JPH0221387B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to a method and apparatus for producing in a continuous process printed and embossed materials suitable for use, for example, as flooring. In particular, it relates to a method and apparatus for producing a multilayer material having a base layer, a printed layer, and an abrasion resistant layer that is embossed to match the print.

[Problems to be solved by conventional technology and invention]

The separate materials, the calendered substrate and the printed plastic film, are laminated together to create a reverse printed film. Continuous processes have been limited to irregular patterns because it is difficult to maintain the necessary area on the already printed plastic film, sheet, or in some cases on the substrate. Plastic films tend to stretch when printed and subsequently dried. When making thin sheets, it is necessary to stretch the printed thin film to remove air and wrinkles, which can distort the printed pattern.

Alternatively, tiles with a pattern matching the cut tiles may be made in a batch process by laminating plastic sheets with already printed silkscreen patterns onto a suitable substrate. The tiles are then manually peeled off from the laminate. The high cost of such a batch process makes matched printed tiles very expensive and limited in demand.

Additionally, difficulties arise when attempting to stamp tiles to create a textured surface. The embossing process also causes distortion, so the embossing of a plastic surface layer in conjunction with a solid non-plastic substrate such as asbestos or asphalt impregnated felt is limited to a few steps.

Alternatively, U.S. Patent No.
As described in No. 4312686, the distortions that occur during printing and lamination can be avoided by printing the pattern on a rigid substrate, preferably a release paper, and by continuously creating the printed pattern with an extruder. Some attempts have been made to minimize this by transferring it onto hot plastic fabric. The hot, unstressed plastic film is then laminated onto the printed fabric to create an abrasion barrier. In order to emboss the material according to the printed pattern, first align the pasted materials using the registration marks printed with the pattern. Embossing is then carried out using a conventional engraved roll with raised areas in the shape of the pattern being printed. After embossing, the fabric is partially cooled and annealed. It is then aligned with the template cutter using the same registration marks used during embossing. As a result, individual tiles are automatically cut to match the printed embossed pattern. Although the method described in the '4312686 patent is workable, the process line using this method runs at speeds of about 90 feet per minute;
Approximately 50% of the products were first-class products, approximately 15% were second-class products, and the remaining 35% were scraps.

[Means for solving problems]

We have devised an improved process to make tiles suitable for continuous manufacturing, where the embossed pattern matches the tile. This improved process generally follows the steps disclosed in the '686 patent. According to this process, a pattern is printed on a rigid substrate, preferably release paper, and then the printed pattern is transferred to a continuously produced plastic fabric. The anti-wear coating is then laminated to the printed fabric and the composite is embossed using a conventional roll engraved with raised areas in the shape of the print.

As in the '4312686 patent, the plastic fabric is placed on a belt that is not integral with the finished product to minimize distortion.
Alignment is performed by manipulating the belt. In addition, according to the present invention, the fabric is given appropriate tension to prevent it from becoming distorted during lamination and embossing. By providing an appropriate tension, the composite membrane can be prevented from becoming distorted by the sagging phenomenon that causes lateral stretching in the direction perpendicular to the direction in which the fabric travels, or by stretching in the same direction as the direction in which the woven fabric travels. become. Proper tension is maintained by constantly monitoring the rotational speed of the rotating drum, embossing roll, and support roll to ensure good speed rates.

After embossing, the fabric is cooled in a water bath and partially annealed before cooling. It is then aligned with the template cutter using the same registration marks used during alignment during embossing. As a result, each tile is automatically separated in accordance with the printed and embossed pattern. It is more advantageous to cut the tiles somewhat larger and anneal and shrink them to the appropriate size.

The anti-wear coating is preferably applied to the printed fabric using a heated rotating drum to apply the plastic film to the printed fabric, and then applied to the printed fabric by heating the film and the fabric.
To prevent the bonded fabric from sticking to the embossed rolls, the rolls and composite fabric are cooled with a water spray, whereby parts of the composite fabric are bonded together at the embossed steps. .

When using this method in a process line, fabric could be fed at speeds up to 160 feet per minute. It is also believed that speeds of about 180 feet per minute are possible. Additionally, about 83% of the products were first-class and 3% were second-class.

〔Example〕

These and other objects, features and advantages of our invention will become apparent from the detailed description of preferred embodiments of the invention.

FIG. 1 is a block diagram showing the main operations in implementing the present invention.

FIG. 2 is a schematic diagram of a preferred embodiment of the apparatus used in practicing the invention.

FIG. 3 is a cross-sectional view of the base material used in practicing the present invention.

FIG. 4 is a cross-sectional view after the print layer has been transferred to the base fabric according to the invention.

FIG. 5 is a cross-sectional view after laminating the vinyl thin film onto the printed layer.

FIG. 6 is a diagram of an embossing roll used in carrying out the present invention.

FIG. 7 is a cross-sectional view of the base fabric, print layer, and vinyl thin film that are embossed according to the print by the embossing roll of FIG. 6.

FIG. 8 is a plan view of a tile embossed to match the print using the embossing roll of FIG. 6;

1 and 2 illustrate a method and apparatus embodying the present invention for making durable vinyl tiles with decorative layers of prints embossed in accordance with the prints. The main parts of the method and apparatus are similar to those described in the '4312686 patent. A cross section and plan view of the finished tile are shown in FIGS. 7 and 8. As shown in Figure 1, the process of making the tile involves creating a continuous vinyl fabric, transferring the print onto this fabric, and laminating an anti-wear coating over the print to create a composite material that matches the print. The process consists of stamping the composite material and cutting the tiles to match the print. According to the present invention, when the composite material is fed into the embossing roll, it is embossed in accordance with the print while giving the fabric an appropriate tension. It is desirable to partially anneal the embossed composite membrane before cutting, and also after cutting.
Anneal the tiles. Infrared heating is used to bring the fabric and anti-wear coating to the appropriate temperature for print transfer, composite film formation, and pre-annealing. The final anneal takes place in a hot air oven.

The specific apparatus for carrying out the process of FIG. 1 is shown in FIG. A continuous base fabric of vinyl is prepared by mixing the components in a mixer 20 and sending the mixture to a continuous mixer 22. mixer 22
The heated plastic from is continuously fed to a calendar 30 consisting of a set of rolls 32, 34 where a continuous thermoplastic base fabric 10 with a surface smooth enough to carry a layer of print is formed. Made. A doctor knife (not shown) may be used to separate the base fabric 10 from the calender rolls, as is well known in the art. A cross-sectional view of the base material 10 as it emerges from the calender roll is shown in FIG.
The thickness of this section is approximately 30-120 mils (0.75-3 mm)
within the range of The width of this section is approximately 14 inches (35
cm). However, other dimensions may be used in practicing the invention.

As described in the No. 4,312,686 patent, the hot plastic fabric 10 is transferred to a moving conveyor belt 40.
Continuously flows upwards. The conveyor belt 40 is made of a material that sticks to the belt while the dough is hot and separates from the belt when cooled. Typically, the belt is made of fiberglass fabric dipped in silicone elastomer. Transport belt 4
0 supports the basic fabric 10 and moves it to the printing, pasting, and embossing processes. The belt is advanced at this speed by a drive roll 46 driven by a conventional line shaft 48. To prevent distortion of the plastic fabric and the pattern printed thereon, the conveyor belt is adjusted by means of a guiding device 42 to guide and align the fabric. Loop velocity sensing device 44 near calendar 30
controls the speed of the conveyor belt, and the hot plastic fabric is transferred to the calender roll 3 at a constant speed.
Make it appear from 2.34.

As the fabric 10 emerges from the calender, it is heated to the temperature necessary to transfer the print from the previously printed release paper to the fabric. A first infrared heater 50 heats the fabric 10 directly, a second infrared heater 52 heats the conveyor belt 40, and the conveyor belt heats the fabric 10. The temperature required for the print transfer operation used in the preferred embodiment of the invention is approximately 250°C.
(121℃).

The fabric then enters a print transfer station 60 where the print layer is transferred to the fabric 10 from the previously printed release paper 62. Any pattern can be used for the print layer. When mass producing tiles, it is desirable to have the pattern converge in the center of the cut tile so that the pattern matches the edges of the tile.

The preprinted paper is sent from a supply roll 64 to a take-up roll 69 via transfer rolls 66 and 67. In practicing the invention, roll 66
It was found that cooling the material to about 70°C (21°C) makes transfer printing easier. An edge guide (not shown) is used to ensure that the printed paper is properly aligned laterally. In addition, in order to be able to splice pre-printed paper rolls, we also have an unwinding roll stand, a splicing table, and a correction to allow time for splicing so that the printed patterns match. It is desirable to use a splicing device (not shown) with a container.

To transfer the print layer from the release paper, the paper 62, the fabric 10 and the transport belt 40 are
It is fed to a point where it is subjected to pressure created by rolls 66, 67, after which the paper is separated from the fabric. It may also be advantageous to use a release plate (not shown) at a position to separate the paper 62 from the fabric 10 and to provide the take-up roll 69 with suitable pressure control means. A cross-section of the printed fabric depicting the base fabric 10 and the printed layer 12 is shown in FIG. This cross section is not drawn to correct proportion. This is because the print layer is the base fabric 1.
This is because it is extremely thin compared to the thickness of 0.075 to 3 mm.

Next, the printed fabric is transferred to a conveyor belt 40
It is indirectly heated by an infrared heater 72 that heats the underside of the . The fabric is then delivered to a bonding station 80 where a thin vinyl film fabric 82 is bonded to the printed side of the fabric 10 to provide an abrasion protection coating. The lamination site 80 includes a heated rotating drum 83, an upper high intensity infrared heater 93, a fabric guide 89, a supply roll 86, and rollers 87, 88, 91 and 92. In addition, it is desirable to have a conventional splicer (not shown) at the splicing site with a rewind roll stage, a heat splicer, and a compensator to allow time for splicing the membranes.

The drum 83 is connected to the line shaft 4
Specon manufactured by Fairchild Hiller by 8.
It is driven using a speed controller 85 such as a speed controller. As described below, the speed controller 85 adjusts the speed of the drum to be a function of the speed of the embossing roll and support roll.

A supply roll 86 delivers a continuous fabric of preformed vinyl thin film. Typically, the vinyl film thickness is 3 to 12 mils (0.075 to 0.3 mm).

Fabric 82 passes through fabric guides 89 which feed the fabric in a perpendicular direction so that it overlaps the printed fabric. The fabric 82, the printed fabric and the transport belt 40 enter the rotating drum 83 and the roller 91 under pressure,
The fabric 82 is pressed and bonded to the printed fabric. These fabrics are used as transportation belt 4
0, it is peeled off from the rotating drum 83 by the roller 92, and passes under the heater 93 on the conveyor belt 40. An infrared heater 93 heats the vinyl film and therefore the printed fabric.
For the thin film used in practicing the preferred embodiment of the invention, an infrared heater 93 raises the temperature of the fabric 82 to approximately 310°C (154°C), thereby relaxing the vinyl thin film and increasing the temperature of the fabric 82. and 10 with a printed layer 12 sandwiched therebetween to form a composite 16. A cross-sectional view of the composite 16 showing the vinyl anti-wear coating 82 on the printed layer 12 is shown in FIG.

The conveyor belt then transfers the composite material to the embossed portion 110.
carry it to In this part there are an embossing roll 112, a rubber support roll 113, and means for lateral and longitudinal positioning of the laminated fabric. As shown in FIG. 6, the embossing roll 112
is a engraved or etched iron or copper roll, the part 122 that is raised above the other parts 123.
There is. Typically, the difference in height between portions 122 and 123 averages about 6 to 14 mils (0.15 to 0.35 mm). Preferably, portion 122 is in the form of a pattern transfer printed onto the base fabric. Both the embossing roll and support roll are water cooled.

The positioning means includes two photoelectric cells 115,1
16, a speed control means 117, and a positioning roll 118. Support roll 113 is directly driven by line shaft 48, so its surface speed is the same as the speed of drive roll 46. The photocell senses the registration marks printed on the fabric along with the printed pattern. Photoelectric cell 115
controls the registration roll 118 which provides lateral guidance of the composite material 16 so that the embossed roll portion 122 is in conformity with the printed fabric. The photocell 116 is a speed controller 117
is connected to adjust the phase of the embossing rolls so that the embossing roll portion 122 is longitudinally aligned with the printed pattern on the fabric. Specific devices for providing lateral and longitudinal registration of the embossing rolls include the Fife photoelectric wire controller and the Bobst Champlain register controller, respectively. It will be obvious to those skilled in the art that there are many other devices available.

The outer surface of the embossing roll 112 is coated with water sprayer 11
9, the sprayer is directly cooled by the composite material 1
The upper surface of 6 is also cooled. Water sprayer 119 cools and hardens composite 16 to an extent that minimizes stretching of composite 16 on rolls 112 and 113. Roll 1 before composite material 16 contacts
The composite material 16 is sprayed with water on the roll 11.
This is to reduce the possibility of sticking to 2. The composite 16 and belt 40 pass through the pressurized gap between the embossing roll 112 and the support roll 113, with the raised portions 122 of the embossing roll indenting the composite at corresponding locations. Figure 7 shows a cross-sectional view of the stamped composite material made at this stage.
A plan view is shown in FIG.

According to the present invention, the surface speed of the rotating drum 83 and the speed of the embossing roll 112 and the support roll 113 are such that the surface speed of the drum 83 is about 98-99% of the speed of the rolls 112 and 113, preferably about 98.2%. It has been found that it is better to adjust it so that it is %. This speed relationship sets the output rotary shaft speed of the speed regulator 85 to 98% of the input rotary shaft speed, which is the same rotational speed as the speed of the linear shaft 48.
It is maintained by setting it within the range of ~99%. This velocity relationship creates the appropriate tension within the composite material 16 to cause it to fold, causing lateral expansion in a direction perpendicular to the direction of fabric travel, or to distort by stretching in the same direction as the fabric travels. I found that it created an appropriate amount of tension that would have never happened before. As a result, the throughput of the production line will be significantly increased and the quality of the products will also be improved.

After passing through the pressurized gap between rolls 122 and 113, the embossed composite 18 is cooled to the point where it can be peeled from the silicone conveyor belt 40. This cooling operation is preferably performed by immersing composite material 18 and belt 40 in water bath 125. In practicing the preferred embodiment of the invention, it has been found that it is advantageous to cool the composite 18 to about 80-90°C (27-32°C). Excess water is then removed from the fabric by a high speed air knife 124 and the embossed fabric is peeled from the conveyor belt 40.

At this point, the conveyor belt 40 changes direction. Meanwhile, the embossed fabric is conveyed on a conveyor belt 130 to a pre-annealing point 132, where it is partially removed from the strains experienced by lamination and embossing. After pre-annealing, the embossed fabric is cooled to approximately 100-110㎓ (38-43℃). The fabric then enters the tile cutting station 140, is straightened and cut into tiles according to the pattern printed on the fabric. At the tile cutting location 140, a tile cutting machine 142 and a photoelectric cell 1 are installed.
44, 145, and a device sensitive to signals from photocells to align the fabric laterally and longitudinally.

A specific device for aligning the embossed composite material 18 is the “Apparatus for Registration of Plastic Fabric”.
It will be clear to those skilled in the art from the description of U.S. Pat. No. 3,465,384 to Barchi et al. It is placed on a conveyor belt 28 and sent to a tile cutter 36. Photocells 32, 34 are used to drive a reversible motor 128 which adjusts the lateral position of the conveyor 28 to maintain the plastic fabric in the desired lateral position. These photocells sense the lateral position of the plastic fabric by sensing the continuous longitudinal stripes 92 that are embossed at the same time as the pattern is embossed onto the fabric. In this manner, photocells 144, 145 sense registration marks printed on the fabric along with the printed pattern.These registration marks are the same as the marks used to align the fabric at the embossing point. It should be clear that there are a number of closed circuit feedback systems for adjusting the lateral and longitudinal position of the fabric.

The tiles are cut somewhat larger. next,
It is annealed in an annealing furnace 150 at a furnace temperature of about 350°C (177°C) to shrink to its normal size. Finally, it is cooled to natural temperature, packaged and shipped. Scrap from the tile cutting operation is sent to the granulator 160 and returned to the mixer 20 for reuse.

Suitable materials for base fabric 10, release paper 62 and vinyl film 82 are described in the '686 patent referenced above. As a base material, a vinyl composite consisting of a plasticized vinyl chloride polymer containing a small amount of at least 80% vinyl chloride and/or a vinyl acetate copolymer mixed equally with a major mineral filler. The minor portion is approximately 16-25% by weight of the composite, and the major portion is approximately 75-84% by weight of the composite.
It's weight.

The above working temperatures are desirable. The scope of work when the plastic base fabric and the plastic anti-wear layer are vinyl composites is as follows. During lamination, the plastic base fabric 10 is heated to approximately 200〓~280〓 (93℃~138℃) prior to transfer printing.
Heat to an average temperature in the range of , release paper 6
2, before transfer printing, about 60〓~120〓(16
Heating the vinyl anti-wear layer and plastic base fabric to an average temperature ranging from 270°C to 49°C
Heat to an average temperature ranging from ~310㎓ (132℃ to 154℃).

Much of the equipment used to practice the invention is conventional. The extrusion equipment, heating equipment, printing equipment, laminating equipment, embossing equipment, die cutting equipment and alignment equipment are old. However, tiles that are embossed to match the print continuously,
What is new is the combination of this equipment to produce high throughput, high rates of usable tiles.

Although specific embodiments of the invention have been described, many alternatives, modifications, and variations will be apparent to those familiar with the technology.

〔Effect of the invention〕

As described above, according to the present invention, it is possible to provide a method and an apparatus that can continuously manufacture a material stamped according to the print with high productivity and good yield.

[Brief explanation of drawings]

FIG. 1 is a block diagram showing the main operations in implementing the present invention. FIG. 2 is a schematic diagram of a preferred embodiment of the apparatus used in practicing the invention. FIG. 3 is a cross-sectional view of the base material used in practicing the present invention. FIG. 4 is a cross-sectional view after the print layer has been transferred to the base fabric according to the invention. FIG. 5 is a cross-sectional view after laminating the vinyl thin film onto the printed layer. FIG. 6 is a diagram of an embossing roll used in carrying out the present invention. FIG. 7 is a cross-sectional view of the base fabric, print layer, and vinyl thin film embossed to match the print by the embossing roll of FIG. 6. Figure 8 shows that using the embossing roll of Figure 6,
FIG. 2 is a plan view of a tile embossed to match the print. 10...Fabric, 12...Print layer, 16,1
8... Composite material, 20... Mixer, 22... Mixer, 30... Calendar, 32, 34... Calender roll, 40... Conveyance belt, 42... Guidance device, 44... Loop speed sensing device, 46... Drive roll, 48... Line shaft, 50, 52, 7
2, 93... Heater, 60... Print transfer location, 62... Release paper, 64... Supply roll, 66, 67... Transfer roll, 69... Winding roll, 80... Pasting location, 82 ... Dough, 83 ... Rotating drum, 85 ... Speed controller,
86... Supply roll, 87, 88, 91, 92...
... Roller, 89 ... Fabric guide, 110 ... Embossed portion, 112 ... Emboss roll, 113 ... Support roll, 115, 116, 144, 145 ...
Photoelectric cell, 117...Speed control means, 118...
Positioning roll, 119...Water sprayer, 122,
123... Embossing roll portion, 124... Air knife, 125... Water bath, 130... Conveyor belt, 132... Annealing location, 140... Tile cutting location, 142... Tile cutting machine, 150...
...Annealing furnace, 160... Granulation machine.

Claims (1)

Claims: 1. A method for producing printed and embossed materials comprising the following steps: proceeding in a substantially horizontal direction to form a continuous base fabric on a continuously moving support surface, said base fabric comprising a vinyl composite, and said moving surface forming a continuous base fabric on a continuously moving support surface, said base fabric comprising a vinyl composite; The base fabric is made of a material that adheres to its surface and separates when the base fabric cools, and the base fabric is heated and a printed pattern is transferred from a preprinted sheet onto a continuous base fabric surface. The printed pattern is made of a vinyl material that is compatible with the base fabric, and the printed pattern has two parts: a first part that becomes the decorative pattern of the finished product, and a second part that becomes the registration mark used during manufacturing. A transparent plastic wear-resistant layer is laminated onto the printed pattern on the base fabric, and after the base fabric is laminated, a direction perpendicular to the direction in which the fabric moves, and a direction in which the fabric moves. Using registration marks, align the fabric so that it lines up perfectly with the embossing roll in the same direction as the pattern, and mechanically align the printed side of the base fabric with an indentation that matches the printed decorative pattern. after stamping, cooling the base fabric; peeling the cooled base fabric from the moving surface; Align the base fabric in a straight line using printed registration marks so that the cutting tool and the base fabric are aligned exactly in the direction perpendicular to the direction of travel and in the same direction as the direction of travel, and After straightening the fabric, cut the base fabric into tiles so that the decorative pattern matches the edge of the tile, and after cutting the base fabric into the tiles, anneal the cut tiles, The continuous movement of the base fabric in the embossing process to maintain an appropriate tension so that the base fabric does not spread laterally in a direction perpendicular to its direction of travel or stretch in the same direction as its direction of travel. Continuously adjust the speed of the continuously moving base fabric in the above laminating process regarding speed. 2. The manufacturing method according to claim 1, further comprising the step of cooling the dough with water prior to mechanical embossing so as to prevent stretching of the dough by the embossing roll. 3. The method of claim 1, further comprising the steps of pre-annealing the fabric after it has been removed from the moving surface and cooling the pre-annealed fabric before cutting. 4. The method of claim 1, wherein the tiles are cut to size and shrunk to the correct size during annealing. 5. A method according to claim 1, wherein the anti-wear layer is applied to the base fabric by means of a rotating drum having a surface speed lower than the speed at which the fabric moves during the embossing step. 6. The method of claim 5, wherein the surface speed of the rotating drum is about 98-99% of the speed at which the base fabric moves during embossing. 7. The method of claim 5, wherein the surface speed of the rotating drum is approximately 98.2% of the speed at which the base fabric moves during embossing. 8. The plastic base material is a vinyl consisting of less plasticized vinyl chloride polymer and/or vinyl acetate copolymer containing at least 80% vinyl chloride, mixed evenly with more mineral filler. 2. The method of claim 1, wherein said less amount is about 16-25% by weight of the compound and said more amount is about 75-85% by weight of the compound. 9. Apparatus for producing printed and embossed materials comprising: means for forming a base fabric of continuous vinyl composite on a moving support surface, the moving surface sticking to the base fabric when it is hot;
means made of a material such that said base fabric leaves said surface when cooled; means for increasing the temperature of said base fabric; and means for transferring a printed pattern from a preprinted sheet to said base fabric in succession; by the means of
The printed pattern is made of a vinyl material that is compatible with the base fabric, and the printed pattern has a first part that becomes a decorative pattern on the finished product, and a second part that serves as a registration mark for use during manufacturing. means for laminating a transparent plastic anti-wear layer on the printed pattern on the base fabric; embossing in a direction perpendicular to and in the same direction as the direction in which the base fabric moves; means for aligning the base fabric after it has been laminated using the printed registration marks so as to align with the roll; mechanically aligning the printed side of the base fabric; means for creating an indentation consistent with said decorative pattern embossed and printed on said base fabric; means for cooling said base fabric; means for peeling said cooled base fabric from said moving surface; said base fabric. is perpendicular to the direction in which it travels,
and means for aligning said base fabric using a register mark in the same direction as the cutting tool so as to align it closely with the cutting tool; means for cutting said cut tiles into tiles, and means for annealing said cut tiles so that said base fabric spreads laterally in a direction perpendicular to its direction of travel or does not stretch in the same direction as its direction of travel; means for continuously adjusting the speed of the continuously moving base fabric in the laminating step with respect to the speed of the continuously moving base fabric in the embossing step in order to maintain a suitable fabric tension; 10. The manufacturing apparatus according to claim 9, further comprising means for cooling the fabric prior to mechanical embossing so as to prevent stretching of the fabric by the embossing roll. 11. Means for applying a pre-anneal to the fabric after it has been removed from the moving surface, and means for cooling the pre-annealed fabric before cutting the fabric The manufacturing apparatus according to scope item 9. 12. The manufacturing apparatus of claim 9, further comprising a rotating drum for applying an anti-wear layer to the base fabric, the drum having a surface speed lower than the speed at which the base fabric is passed through the embossing rolls. 13. The manufacturing apparatus according to claim 12, wherein the surface speed of the rotating drum is about 98 to 99% of the speed at which the basic dough is fed. 14. The manufacturing apparatus according to claim 12, wherein the surface speed of the rotating drum is approximately 98.2% of the speed at which the base dough is fed. 15. The embossing means comprises a support roll and an embossing roll, further comprising a rotating drum having a surface speed lower than the surface speed of the support roll and for applying an anti-wear layer to the base fabric. The manufacturing apparatus according to item 12. 16. The manufacturing apparatus according to claim 15, wherein the surface speed of the rotating drum is about 98 to 99% of the surface speed of the support roll. 17 The surface speed of the rotating drum is approximately 98.2% of the surface speed of the support roll.
The manufacturing device according to item 5. 18. The manufacturing apparatus of claim 9, wherein the tiles are cut to size and shrunk to the correct size during annealing. 19. The plastic base fabric is a vinyl composite consisting of a lesser amount of plasticized vinyl chloride polymer and/or vinyl acetate copolymer, containing at least 80% vinyl chloride, evenly mixed with a greater amount of mineral filler. The above-mentioned less means about 16-25% of the weight of the composite, and the above-mentioned more means about about 16% to 25% of the weight of the composite.
9. The manufacturing apparatus according to claim 9, wherein the weight is 75 to 84%.