Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Including a second component containing structurally defined...
Reexamination Certificate
2000-08-23
2003-11-18
Jones, Deborah (Department: 1772)
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Including a second component containing structurally defined...
C428S206000, C428S320200, C428S327000, C428S363000, C428S339000
Reexamination Certificate
active
06649257
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to composite materials with visible bulk decorative features within the body of the material, and to methods for producing such materials in sheet or block form. Such materials are useful as surface coverings for walls, floors, furniture etc. and as materials for making jewelry or other decorative objects. Broadly speaking, such materials are formed of castable pigmented liquids and solid particles specifically chosen to interact mechanically with the pigments to produce bulk decorative effects in extended forms such as streaks, comet-tails, waves, curves, etc.
DESCRIPTION OF THE PRIOR ART
Various methods for producing decorative materials which can be formed as laminates and used as surface coverings or from which decorative objects can be produced are well-known.
For example, decorative laminates formed of sheet material of a resinous polymer composition, e.g. polyvinyl chloride, on a suitable substrate, e.g. a fibrous backing sheet, have been used for many years as sheet flooring. Similarly, laminates with simulated wood-grain or marbleized surfaces are used to produce furniture which is attractive and durable but inexpensive compared to natural materials.
Methods for producing such materials include mechanical embossing, chemical embossing or inlaying to provide contrasting surface finishes and other decorative effects.
Another type of decorative composite material consists of a transparent binder with embedded particles of various types. In these, the particles themselves provide decorative bulk effects and/or other functionality. Patents covering such materials include U.S. Pat. No. 3,941,607 to Schuhbauer which discloses a high traffic surface layer having chip grains, bituminous binder, and a high viscosity mortar; U.S. Pat. No. 3,950,581 to Maurin which shows a prefabricated tile panel having asbestos coated PVC chips; U.S. Pat. No. 4,126,727 to Kaminski covering a resinous polymer sheet containing mica, and transparent or translucent PVC chips; U.S. Pat. No. 4,257,834 to Iida which teaches a process for producing floor or wall sheet having a “chip like” pattern wherein the chips can be resin (PVC), inorganic, ceramic, metallic, stone, and wooden together with an epoxy or urethane resin; U.S. Pat. No. 4,530,856 to Kauffman which is directed to a floor covering laminate having a textured and glossy finish, wherein various types of PVC resin particles are used.
To the extent these patents are concerned with decorative effects, however, such effects are achieved from the appearance of the embedded particles themselves. So far as applicants have been able to determine, the prior art does not disclose materials or processes for manufacturing materials in which bulk decorative effects are achieved in continuous or extended form such as streaks, waves, curves, etc. through mechanical interaction between the constituents.
SUMMARY AND OBJECTS OF THE INVENTION
Broadly stated, decorative materials produced in accordance with this invention are comprised of a castable, pigmented liquid vehicle and a quantity of dispersable particles having a high specific gravity relative to the liquid vehicle, and a second castable liquid vehicle. The manufacturing process itself can be quite simple: after the first liquid and particles are thoroughly blended, the material is poured onto a suitable surface and allowed to begin to set. Then the second vehicle is applied in a desired pattern and the two vehicles allowed to set. The thickness of the casting can be adjusted mechanically and the surface textured or smoothed as desired. The first liquid can be poured onto a backing material if desired to produce a laminate, and a protective coating can be added after the composite has set and/or hardened.
As the first liquid is poured or cast, the included particles tend to float then sink due to the difference in specific gravity. The flow of the liquid is thus interrupted both vertically and horizontally by the movement of the particles, and the resulting non-uniformity of the dispersal of the pigment produces characteristic streaks, whirls, comet-tails and other extended bulk decorative effects.
Among the liquids which may be used are resinous polymers such as epoxy, PVC plastisols, acrylics, urethanes and the like, or other castable liquids such as glass. Any compatible colorant materials which have suitable light refracting properties may be used. A wide range of particle materials may be used, subject the various requirements discussed in detail below. Such materials include chips or flakes formed of PVC, acrylic, urea or polyester etc., or natural materials such as mica, quartz, sand or metal.
The process according to this invention makes available a new class of decorative materials for use as floor and wall coverings, laminated surfaces for furniture and even artists materials. Additionally, these materials can be produced easily and inexpensively in continuous sheet form or as discrete blocks or other desired shapes.
It is accordingly a general object of this invention to provide a new class of decorative materials and methods of manufacturing such materials.
More particularly, it is an object of this invention to provide materials having dimensionally extended bulk decorative effects which may be as floor and wall coverings, as surfaces for furniture and for a variety of other decorative purposes.
A related object of the invention is to provide a convenient and cost effective process for manufacturing the materials of this invention.
Another object of the invention is to provide decorative materials having bulk decorative effects in the form of extended streaks, comet-tails, waves or other curves and the like.
A further object of the invention is to provide decorative materials comprised of a castable pigmented liquid vehicle and a quantity of dispersable particles having a high specific gravity relative to the liquid vehicle, and a second vehicle, as well as a method of manufacturing such materials.
A related object is provide decorative materials having bulk decorative effects which are achieved by mechanical interaction between a pigmented castable liquid vehicle and dispersed particles contained therein as the liquid is cast and cures and/or hardens.
A further related object is to provide such materials and the process for manufacturing same in which the decorative effects are in the form of extended streaks, comet-tails, waves or other curves and the like.
Yet another object of the invention is to provide decorative materials and methods for manufacturing the same in which the materials are comprised of a castable pigmented liquid vehicle and included particulate material, and in which the decorative effects are achieved by proper selection of the properties of the liquid vehicle and the particulate material relative to each other.
Other objects, advantages and novel features of the invention will become readily apparent to those skilled in the art from the following drawings and detailed description of a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The first material according to this invention is comprised of a castable pigmented liquid and solid particles which interact mechanically with the pigmented liquid to produce the desired decorative effects. This is described in application Ser. No. 09/276,996, filed Mar. 26, 1999, which is hereby incorporated herein by reference.
In accordance with several preferred embodiments of the invention, suitable liquids include resinous polymers such as epoxies, PVC plastisols, acrylics, urethanes and the like. Other non-resinous castable liquids such as glass may also be used.
Any colorant materials which are compatible with the liquid vehicle and have suitable light refracting properties may be used. For resinous vehicles, preferred colorants include mica-based pigments such as Mearl Hilite Pearl manufactured by Engelhard Corporation of Iselin, N.J. or metallic pigments such as manufactured by Silberline Manufacturing Co., Inc. of Tamaqua, Pa.
A wide range of p
Bahta Abraham
Jones Deborah
Ostrolenk Faber Gerb & Soffen, LLP
Ronald Mark Associates, Inc.
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