US3804657A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for producing decorative surface covering
Assignee: Armstrong World Industries Inc
•
Filing: 1971-06-07
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Granted: 1974-04-16
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Expires: 1991-06-07
Abstract
Abstract A process for producing a resinous composition surface covering having a multi-level decorative surface by depositing a layer of granular resinous dryblend on a backing sheet, heating the granules to form a porous cohesive layer therefrom, cooling the layer and applying settable resinous inks thereto to form a design thereon, gelling the ink, removing non-design carrying portions of the porous layer, and heating to fuse all of the remaining resinous material. Additional surface alterations of the multi-level surface, such as texturing, may be accomplished by chemical or mechanical means. After-finish coatings may be applied to enhance the appearance and utility of the surface covering.
Inventors
- 👤 D Eyman
- 👤 W Lewicki
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 15:57
CPC Classifications
D; D06; D06N; D06N7/00; D06N7/0005; D06N7/0039; D06N7/0057; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24521; Y10T428/24612; Y10T428/24802; Y10T428/24851; Y10T428/24868; Y10T428/249921; Y10T428/249953; Y10T428/31504; Y10T428/31551; Y10T428/31645; Y10T428/31649; Y10T428/31652; Y10T428/31855; Y10T428/31935
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
28 words
The process according to claim 1, including the step of depositing a plastisol coating on the surface of the backing sheet prior to deposition of the resinous dryblend.
Claim 2
Dependent Claim
44 words
heating to form a cohesive porous layer from said dryblend by causing partial melting of at least the surface portions of the granules of the dryblend at their points of contact, thereby forming bonds which result in the formation of the cohesive porous layer;
Claim 3
Dependent Claim
36 words
producing a design on said cohesive porous layer by applying a settable resinous ink in sufficient amounts to permit penetration thereof through substantially the entire thickness of the cohesive porous layer at the points of application;
Claim 4
Dependent Claim
14 words
The process according to claim 2 wherein the plastisol coating is a filled plastisol.
Claim 5
Dependent Claim
19 words
The process according to claim 2, including the step of gelling the plastisol prior to deposition of the dryblend.
Claim 6
Dependent Claim
15 words
heating to a temperature below the fusion temperature of the dryblend to set the ink;
Claim 7
Dependent Claim
32 words
loosening the bonds between the granules of the cohesive porous layer in the non-design carrying portions thereof to a depth substantially equal to the depth of penetration of said settable resinous ink;
Claim 8
Dependent Claim
12 words
The process according to claim 2 wherein the plastisol coating is foamable.
Claim 9
Dependent Claim
32 words
The process according to claim 1, including the step of applying a clear coat subsequent to removing non-design carrying portions of the cohesIve porous layer and prior to the final heating step.
Claim 10
Dependent Claim
19 words
removing the loosened granules from the cohesive porous layer while leaving the design carrying portions thereof substantially unaffected; and
Claim 11
Dependent Claim
23 words
The process according to claim 1 wherein the backing sheet is decorated by printing immediately prior to deposition of the resinous dryblend thereon.
Claim 12
Dependent Claim
7 words
heating to fuse the remaining resinous material.
Claim 13
Dependent Claim
14 words
The process according to claim 1 wherein the dryblend particles have an adhesive coating.
Claim 14
Dependent Claim
36 words
The process according to claim 1 wherein formation of the cohesive porous layer includes deposition of at least two layers of resinous dryblend on the backing sheet, each layer differing in formulation and degree of sintering.
Claim 15
Dependent Claim
31 words
The process according to claim 9, including heating the first dryblend layer to form a cohesive porous layer and decorating it prior to the deposition of the second dryblend layer thereon.
Claim 16
Dependent Claim
31 words
The process according to claim 1 wherein the removal of the porous material from the non-design carrying portions thereof includes the step of applying a solvent to soften the porous layer.
Claim 17
Dependent Claim
17 words
The process according to claim 11 wherein the solvent is applied only to the non-design carrying areas.
Claim 18
Dependent Claim
23 words
The process according to claim 11 wherein the solvent is applied as an overall coating to the design carrying surface of the sheet.
Claim 19
Dependent Claim
22 words
The process according to claim 1 wherein the removal of the non-design carrying portions of the porous structure is effected by brushing.
Claim 20
Dependent Claim
25 words
The process according to claim 1, including the step of forming a textured top surface on the fused design carrying portions of the surface covering.
Claim 21
Dependent Claim
9 words
The product produced by the process of claim 1.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-04-15 | 1977-10-15 | 1978-04-16 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-04-15 | 1981-10-15 | 1982-04-16 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-04-15 | 1985-10-15 | 1986-04-16 | $7700.00 | Window Closed / Lapsed |