Inc | DECORATIVE LAMINATE AND MANUFACTURING METHOD THEREOF |
| FR2531010A1 (en) * | 1982-07-29 | 1984-02-03 | Armstrong World Ind Inc | DECORATIVE LAMINATE AND METHOD FOR MANUFACTURING THE SAME |
| EP0100595A2 (en) * | 1982-07-06 | 1984-02-15 | Toyo Linoleum Company, Limited | Non-slip floor material |
| FR2572022A1 (en) * | 1984-10-24 | 1986-04-25 | Armstrong World Ind Inc | Prodn. of decorative laminate, especially flooring |
| US5612081A (en) * | 1994-11-25 | 1997-03-18 | Netlon Limited | Applying grit particles to a continuous web |
| EP0803603A1 (en) * | 1996-04-26 | 1997-10-29 | Gerflor Sa | Process and installation for coating a web of plastic material |
| EP2042286A1 (en) * | 2007-09-27 | 2009-04-01 | Tarkett SAS | Method of producing flooring |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4675212A (en) * | 1981-09-21 | 1987-06-23 | Mannington Mills, Inc. | Process for manufacturing decorative surface coverings |
| US5670237A (en) * | 1995-06-07 | 1997-09-23 | Mannington Mills, Inc. | Method for making a surface covering product and products resulting from said method |
| US5891564A (en) * | 1995-06-07 | 1999-04-06 | Mannington Mills, Inc. | Decorative surface coverings |
-
1977
- 1977-01-20 CA CA270,150A patent/CA1083896A/en not_active Expired
- 1977-01-26 GB GB3207/77A patent/GB1569943A/en not_active Expired
- 1977-03-03 NL NL7702272A patent/NL7702272A/en not_active Application Discontinuation
Cited By (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2500369A1 (en) * | 1981-02-24 | 1982-08-27 | Armstrong World Ind Inc | NON-SLIP PLASTIC MATERIAL FOR FLOOR COVERINGS AND MANUFACTURING METHOD |
| EP0100595A2 (en) * | 1982-07-06 | 1984-02-15 | Toyo Linoleum Company, Limited | Non-slip floor material |
| EP0100595A3 (en) * | 1982-07-06 | 1985-06-26 | Toyo Linoleum Company, Limited | Non-slip floor material |
| FR2531009A1 (en) * | 1982-07-29 | 1984-02-03 | Armstrong World Ind Inc | DECORATIVE LAMINATE AND MANUFACTURING METHOD THEREOF |
| FR2531010A1 (en) * | 1982-07-29 | 1984-02-03 | Armstrong World Ind Inc | DECORATIVE LAMINATE AND METHOD FOR MANUFACTURING THE SAME |
| DE3323853A1 (en) * | 1982-07-29 | 1984-02-09 | Armstrong World Industries, Inc., 17604 Lancaster, Pa. | DECORATIVE LAYER |
| DE3323854A1 (en) * | 1982-07-29 | 1984-02-09 | Armstrong World Industries, Inc., 17604 Lancaster, Pa. | DECORATIVE LAYER |
| FR2572022A1 (en) * | 1984-10-24 | 1986-04-25 | Armstrong World Ind Inc | Prodn. of decorative laminate, especially flooring |
| US5612081A (en) * | 1994-11-25 | 1997-03-18 | Netlon Limited | Applying grit particles to a continuous web |
| EP0803603A1 (en) * | 1996-04-26 | 1997-10-29 | Gerflor Sa | Process and installation for coating a web of plastic material |
| FR2747943A1 (en) * | 1996-04-26 | 1997-10-31 | Gerflor Sa | METHOD AND INSTALLATION FOR MANUFACTURING A PLASTIC STRIP BY COATING |
| US5965198A (en) * | 1996-04-26 | 1999-10-12 | Gerflor Sa | Process for the manufacture of a plastic web by coating |
| AU721019B2 (en) * | 1996-04-26 | 2000-06-22 | Gerflor S.A. | Process and plant for the manufacture of a plastic web by coating |
| EP2042286A1 (en) * | 2007-09-27 | 2009-04-01 | Tarkett SAS | Method of producing flooring |
| WO2009040332A1 (en) * | 2007-09-27 | 2009-04-02 | Tarkett Sas | Method for making ground coatings |
| US9266264B2 (en) | 2007-09-27 | 2016-02-23 | Tarkett Sas | Method for making ground coatings |
Also Published As
| Publication number | Publication date |
|---|---|
| NL7702272A (en) | 1977-09-06 |
| CA1083896A (en) | 1980-08-19 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PS | Patent sealed [section 19, patents act 1949] | ||
| PCNP | Patent ceased through non-payment of renewal fee |