Armstrong World Industries, Inc.

Armstrong Cork Company

Other

Walter J Lewicki, Jr

John H Bowers

Richard M Ringer

William M McQuate

William J Kauffman

Stephen E Becker

John S Forry

Kenneth K Ko

William C Dorsey

Dean L Putt

Harry F Long

Jacob A Otthofer, Jr

Charles R Culp

Raymond G Davey

Charles H Hines

Larrimore B Emmons

Thomas C Creighton

James J Lawson

Stavros C Stavrinou

Ivan Diamond

This invention describes the manufacture of partially cured binder compositions based upon modification of drying oils with at least one multi-functional co-vulcanizing agent. The partially cured binder compositions can be blended with polymeric materials to prepare polymer blends. These polymer blends can be used to produce products such as cured solid layers. Methods of manufacturing the partially cured binder compositions and cured solid layers are described.

Materials based on drying oils

This invention describes the manufacture of partially cured binder compositions based upon modification of drying oils with at least one multi-functional co-vulcanizing agent. The partially cured binder compositions can be used to produce products such as cured solid layers. These layers can be used in flooring materials, coatings, printing inks, and paints. Methods of manufacturing the partially cured binder compositions and cured solid layers are described.

A binder composition comprising a partially pre-oxidized drying oil and at least one co-vulcanizing agent. A method provides rapid curing of the compositions. The materials find utility in flooring, coating, and decorating applications. One preferred utility is in the manufacture of linoleum type flooring. Another preferred utility is in the manufacture of a transparent/translucent coating for improving the wear properties of surfaces.

This invention provides a process for electrographically imaging a plurality of substrates heretofore not usable in such a system. While prior art dielectric substrates could be used in the present process, the specific parameters outlined in this invention allows many more charge retentive surfaces or substrates to be used in electrostatic imaging. The process involves developing the latent electrostatic image before dissipation of the image charge which can be calculated by the inventive process for each substrate to be used.

Electrographic printing

This invention involves a process for producing in an electrographic system a product having an image depth perception. The process includes dispensing in a system a first dielectric layer and electrographically imaging this layer and developing the image. A second dielectric layer is subsequently dispersed in the system, imaged and developed. A preselected plurality of dielectric layers may be imaged and developed. These developed layers are superimposed and adhered together to form a multilayered substrate having a depth perception. The layers can be superimposed, adhered together and overcoated either before or after separation from the system.

Electrographic process for producing an image with depth perception and

The system of this invention uses both a process and apparatus for printing an image on a removable thicker dielectric layer than conventionally used in other systems. The dielectric layer is at least 0.2 mils thick and is removed from the system after it is imaged, developed and fixed. Several alternate ways are used to imagewise charge the dielectric layer. The toner used preferably incorporates a resin of the said family resin as used in the dielectric layer or layers. The imaged layer may be attached to a base such as a tile or wallpaper support structure. The base support substantially strengthens the dielectric layer which is important for shipping, storage, ultimate use and durability.

Printing system

This invention involves a structure containing a layered imaged configuration with an overcoating layer. The overcoating layer, in addition to encapsulating the toned image, substantially strengthens the dielectric layer after it is removed from the system. Also, a process for producing a product having an image depth perception and the product itself are disclosed. The layered structure may have one or two dielectric layers having a combined thickness of from about 0.2 to about 10.0 mils.

Electrographic structure and process

The adhesive system of the present invention is suitable for use in adhering an incompatible ink system to a polymeric film; particularly, adhering a lithographic ink or electrographic toner bonded to a floor covering. The polymeric sheet and incompatible ink have a primer layer interposed between them or the ink layer is encapsulated between the two primer layers. The primer may be solvent based or aqueous based and preferably includes a benzene derivative, ketone, acetate or nitroparaffin solvent or film former. The primer is compatible with the polymeric sheet and diffuses into the ink layer. The preferred solvent or film former includes methyl isobutyl ketone, methyl ethyl ketone, n-propyl acetate, isopropyl acetate, or N-methyl-2-pyrrolidone. The primer also includes a polyvinyl resin, acrylic resin, polyurethane resin or polyester resin, and optionally a pigment. To deter dot distortion of the ink, the primer should have a glass transition temperature (T.sub.g) of at least about 60.degree. C., and preferably at least about 100.degree. C.

Polymeric sheet having an incompatible ink permanently bonded thereto

This invention involves both a process and apparatus for printing an image on a removable thicker dielectric layer than conventionally used in other systems. The process and apparatus can have one or more image-toning stations on a conductive substrate. When multiple stations having separate imaging and toning means are used, complicated image registration structures are avoided. The dielectric layer used is at least 0.2 mils thick and is removed from the system after it is imaged, developed, fixed and laminated or overcoated with a layer of the same family resin as used in the dielectric layer or layers. The imaged and overcoated layer may be attached to substrate such as a tile or wallpaper base, either before or after the process of this invention is completed. The overcoating substantially strengthens the dielectric layer in addition to overcoating the image. The final colored image (or monochrome) is removed from the printing apparatus after the overcoating is laminated thereon.

Non-electrographic printer with lamination means

This invention involves both a process and apparatus for printing an image on a removable thicker dielectric layer than conventionally used in other systems. The dielectric layer is at least 0.2 mils thick and is removed from the system after it is imaged, developed and fixed. The toner used preferably incorporates a resin of the same family resin as used in the dielectric layer or layers. The imaged layer may be attached to a base such as a tile or wallpaper support structure. The base support substantially strengthens the dielectric layer which is important for shipping, storage, ultimate use and durability.

A tile product having a substantially non-porous vinyl composition base and a multilevel embossing and gloss which has a mechanically embossed mortar-line surround and which is free of gloss defects formed by pockets of air trapped between the wear layer and embossing mold during embossing is produced by applying a vacuum to the press during embossing. Preferably, the tile is laminated in a hot press heated by RF energy and cooled in a cold press to reduce the temperature of the wear layer to below its glass transition temperature.

Tile product having multiple levels of height, multiple levels of gloss

The process for making a dimensionally stable, embossed, ornamented surface covering suitable for use as a floor or wall tile, involving, inter alia, laminating and embossing a resinous thermoplastic top layer having a plurality of openings extending through its thickness to allow the escape of air and extending to base material or substrate of pre-formed, low-density, reinforced, porous thermoplastic material. The base material may include hollow non-thermoplastic particles. The composite structure is subjected to heat and pressure in a flatbed press to emboss the structure without deformation, fuse the resins and render the top layer substantially impermeable. The improvement comprises the use of a rigid vinyl wear layer in a two step embossing operation involving a first embossing step in a heated press and immediately thereafter a second embossing step in a cooled press. The improvement also comprises partly providing a second resinous thermoplastic layer between the top layer and the base material, the second layer being capable of allowing passage of air through its thickness during the embossing and fusion step, and being adapted to soften and flow before the top layer does, thereby assuring complete closure of all openings in the top layers of the product.

Ornamented tile surface covering

The process for making a dimensionally stable, embossed, ornamented surface covering suitable for use as a floor or wall tile, involving, inter alia, laminating and embossing a resinous thermoplastic top layer having a plurality of openings extending through its thickness to allow the escape of air and extending to a base material or substrate of pre-formed, low-density, reinforced, porous thermoplastic material. The base material may include hollow non-thermoplastic particles. The composite structure is subjected to heat and pressure in a flatbed press having a cooled embossing plate and a cooled back-up plate, to emboss the structure without deformation, fuse the resins and render the top layer substantially impermeable. The improvement comprises providing a second resinous thermoplastic layer between the top layer and the base material, the second layer being capable of allowing passage of air through its thickness during the embossing and fusion step, and being adapted to soften and flow before the top layer does, thereby assuring complete closure of all openings in the top layers of the product.

Process for making a dimensionally stable, embossed, ornamented tile

The process for making a dimensionally stable, embossed, ornamented surface covering suitable for use as a floor or wall tile, involving, laminating and embossing a resinous thermoplastic top layer having a plurality of openings extending through its thickness to allow the escape of air and extending to a base material or substrate of pre-formed, low-density, reinforced, porous thermoplastic material. The composite structure is subjected to heat and pressure in a flatbed press to emboss the structure without deformation, fuse the resins and render the top layer substantially impermeable. The improvement comprises the use of a rigid vinyl wear layer in a two step embossing operation involving a first embossing step in a heated press and immediately thereafter a second embossing step in a cooled press. The improvement also comprises partly providing a second resinous thermoplastic layer between the top layer and the base material, the second layer being capable of allowing passage of air through its thickness during the embossing and fusion step, and being adapted to soften and flow before the top layer does, thereby assuring complete closure of all openings in the top layers of the product.

Process for making a stress-free embossed and ornament surface covering

A stress-free embossed, ornamented surface covering, suitable for use as a floor or wall tile, is made by: providing a decorated resinous film on a release carrier, with the decorated surface of the film facing away from the carrier; providing on a release carrier a pre-formed, low-density, reinforced, porous thermoplastic base material, which may include hollow, non-thermoplastic particles; interfacing the decorated surface of the film with the top surface of the base material; perforating the film, after removal of the release carriers; and, subjecting the structure to high frequency electrical energy and pressure in a flatbed press having a cooled embossing plate and a cooled back-up plate, to emboss the structure, fuse the resins and render the film substantially impermeable. The film may be die cut in register with the decoration thereon while it is on the release carrier, without cutting the carrier, prior to lamination of the film to similarly cut and shaped pieces of the base material or, the base material and the decorated film thereon may be simultaneously cut in register with the decoration after removal of the release carriers. An adhesive coating and a releasable paper may be applied to the back of the product to facilitate installation thereof on a surface upon removal of the paper.

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Lancaster, PA, United States of America

Walter J Lewicki, Jr