Armstrong Cork Company

Awi Licensing Company

Armstrong World Industries, Inc.

William M McQuate

Walter J Lewicki, Jr

Peter A Christie

Donald E Schneider

Richard M Ringer

Elizabeth A Malkowski

John J Orlando

David A Kraft

The invention relates to a textured surface covering having a hot melt wear layer without distortion of the visual image of the textured substrate. The wear layer substantially follows the contours of the substrate with minimum change in thickness of the wear layer over the textured surface and provides an aesthetically pleasing three dimensional appearance to the textured surface of the substrate. The wear layer exhibits significant clarity and visual depth, as well as improved maintenance (cleanability) properties. The resulting product has a visual image clarity reflecting any texture in the substrate including very light reflective (lenticular moray) embossings.

Hot melt calendered or extruded wear layer for embossed substrates

An apparatus for placing particles onto a substrate, methods for using the apparatus to deposit particles on a substrate and substrates prepared using the apparatus are disclosed. The apparatus includes a rotary screen, a blade disposed for directing and urging the particles through the screen, and a sheet mounted in a position to receive the particles from a feeder and deliver the particles to the rotary screen substantially across the blade. The apparatus can include a frame on which a rotary screen is rotatably mounted and a feed system disposed within and extending substantially along the length of the screen for distributing the particles. The apparatus can optionally include a vacuum means, an anti-static means and/or collection pans for handling stray particles. The screen can include a series of openings in the form of a pattern, and can be used to place particles in a pattern in register with a design or pattern on a substrate as the substrate passes under the openings in the screen.

Apparatus for placing particles in a pattern onto a substrate

The invention relates to a textured surface covering having a hot melt wear layer and methods of applying the hot melt wear layer to a textured or embossed surface without distortion of the visual image of the textured substrate. The wear layer substantially follows the contours of the substrate with minimum change in thickness of the wear layer over the textured surface and provides an aesthetically pleasing three dimensional appearance to the textured surface of the substrate. Melt applying the melt processable polymer resin to the textured substrate with a conformable pressure roll deter entrapment of bubbles between the wear layer and the textured substrate. Therefore, the wear layer exhibits significant clarity and visual depth, as well as improved maintenance (cleanability) properties. The resulting product has a visual image clarity reflecting any texture in the substrate including very light reflective (lenticular moray) embossings.

Hot melt calendered or extruded wear layer for embossed substrates and method of manufacture

A mechanical embossing process wherein a web of material composed of a composite structure having at least a carrier and a thick foam layer to be embossed is heated in an oven to a temperature of 250.degree. F. to 350.degree. F. and thereafter cooled by wetting the carrier, which is the back surface of the web, to approximately 100.degree. F. below the top surface of the web prior to embossing of the foam. In certain areas of the web, hot spots may occur resulting in a top surface-back surface temperature of less than approximately 100.degree. F. Just prior to embossing, these hot spots are eliminated by selectively and intermittently cooling the back surfaces of the hot spot areas to obtain a top surface-back surface temperature difference of approximately 100.degree. F. The process is used for achieving multilevel mechanical embossing of a fused or cured wear layer in register with a print-on and expanded foam.

Selective cooling of sheet to be embossed

The process and apparatus herein is used for achieving multilevel mechanical embossing of a fused or cured wear layer in register with a print on an expanded foam thereunder. The expansion of the decorative foam and fusion of the wear layer are carried out and then the back of the foam is cooled by wetting and liquid evaporation. The wear layer is maintained at a high temperature for embossing and is embossed with registry between the embossed pattern and the printed pattern on the foam. Just prior to embossing, the decorative foam-wear layer web is wrapped around the backup roll of the embossing apparatus, and after embossing, is wrapped partially around the embossing roll of the embossing apparatus.

Multilevel embossing of foamed-sheet materials -- II

The process herein is used for achieving multilevel mechanical embossing of an expanded foam having a fused or cured wear layer in register with a print on the foam. The expansion of the decorative foam and fusion of the wear layer are carried out and then the back of the foam is cooled by back wetting with or without drum cooling. The wear layer is maintained at a high temperature for embossing and is embossed with registry between the embossed pattern and the printed pattern on the foam.

Multilevel embossing of foamed-sheet materials

The process herein is used for achieving multilevel mechanical embossing of a fused or cured wear layer in register with a print on an expanded foam thereunder. The expansion of the decorative foam and fusion of the wear layer are carried out and then the back of the foam is cooled by wetting and liquid evaporation. The wear layer is maintained at a high temperature for embossing and is embossed with registry between the embossed pattern and the printed pattern on the foam. Just prior to embossing, the decorative foam-wear layer web is wrapped around the backup roll of the embossing apparatus, and after embossing, is wrapped partially around the embossing roll of the embossing apparatus.

Growing community of inventors

Denver, PA, United States of America

William M McQuate