Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
2000-03-06
2001-10-02
Michl, Paul R. (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
C428S522000
Reexamination Certificate
active
06297297
ABSTRACT:
TECHNICAL FIELD
This invention relates to floor covering.
BACKGROUND
Laminated floor coverings incorporating thermoplastic resins are widely used in residential and commercial settings. Such products often include a felt backing material and a clear top layer (sometimes called a “wear layer”) overlaying a printed design or decorative chips or flakes on a core layer of thermoplastic. Because they are relatively soft in comparison with concrete or ceramic tile, laminated floor coverings are also known as resilient floor coverings. Laminated floor coverings are marketed as sheet materials and as square “tiles.”
SUMMARY
The invention provides a method of making a multi-layered floor covering containing a multicolored pattern. The method includes applying a multiplicity of pigmented, thermoplastic microbeads to a top surface of a thermoplastic base layer to form a pattern layer on the base layer. Preferably, the base layer remains sufficiently hot so that it is molten or tacky when the microbeads are applied. In some embodiments the method includes covering the base layer and pattern layer with a substantially transparent material, e.g., a polyurethane or liquid PVC plastisol to form a clear top layer. In some embodiments of the method, formation of the clear top layer involves heating the substantially transparent material, for example by passing the base layer, pattern layer and clear top layer through a fusion oven.
A base layer having a top surface and a bottom surface can be formed by melting a dry blend comprising polyvinylchloride (PVC) to produce a molten PVC output, and shaping the molten PVC output into a substantially smooth PVC sheet of substantially uniform thickness. This can be accomplished by feeding the molten PVC output into a three-roll or four-roll calender. A fluxing device can be used in producing the molten PVC output. In some embodiments, the molten PVC output is fed from the fluxing device into a mill for further melt mixing prior to formation of the base layer. If a dry blend is used to produce the base layer, the dry blend can contain one or more of the following: a plasticizer, a stabilizer, a lubricant and a filler.
The microbeads can applied to the base layer using a stencil. The multiplicity of microbeads can include microbeads of two or more colors. The microbeads can contain a thermoplastic such as a polyvinyl chloride, a polyurethane, a polypropylene, a polyethylene, a polystyrene, an epoxy and an alloyed polyvinyl chloride. Preferably, the microbeads are approximately spherical and have an average diameter between 0.002″ and 0.040″.
Optionally, the method includes bonding a backing layer to the bottom of the base layer. Bonding of the backing layer can be carried out prior to formation of the pattern layer. An exemplary backing layer is a dense felt material.
All publications, patents and other references mentioned herein are incorporated by reference. The details of one or more embodiments of the invention are set forth in the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
REFERENCES:
patent: 4599264 (1986-07-01), Kauffman
patent: 4923657 (1990-05-01), Gembinski et al.
patent: 5015516 (1991-05-01), Lussi et al.
patent: 5059471 (1991-10-01), McNally
patent: 5169704 (1992-12-01), Faust et al.
patent: 5246765 (1993-09-01), Lussi
patent: 5260118 (1993-11-01), Lussi
patent: 5525274 (1996-06-01), Grimmer
patent: 5654102 (1997-08-01), Grimmer
patent: 5670237 (1997-09-01), Shultz
Brookman Robert S.
Gates Charles
Wallace Lawrence
Fish & Richardson P.C.
Michl Paul R.
Teknor Apex Company
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