IE76461B1 - Decorative inlaid types of sheet materials - Google Patents

Abstract

Decorative, inlaid sheet materials which incorporate a matrix layer of discreet, low aspect ratio resinous particles embedded in a resinous coating. The use of printed patterns which are visible beneath the adhesive matrix containing the particles constitutes a preferred embodiment of the invention. The sheet materials of this invention are real through-patterned inlaids which do not lose their pattern due to wear in use, and which offer unique design advantages and flexibility, as well as superior properties.

Description

Field oi the Invention The present invention relates to decorative inlaid sheet materials and the like. More particularly the invention is concerned with the use oi polyvinyl chloride (hereinafter WFVC") polymerization agglomerates ea decorative particles and their application on floor and wall covering substrates to produce realistic inlaid patterns, utilising heretofore unobtainable design strategies and exhibiting superior properties.

The particles can be spherical sad, when such is the case, are hereinafter sometimes referred to as ’pearls. These pearls can be random-sifted on the substrate or applied in geometrical patterns. Also disclosed is the use or blends containing transparent or partly pearls allowing visible underprinting as a of mixes transparent further strategy for unique design variations.

Background of the Invention Sheet materials, in particular sheet vinyl flooring products, made with chips or particulate material, ar© commonly referred to as inleids. These processes for their manufacture are well floorcovering business linoleum times where products and known in the and originate back to the early through patterned floorcoveriags, based on linseed oil, cork dust and resins were developed by the industry. The process was later modified for vinyl.

Vinyl inlaid floorcovering consists of coarse colored particles, such as chips or dry blends, which are ®lsid on® a substrate and then eintered by heat, or laid in a transparent liquid or solid matrix and fused by heat. The chips ere produced from pre-gelled or fused spread, calendered or extruded compounds cut into geometrically regular proiilee or ground into randomly shaped particles.

The dry blends are made by mixing fine PVC powder with plasticizer, filler end color pigments and heating above the PVC compound's softening temperature. The small original fluffy particles mass. ’’grow·5 end form a loose,, porous,, coarse,.

Currently, sheet vinyl, distribute the different steps atencils, followed to produce realistic inlaid patterns for conventional menusacturing procedures coarse particles on the substrate in with the help of area-complementary by topcoating with a clear wear-layer.

This method ia complicated and can only be used to produce large geometric patterns.

Th® inlaid floorcoverings are normally characterised as those which maintain their decorative appearance as the surface is worn or abraded away. This characteristic makes such products particularly suitable for use in commercial areas where significant wear is encountered. hodem inlaids generally fell into two classificationsx resilienta end non-resilients. Resilients include a substantially continuous layer of foam and are usually made by incorporating solid particulate material into a plastisol coating,, followed by gelling end fusing. Hoa-reail.lenta do not contain a foam layer end usually are made by sintering and/or calendering^ or otherwise compacting,, particulate material.

The non-resilient products commercially offered are 3mm9 i.e. those containing large (about/X/Q inch) square chips in a J 0.1 mm, i.e. clear matrix and those containing small ίsbouiy O.004 inch) dry blend resin particles made by sintering and/or blend resins. compacting normal dry the reason no products containing chips,, grenul^^^p-j *pr particles o£ an intermediate particle size, for /ranging 1.0 mm from Q ·, (θ. 004 inch to 0.040 inch) are offered results from limitations inherent in current inlaid manufacturing technology,, discussed more fully hereinafter.

While construction of inlaid products by compaction from discreet chips or particles (normally of different colors) offers distinct styling opportunities, a significant premium is paid in terms of expensive, cumbersome equipment. Furthermore, the nature of the process restricts the range of designs available. For example, in order to effect specific registered pattern definition, it is necessary to deposit chips of different colors in preselected erees on the sheet. This is difficult aechanically, and results ia a alow euabersoae process which does not produce finely defined designs.

Some of the production techniques minimised by use of end design techniques. inherent difficulties in current for non-resilient inlaids have been increasingly sophisticated materials such as using fine particle size,. dry blend resins, printing over the .surface of the resulting inlaid product, optionally, embossing, with and without application of a wearlayer. Unfortunately, whereas the use of the finer particle size preserves the specific characteristic of an inlaid product, ie. the pattern does not change ss the product wears through, overprinting the product, whether v or not e wear layer is applied, essentially negates this characteristic because wearing through the print layer essentially destroys the pattern. This eliminates the product from commercial, high-use environments and limits its utility principally to styling effect in. residential and related applications.

Resilient inlaids are usually made by embedding ground plastic particulate material in a plastisol coating. US-A-4,212,691 exemplifies such product and methods for their manufacture. As taught in this patent, the thickness of the particles of the decorative chips or flakes is stated to be from about 0.075mm (3 mils) to about 0.62mm (25 mils) : see for example column 7, lines 62-64. However, it is the length of the particle, ie. its largest dimension, rather than thickness that is observed when viewing the pattern. That dimension is stated to be from about 1.2mm to 12mm (50 to 500 mils) at column 8, lines 1718. It is to be noted that the products disclosed all contain embedded chips or flakes ground from plastic sheet stock, even when chips or flakes from other stock materials are added (eg. see column 8, lines 4 et seq) . These chips or flakes characteristically have a high aspect ratio (ie. length/thickness).

Other disclosures of products with applied chips or flakes are US-A-3,239,364 which discloses pressing solid particles into a printed base coat and US-A-4,440,826 which discloses a product, in which·'transparent chips are pressed into an opaque layer until they create windows exposing a printed layer below. US-A-4,196,243 discloses particles incorporated into a wearlayer so as to provide a non-slip wearlayer over a pigmented rather than printed base.

US-A-4,450,194 discloses decorative coverings for floors and walls in which resin particles are used to provide differentials in gloss and texture. This document discloses an arrangement in which a vinyl plastisol ink is applied to selected areas registering with a printed image applied to a substrate. Resin particles are applied and adhere to the plastisol ink in the selected areas only. A top layer of PVC plastisol over the entire product provides a smooth surface outside the selected areas but leaves the particles projecting above the surface in the selected areas, thus giving selected areas of greater texture and lower gloss. In between these areas, the surface is smooth .

Thus, existing inlaid technology, although capable of producing commercially satisfactory inlaid products, has limitations and deficiencies. State of the art inlaid technology for chip products first grinds the chips from plastic sheets. This predefines the particle shape and is expensive. Furthermore, spherical particle shapes cannot be made by the grinding techniques currently in use for inlaids.

Additionally, products formed by compacting or sintering dry blends have always shown limited particle distinction due to process limitations and available particle sizes. The particles tend to lose their identity due to agglomeration or lumping caused by sintering process .

Purposes and Objects of the Invention It is, therefore, a principal purpose and object of this invention to provide heretofore unobtainable real through patterned inlaids, offering unique design advantages and flexibility, as well as superior properties. For example, wear resistance is significantly increased in comparison with leading commercially available inlaids. It is also a primary purpose and object of this invention to provide a novel process for producing such inlaids which is believed to be simpler and significantly less complicated than state-of-the-art inlaid production technology.

Another purpose and object is to provide a process that in the main utilizes today's plastisol equipment and technology. Other principal purpose and objects of this invention will be apparent from the following discussion.

Summary of the Invention The foregoing and other purposes and objects of this invention are accomplished by providing a decorative, inlaid floor or wall covering product which incorporates as the essential elements thereof (i) resinous particles having an aspect ratio significantly lower than those currently employed in inlaids commercially offered in the United States, (ii) an adhesive matrix in which said particles are embedded, and (iii) a substrate which supports these over a p?_'int layer which is visible through the adhesive matrix layer.

Thus, the invention provides a decorative, inlaid floor or wall covering in the two forms as claimed in the claims.

Preferably the particles have a size within a range from 0.1 to 1.0mm (0.004 to 0.04 inch) . Preferably also the particles employed in this invention have as aspect ratio of no greater than 1.5:1. Particles having an aspect ratio of about 1:1 and, in particular, particles which are also spheroidal, are especially preferred because of the excellent results achieved therewith, as discussed more fully hereinafter. The use of particles which are essentially as thick as they are £let? ie. having a low aspect ratio, provides a product that will not lose its pattern due to wear in use, thus preserving the unique property which characterizes true inlaids.

The use ox printed patterns which are visible beneath the adhesive matrix containing the particles broadens the options available to the pattern designer and constitutes another embodiment ox this invention. Exemplary is 'a decorative, inlaid floor or wall covering vhich comprisess a) a substrate, b) a printed layer, generally comprising a printable substrate coating or sealant, onto which is printed a pattern in an ink suitable for floor or wall applied over and substrate, and an adhesive matrix»' covering applications, in contact with said overlaying said printed layer, and in contact therewith, in which are embedded the resinous particles» said matrix being sufficiently transparent or transluscent to permit the underprint to show through.

Such product provides options for a wide variety of design strategies heretofore unobtainable· with state-of-the-art sheet vinyl technology and constitutes a preferred embodiment of this invention.

The inlaid products of this invention offer unique design advantages. Further,, cost advantages can also be realised by utilising raw materials which are believed to be unique to inlaid manufacture. For example» certain of the novel products of the invention incorporate an adhesive matrix consisting essentially of a plasti’sol layer containing a high loading of transparent and/or trenaluscent end colored, spheroidal resinous particles, ,1 „0 mm which, preferably, range in size from 0.1 to/O.004 inches to O. 040 inches). When this matrix is applied over a printed pattern, a unique visual effect is produced.

Such particles can be made in uniform controlled sixes by employing technology described in United States Patent 3,Q5S,900 Alternatively, special large particle size dry blend resinous particles, either screened to the desired size ranges of this invention from oversized material obtained from normal production variations, or specially sasde particles in the desired size range, can be utilized .

Another, and preferred, embodiment of this invention is a decorative, inlaid floor covering which comprisess a ) b) d) a- non-asbestos felt sheet substrate, a gelled, printable, plastisol coating over said substrate, one or more solvent based PVC-polyvinyl acetate copolymer inks applied to the surface of the plastisol layer, a gelled adhesive matrix, overlaying said piesfisol/prini layer, end in contact therewith, containing en effective amount of a homopolymer or a copolymer of vinyl chloride, in which are embedded discreet spherical and essentially spherical, gelled and resinous particles, at least some of which permit the underprint to show through, and wherein said particles are coarse PVC homopolymer or ' copolymer polymerization agglomerates, sized fo between 0.1 to 1.5 mm <0.004-0.060 inches) preferably less than 1.0 mm (0.040 inches), and optionally, e) a fused, treaspereni, plastisol seerleyer bs a top coet.

General Description of the Invention The product is comprised of a base supporting 5 material, which, optionally, may be precoated with a plastisol to enhance printability, a print layer offering decoration, sad an adhesive matrix containing transparent and pigmented resin particles, which are preferably spherical or spheroidal. In one embodiment the resulting product has an additional costing on its top surface to enhance surface properties, such as gloss and the like, and insure there is rao residual porosity resulting from the process of embedding the particulates in the adhesive Matrix, The incorporation of particulate aateriale of «such size -and shape, -and .at --the · loadings -herein· · -described provides the retention of pattern as the product wears through characteristic a£ inlaid products. The 2® incorporation of underprint to show dimension in design transparent transparent transparent through, capability. particles allowing the provides an additional The combination of a or transluscent adhesive Matrix loaded with or transluscent and/or pigmented or colored particulate material and the use of rotogravure or other forms of print offering fine registered dete.il and definition, provide a product which is believed to be unique and a significant advance in the art.

One of the advantages of this invention is that it employs ingredients and processing technology well known to those skilled in the art. Also, by employing a fluid plastisol as the Matrix Material binding the particles together, the product can be Manufactured without the need for the high pressures or temperatures characteristic of •the calendering or agglomeration steps oi the prior ert processes. This processing cheracteristic also distinguishes the subject process from those oi the prior art which employ only dry blend resins, which are agglomerated through heat sintering.

Substrate The substrate is a relatively flat fibrous or non-fibrous backing sheet material, such ss a fibrous, felted or matted, relatively fist sheet oi overlapping, intersecting fibers, usually of aon-esbeatoa origin. The substrate can, if desired, be asbestos or nosi-esbestos felts or pepers, woven or non-wovea; knitted- or otherwise fabricated textile material or fabrics comprised of cellulose, glass, natural or synthetic organic fibers, or natural or synthetic inorganic fibers, or supported or non-supported webs or sheets made therefrom or filled or unfilled thermoplastic or thermdset polymeric materials. These end other substrate or bass materials are well .known in the art and need not be further detailed here.

Substrate Coating The substrate or base materiel, optionally, can be coated to improve the print quality of the substrate. Such coatings can be plastisols, organosols, lacquers, filled or unfilled latex coatings, or other costings conventionally employed as preprint sealants in the manufacture of floor or wall covering products.

As used herein, the term •'plastisol’1 is intended to cover a relatively high molecular weight polyvinyl chloride resin dispersed in one or more plasticixers. The plastisol upon heating or curing forms a tough plasticised solid. For purposes of the present invention plastisol compositions are intended to include organosols, which are similar dispersed polyvinyl chloride resin materials that, in addition, contain one or more volatile liquids that are driven off upon heating.

Those skilled in the art will appreciate that, in addition to the basic resin constituents, other commonly employed constituents can be present in the plastisol compositions in minor proportions. Such other constituents commonly include beet and light stabilisers, viscosity depressants, and/or pigments or dyes, the latter in order to contribute color to the polyvinyl chloride resin.

Typically the substrate costing employed in the products of this invention is a resinous polyaner composition, preferably, a polyvinyl chloride plastisol which is substantially uniformly applied to the substrate surface, for exoaple roll coaler or wire wherein the grooves metering the for applying substrat and any by means of a conventional reverse wound bar, eg. a Heyer Rod Coster, .provided by. the wires assist in flow of the plastisol. The particular means th© substrate coating to the surface of the does not relate to the essence of the invention .suitable costing means can be employed. Exemplary of other coating means are knife-over roll coater, rotary screen, direct roll coster end the like.

. The plaatisol, substrate. 0.075 /β ‘°»ϊϊΐ ΐο or thicker application. thickness of the resinous polymer composition or as if is applied to the surface of the preferably is substantially uniform, and isy in the range of 30 mils) .

The substrate can be thinner as may be required by the particular product Although the preferred and typical substrate costing is a polyvinyl chloride homopolymer resin, other vinyl chloride resins can be employed. Exemplary are a vinyl chloride-vinyl acetate copolymer, e vinyl chloridevinylidene chloride copolymer, end copolymers oi vinyl chloride with other vinyl esters» such es, vinyl butyrate» vinyl propionate» and elkyl substituted vinyl esters» wherein the alkyl moiety preferably is lower elkyl containing between ebout 1-4 carbons. Other suitable as polystyrene» substituted wherein the substituents ere (C1"C1O' CSC14L Synthetic resins such polystyrene» preferably selected from the group consisting of elkyl preferably C^-C^)» aryl (preferably, polyolefins such as polyethylene and polypropylene» acrylates and methacrylate®» polyamides» polyesters» and any other natural or synthetic -esin capable of being applied to the substrate or base coatings of this invention to provide a smooth and uniform surface and/or to improve the print quality of the substrate or base.coating surface, are also applicable? provided such reels is otherviee compatible with the overall product composition and, therefore, within the principles of this invention. ,· Thus» it is not essential that a plastisol always be used. Organosols and aqueous latices (aquasols ©nd hydrosois) are also of use, employing as the dispersing or suspending media» organic solvents and water» respectively» rather than plasticizers, as in the gees of a plastisol. y.here the preferred plastisol is employed» typical of the ' plasticisers which can be used are dibutyl sebacate» butyl benzyl sebacate» dibenzyl sebacate» dioctyl adipate» didecyl adipate» dibutyl phthalate, dioctyl phthalate9 dibutoxy ethyl phthalate, butyl benzyl phthalates dibenzyl phthalate., di(2-ethylhexyl) phthalatea alkyl or aryl modified phthalate esters» alkyl» aryl» or alkylaryl hydrocarbons··,, tricresyl phosphate» octyl diphenyl phosphate» dipropylene glycol dibenzoate» dibasic acid glycol esters, and the like. Other constituents of the resinous substrate coating can include a blowing or foaming agent such as azodicarbonamide (if a blowing or foaming procedure is desired), conventional stabilizers/ accelerators, initiators, catalysts, etc., such as zinc oleate, dibasic lead phosphite, etc. , conventional heat or light stabilizers, such as metallic soaps, etc., UV absorbers, colorants, dyes or pigments, notably, titanium oxide, solvents end diluents, such as methyl ethyl ketone, methyl isobutyl ketone, dodecyl benzene, etc., fillers, such as clay, limestone, etc, viscosity modifiers, antioxidants, bacteriostats and bacteriOCl dee, and the like.

Print Layer Suitable inks manufacture of covering. These include those normally used in the floor covering, preferably resilient floor include plastisol, solvent based systems end water based systems. Such system can include a chemical suppressant in those cases where the substrate to which the ink is fo be applied is a foamable plastisol or organosol. Such suppressants are (eg. see U.S. -A- 3,293,094). well known in the art Printing onto the substrate can be effected by rotogravure, £lexigraphic, screen printing, or other printing techniques conventionally employed in making floor or wall covering products.

Adhesive Layer The adhesive layer is normally a plastisol or organosol additionally containing a plasticizer system, associated diluents, viscosity control aids and stabilisers. Those discussed above are exemplary. When underprinting is present, the adhesive would not normally contain colors or pigments which would render the adhesive layer opaque.

Although other homopolysners and copolymers of vinyl chloride, (ie. vinyl resins other than a plastisol or organosol) such as those discussed above, can also be employed, as a practical matter, current economics dictate the use of polyvinyl chloride plastisols of the type set forth in the examples hereinafter.

Resinous Particles The resinous particles of this invention can be of various sizes and geometric shapes, spherical and essentially spherical, (sometimes referred to herein as spheroidal) being especially preferred as having the low aspect ratios discussed herein required to obtain the desirable design effects this invention is capable of providing. Each transluscent or opaque particle can contain its own individual colorant, dye or pigment. It may be preferred that in some embodiments of this invention at least some of the particles are sufficiently transparent or sufficiently transluscent, to permit the printing on the print layer to show through the particles concerned.

Employing discreet spheroidal particles is advantageous for enhanced visual effect of depth and improved wear characteristics. Illustrative of those spheroidal particles which are especially preferred are the particles and the methods for their manufacture taught in U5=-A-3 t 856,900. This procedure is particularly convenient for the production of relatively small plastisol beads or pearls having a particle size of generally about 0.75mm (0.030 inch) or smaller.

Particles can also be obtained by screening the oversized particles from normal suspension grade resin production or by making special particle sizes, for example, in accordance with US-A-3,856,900.

Particles in this size range are particularly useful for achieving certain desirable design effects. Such procedures ere also capable of making smaller particle sizes, (eg. see U.S. US-A- 3, 345,, 235), but in ^the case of spheroidal particles, the procedure of U. S./ 3, 656, 900 is preferred.

Although spherical or essentially spherical pferticles are preferred, in general, the particles employed in this invention can have a wide variety of geometric shapes, provided that the aspect ratios of such particles fall within the ranges discussed herein. Exemplary of other geometric Outlines are squares, triangles, circles, annuli, other polygons, etc, or irregular sizes and shapes, or a mixture of any or all of such shapes, including spheroidal.

It. j thaa>£ been found that the size of the particles employed in carrying out this invention have a pronounced effect on the results obtained. Use of relatively smell eg. ranging from about 150 (100 mesh) fo (30 mesh) are most advantageous in desired design effects. Particles, spheroidal particles, averaging about 600 (by Bieroscopic observation) are especially particles, about 600 pm producing the especially pm preferred.

The ratio of transparent to colored particles determines the visibility of the printed pattern underneath the resulting adhesive matrix. Generally, 50% or less, and preferably 0-30 %„ transparent to colored particle loading is preferred. The amount actually used will, of course, depend upon the type of end-use application and design effect desired. Good results have even been achieved in the range of 0-10% transparent fo colored particle loading.

Wearlayer The optional overcoat or wearlayer is preferably a plastisol of the same or similar type as that discussed above in connection with the resins employed in the substrate coat and the adhesive layer or matrix. The formulations generally include materials to enhance special specific properties, for example gloss, wear, stain resistance, and scuff resistance.

Other resins suitable for use ©s a top coating can be employed. Exemplary are wear resistant polyurethanes, such as those described in U.S. "A-087,400.

Thus in another embodiment of this invention the decorative, inlaid floor or wail coverings comprises a) © flexible mat substrate, b) a gelled, resinous print layer, applied over said substrate, the surface of which is printed with one or more inks suitable for use in the manufacture of floor or well covering products, and c) an adhesive matrix, overlaying said print layer, containing an effective amount of a homopolymer or a copolymer of vinyl chloride, and in which are embedded resinous particles, at least some of which permit the underprint to show through, and d) en optional fopcoating or wearlayer or wearlayers selected from the group consisting of a plastisol, a polyurethane resin or a suitable mixture of each.

The following examples are Intended to demonstrate preferred embodiments of this invention without limiting the scope thereof. In the following examples all parts and percentages ere by weight.

Example 1 Floor Covering with Overall Pattern Suitable for Commercial Uses A floor covering substrate sheet of conventional type non-aelgegjos felt (Terkett Inc., Whitehall, Pa. ), approximately / (32 mil ) thick, wee bar coated (wire wound 0..075 nun . bar) with approximately (3 mils) of s layer of white printable plastisol, the composition of which was ss follows: Parts by Weight PVC emulsion: relative viscosity 2.05 70 (Occidental FPC SOS) PVC extender: k value SO 30 (PLIOVIC *-50) Di(2-elbylhexyli phthalate 30 Butyl benzyl phthalate 30 Titanium dioxide 5 Crystalline calcium carbonate SO Barium-zinc type stabilizer 3 (IRGASTAB 32 530) 149°C After /(300°F„), the on a flat Inks, Inc.. gelling against a heated resulting smooth surface print press using Series 125 chromium drum at is gravure printed inks from American 60°C air at about ! (i4O°fJl, an After drying in warm 1).25 mm a adhesive layer about ΛΧΟ mils/ thick was applied by drawdown bar and an excess of premixed plastisol pearls < produced in Example 3 and having the composition set forth hereinafter), about half of which were transparent and the remainder colored, were evenly distributed on the surface of the wet, tacky adhesive layer from a vibrating pan (SYIMTRQM vibrator manufactured by FMC Corp. ). The composition of the adhesive mix was: PVC dispersion; Parts by Weicht 70 (Occidental FPC 6458) PVC extender: k value 60 30 (PLIOVIC M-5O) Butyl benzyl phthlate 25 Dl-isononyl phthlate 25 Stabilizer, barium-zinc type 4 (SYNPROM 1665) Tine composition of the pearl particles was · Parts by Weicht Colored Transoarent Suspension grade PVC reabv. k value S3 100 100 «psviKOM sssa gk> Butyl benzyl phthalate 40 40 Stabilizer, barium-zinc type 4 4 (SYHPSON 1665) Titanium dioxide 5 Colo:—pigment 5 (Purchased blend of red iron oxide, yellow iron oxide and carbon black dispersed in di(2-ethyl-hexyl) phthalate) ΡΞΦΧΚΟΝ SSoQ 6K resin had an aspect ratio of about particles were round) and the particle size veg The < the found by pm follows s microscopic observation (approximately 30 mesh). to average about 600 Screen analysis was as Mesh (589 pm) (208 " ) 100 (147 ) X Retained 68. 0 25. 2 1. 4 Thru 100 mesh . 4 The excess neerlaf which were not wetted by the adhesive coating end embedded therein were blown awsy by a gentle air stream. The resultant grainy matrix was then gelled by contepiipg the coated side against a heated (177 Cg *1.6. chromium drum / 35Q°F.) and smoothed between a rubber pressure roller and the drum surface. The thickness of the (10.25 mm9 i.e. matrix containing the adhesive coat / IO mils) and the 0.5 mm, i.e. 0.75 mm, i.e. embedded pearls The surface of the matrix was then bar coated using a drawdown bar with a transparent plasfisol weeriayer having the following compositionj Parts by Weight Dispersion grade PVC, 100 ίOccidental PC 645β) Isebaatyric acid and glycol ester of benzoic acid SS (Hoassnto SANITIZER S-377 plasticizer) Stabilizeri barium-zinc type *5 (SYNPRON 1SS5) Epoxidized soybean oil 5 Kerosene 2 Brookfield Viscosity: -1200 cps 149°C The wearlayer was fused in a hot air oven et about /(3OO°F. ) for 3.5 minutes and then embossed between a cooled embossing roll and a rubber pressure roll. The resultant U.3h mm wearlayer has a thickness of sbouVllS mile).

The wear characteristics of the decorative inlaid product thereby produced are set forth in the following Table I and compared with leading competitive products.

TABLE I TABER ABRASION Run on Taber Abrasion Model #505 using H-18 wheels Product PRODUCT Initial Wt 4X4 Smpl LsJ Caliper Wt. Loss % 1000 cycles - (g) Wear-out Point (cycles) Thickness Wear-out Point (mm) (mils ) (mm) (mil s TARKETT Residential 21.3014 2,34 92 .0803 36,000 0.91 36 Commercial 22.3489 2.11 83 .0919 60,500 1.14 45 ARMSTRONG Crown© CorIon 46,0910 1.90 75 .2294 22,500 1.06 1 < 42 Designer Solarian 28.2392 2.24 88 .2696 27,500 1.54 eD.t5 Solarian Supreme II 28.7303 2.34 92 .3131 3,000 0.13 5 CONGOLEUM Innovation 17.2543 1.83 72 .0905 8,000 0.25 1θ FORBO Smaragd 18.1629 1.42 56 .0416 24,000 0.69 2? Example 2 Residential Floorcoverlnq with Registered Printed end Embossed Patterns (Chemically Embossed) A floorcovering substrate sheet of conventional type r?o?,-Qabg3ios felt <7arkett Inc. , (L80 mm .

Whitehall,, Fa. ) approximately/Q2 mils) thick vea coated with a· foamable plastisol the composition of which was es follows : Parts by Weight PVC dispersions k value S5 ίOccidental FPC 5C5) PVC extender resist k value SO 30 (PLIOVIC w=5Q) Di (2-ethylhexyl) phthlete 28 Butyl benzyl phthlete 15 Texanol isobutyrate (TXIS) 15 Titanium dioxide IO Azodicarbonauide 2. 5 Kerosene 4 Zinc oxide 1.5 Viscositys 2500 cps 135°C coated substrate is then pregelled in a hot oven af/(275°F.) for 2.5 minutes. The surface is then gravure printed on ε flat., bed press using inks having the same composition as those of Example 1 except that the inks used to cover the plate printing the valley areas of the pattern (ie. the grouts) contain additionally 140 parts benzotriesole, a chemical suppressant, to inhibit in these selected areas the expansion of the foamable plastisol.

After drying the print,, an adhesive layer having the same composition as that of Example 1 was applied by a drawdown bar. Premixed colored and transparent, pearls, in as in the same ratio/ Example ·, were evenly distributed, gelled and smoothed as described in Example 1. The,-thickness of (0.3b mma i.e. the resulting matrix containing, the pearls/ n 15 mils) w (0.0Ϊ2 nm, i.e. O.b mm9 i.e. embedded in the adhesive/ 5 mils) was about / 20 mils. 0.25 mm3 i.e. 7 Approximately / 10 mils,of a transparent veerlaysr having the same composition as that of Example 1 was applied with a drawdown ber. The resulting product was ^hen fused and expanded (ie. foamed) in a hot air oven af/{360oF.) for 3 minutes.

The xloorccveriag produced shows a relief structure (embossing) in register with the printed areas. The decorative inlaid nroduct thereby produced has an overall 2.08 mm thickness of afooirty(Q2 mils)and exhibited excellent wear ©nd 15 design characteristics.

J Example 3 The plastisol spherical peerls® used in the foregoing examples were prepared using the following formulations ϊ Parts bv Weight Colored Transparent Suspension grade PVC resin, coarse: k value SS (PEVICOS SSS8 GK) Butyl benzyl phthalate Berium-sinc stabiliser (SYMPRON 1SSS) Titanium dioxide Color-pigment 100 4.0 4. 1OO In preparing the colored transparent plastisol composition» the PVC resin (at/ 70°F. ) *ss charged to a high intensity sixer running at 35^30 RPW and mixed until the batch temperature reached /^(lSO°F.) (about IO minute®). The speed of the sixer »as then reduced to 500 revolutions per minute and the pigment pastes» plasticizer and stabilizer were added slowly over a period of about 5 minutes. The speed «as then increased to 2000-3000 rpm and th^ material mixed until the batch temperature reached /lisO^F. ) (approximately 15 minutes additional). The speed was then reduced to 500 SPh and the material was mixed 21-35: C, i.e, until the batch temperature cooled to/70-90°F\ (about 30 additional minutes)., The pearls produced were essentially spherical, dry and free running? did not exceedy^C-.06 inch) in diameter, and had a particle size distribution range* *© ftUS to .040 inch).

The following table swnarizes the process parameters employed s Equipment: High intensity mixer 9.8 litre (2.6 gal.) volume 1.36Kg (3 lbs ) loading Elapsed Time Min. Temperature Speed Rev/Min •c °F 0 -^21 ^70 3500 71 160 500 pigments, plasti cizer and stabi- lizer added 15 127 260 2000-3000 30 500 cooling 60 ~^21 --’70 Examples 1 and 2 demonstrate decorative, inlaid floor coverings which constitute highly preferred embodiments of this invention and which comprise: a) a substrate sheet of conventional type nonasbestos felt, b) a gelled, thin, white, or tinted, printable plastisol coating over said substrate, prepared from effective amounts of a formulation comprising: - an emulsion type PVC, - a PVC extender, preferably having a k value about 60, - a plasticizer, preferably a phthlate such as di(2-ethylhexyl) phthlate or butyl benzyl phthalate, - a pigment, preferably titanium dioxide, - crystalline calcium carbonate, and - a barium-zinc type stabilizer c) a print layer of one or more inks made from effective amounts of a formulation comprising: - a PVC-PVAc resin copolymer. - one or more pigments, - ε solvent, preferably consisting essentially of methyl ethyl ketone end xylene, and & - e dispersion aids d) a gelled adhesive layer made from effective amounts of a formulation comprising? - a PVC dispersion, - a PVC extender, preferably having a k value about 30if - a plasticiser, preferably butyl benzyl phthalate or di-isononyl phthalate, and - a beriu»-sinc type stabilizer, and e) a mixture of gelled, transparent end colored pearls, wherein the pearls are about SOX transparent and about SOX colored, evenly distributed on the adhesive layer, prepared from effective amounts of a formulation comprising s - a PVC suspension resin, preferably coarse and having a k value about 35, - a plasticizer, preferably butyl benzyl phthalate, - a barium-zinc stabilizer, and, optionally, - a pigment or s color, selected from the croua iron ίron consisting of red / oxide, yellow / oxide, chrome yellow, molybdate orange, carbon black, titanium oxide, quinanthrone red, phthallo blue and phthallo green.

Although the forgoing discussion describes this invention in terms of floor or wall covering products, this invention is > intended to encowpaes any covering including, but not necessarily limited to, floor or wall covering, which incorporates a matrix layer of discrete» , low aspect . ratio resinous particles embedded in a resinous coating.

Claims (20)

CLAIMS :

1. A decorative, inlaid floor or wall covering which comprises : a) a substrate b) a printed layer in the form of a pattern applied over said substrate, and c) an adhesive matrix layer overlaying said printed layer, in which are embedded resinous particles generally having an aspect ratio no greater than 2:1, wherein the adhesive matrix layer extends-over the whole area of the decorative covering, the embedded resinous particles are distributed over the whole area of the decorative covering, the underprint is visible through said adhesive matrix layer .

2. A decorative, inlaid floor or wall covering which comprises: a) a substrate b) a printed layer in the form of a pattern applied over said substrate, and at least one layer above said printed layer, comprising c) an adhesive matrix layer overlaying said printed layer, in which are embedded resinous particles generally having an aspect ratio no greater than 2:1, wherein the underprint is visible through said adhesive matrix layer, the said embedded resinous particles do not cause the decorative covering to have a

3. The product of claim 2 wherein the layer is applied only in selected areas

4. The product of any one of claims 1 adhesive matrix layer is coated with at wearlayer. textured surface. adhesive matrix to give a pattern. to 3 wherein the least one

5. The product of any one of the preceding claims wherein 10 the said resinous particles are essentially spheroidal.

6. The product of any one of the preceding claims wherein the substrate is a flexible mat.

7. The product of any one of claims 1 to 5 wherein the substrate is a non-asbestos felt sheet. 15

8. The product of any one of the preceding claims wherein the printed layer is a gelled, resinous layer, the surface of which has been printed with an ink suitable for use in the manufacture of floor or wall covering products.

9. The product of any one of the preceding claims wherein 20 the adhesive matrix layer contains a major amount of a homopolymer or copolymer of vinyl chloride.

10. The product of any one of the preceding claims wherein the resinous particles are a blend of pigmented and transparent particles.

11. The product of claim 10 wherein said particles are plasticized polyvinyl chloride particles having an aspect ratio no greater than 1.5:1.

12. The product of any one of the preceding claims wherein the resinous printed layer is a gelled, foamed or foamable layer and at least one of the inks is a suppressant ink.

13. The product of·any one of the preceding claims wherein the particles are discrete, vinyl chloride, homopolymer or copolymer polymerization agglomerates, sized between 0.1 to 1mm (0.004 to 0.04 inches).

14. The product of any one of claims 1 to 5 wherein the substrate is a non-asbestos felt sheet substrate, the printed layer is a gelled, printable plastisol coating over said substrate with one or more solvent based polyvinyl chloride/polyvinyl acetate inks, applied to the surface of . the plastisol layer, the adhesive matrix layer contains a homopolymer or a copolymer of vinyl chloride, in which are embedded the resinous particles, and wherein said particles are essentially spheroidal polyvinyl chloride homopolymer or copolymer polymerization agglomerates, sized between 0.1-lmm (0.004-0.040 inches) and the product of comprising a fused, transparent, plastisol wearlayer as a top coat.

15. The product of claim 14 wherein the ink is made from a formulation comprising: a) a polyvinyl chloride/polyvinyl acetate copolymer resin, b) one or more pigments, c) one or more solvents, and d) a dispersion aid.

16. The product of claim 15 wherein said formulation additionally comprises benzotriazole and wherein the plastisol is foamable.

17. The product of claim 14, claim 15 or claim 16 wherein the resinous particles are a blend of pigmented and transparent particles evenly distributed within the adhesive matrix layer.

18. The product of any one of claims 14 to 17 wherein the printable plastisol. coating is .a foamable plastisol, pregelled in a hot air oven at the surface of which is then printed using at least one solvent based polyvinyl chloride/polyvinyl acetate ink containing a chemical suppressant to locally inhibit the expansion of the foamable plastisol in preselected areas, and wherein the product is fused and foamed in a hot air oven to form an. . embossed pattern.

19. The product of any one of claims 1 to 7 wherein the printed layer is a foamed layer overlaying the substrate, the surface of which foamed layer is printed.

20. The product of any one of claims 14 to 19 wherein said resinous particles are plasticized polyvinyl chloride particles having an aspect ratio no greater than 1.5:1. 2k A decorative, inlaid floor or wall covering as defined in Claim substantially as hereinbefore described by way of Example.