Congoleum Corporation

John R Stetson

Rudolf Frisch

Alan A Graham

A process is disclosed for the preparation of a composite mat having smooth upper and lower faces which composite mat comprises a mat of fibrous material encapsulated within a resinous polymeric gel.

Process for the preparation of a composite mat

Methods of obtaining deep through penetration of colorants into firmed printable gelled plastisol or sintered dry-blend polyvinyl chloride compositions which comprise: applying a transfer paper or other substrate coated with a sublimable disperse dye to the surface of a firmed printable gelled plastisol or sintered dry-blend polyvinyl chloride composition, wherein the polyvinyl chloride resin is in particulate form having an average particle size of from about 0.5 micron to about 420 microns and contains specified percentages of plasticizer and stabilizer; applying heat thereto in the range of from about 300.degree. F. to about 430.degree. F. for a period of time of from about 6 seconds to about 20 seconds, whereby the sublimable disperse dye sublimes and, while in the sublimed vapor phase, penetrates deeply into the firmed printable gelled plastisol or sintered dry-blend polyvinyl chloride composition; removing the transfer paper or other substrate, leaving the disperse dye in the firmed printable gelled plastisol or sintered dry-blend polyvinyl chloride composition; applying a resinous polymer composition to the surface of the dyed firmed printable gelled plastisol or sintered dry-blend polyvinyl chloride composition as a wear layer; and applying heat to the dyed firmed printable gelled plastisol or sintered dry-blend polyvinyl chloride composition in the range of from about 310.degree. F. to about 470.degree. F. to fuse the polyvinyl chloride resin.

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Lebannon, NJ, United States of America

John R Stetson