Method and apparatus for making a printed and embossed floor covering

Abstract

An improved process suitable for continuously producing tiles which have the sharp and vivid coloring characteristics of ceramic tiles. In accordance with this process, a release paper is coated with a clear liquid plastisol layer. The clear liquid plastisol layer is given a completely smooth upper surface. A decorative design is then applied to the smooth upper surface by transfer printing. The printed plastisol is then covered with an opaque plastisol backing layer to form a cast wear layer comprising the clear plastisol layer, the printed pattern, and the opaque plastisol backing layer. The cast wear layer is then transferred to a continuous plastic base web that has been made previously so that the backing layer is in contact with the base web. The cast wear layer is laminated onto the base web, and this laminate is embossed using an engraved roll having raised sections which are images of the printed design. The web is cooled, partially annealed, cooled and cut into individual tiles in register with the printed and embossed pattern. Preferably, the cut tiles are then beveled so that only the top plastisol layer is beveled. A urethane no-wax coating is then applied to the beveled tiles. Because the decorative print is transfer printed onto a clear plastisol layer which has a completely smooth surface, all of the print on the transfer print release paper is transferred. This clear print is visible through the clear plastisol layer resulting in tiles that have the sharp and vivid color characteristics of ceramic tiles.