US3924023A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Floor tile production and products
Assignee: GAF Corp
•
Filing: 1973-04-03
•
Granted: 1975-12-02
•
Expires: 1993-04-03
Abstract
Abstract The vinyl asbestos and asphalt floor tiles are formed with a predetermined image printed on the surface thereof by rotogravure, planograph, letterpress or other printing techniques. Unlimited design possibilities not heretofore feasible by conventional valley printing of the continuous sheet of tile composition prior to cutting into individual tiles, are thus presented, the sheet being printed either during or after the sheet calendering operation. The continuous sheet, traveling at a rate of about 80-200 ft./min. is surfaced following said printing with a clear, durable wear layer having, upon curing, an advantageous combination of enhanced properties including enhanced resistance to scratching and abrasion, together desirably with improved resistance to staining, scorching and other desirable properties. The dimensional stability characteristics of the surfaced tiles are comparable to those of the untreated base tile, minimizing the problem of curling during storage, application and use. The clear wear layer is a crosslinked polymeric product of a fluid photo-polymerizable coating applied to the continuous sheet at a temperature of at least about 140*F and cured by exposure to ultraviolet light of sufficient intensity to initiate curing in less than about 15 seconds, typically with exposure times of from a fraction of a second to about 10 seconds. The thus-printed treated sheet is thereafter cut while warm to form individual tiles surfaced with said clear, durable, dimensionally stable wear layer having an advantageous combination of improved wear characteristics.
Inventors
- 👤 Armen G Boranian
- 👤 Bruce Terwilliger
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 22:56
CPC Classifications
D; D06; D06N; D06N3/00; D06N3/04; D06N3/06; D06N3/08; Y; Y10; Y10T; Y10T428/00; Y10T428/26; Y10T428/263; Y10T428/31504; Y10T428/31551; Y10T428/31573; Y10T428/31652; Y10T428/31815; Y10T428/31855; Y10T428/31909; Y10T428/31928
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
349 words
A PROCESS FOR PRODUCING AN IMPROVED VINYL ASBESTOS OR ASPHALT FLOOR TILE PRODUCT COMPRISING: A. CALENDERING A UNIFORM MIX OF VINYL ABSETOS OR ASPHALT FLOOR TILE INGREDIENTS TO FORM A CONTINUOUS SHEET DISCHARGED FROM THE CALENDERING ZONE AT A TEMPERATURE OF FROM ABOUT 110*F TO ABOUT 180*F AND AT A TRAVEL RATE OF FROM ABOUT 80FT./MIN. TO ABOUT 200FT./MIN. B. PRINTING A PREDERTERMINED IMAGE ON THE EXTERIOR PLANAR SURFACE OF THE SHEET DURING PASSAGE OF SAID SHEET THROUGH A PRINTING ZONE ESSENTIALLY AT THE INDICATED TRAVEL RATE, C. COATING THE CONTINUOUS SHEET HAVING THE DESIRED IMAGE PRINTED THEREON AND TRAVELING ESSENTIALLY AT SAID TRAVEL RATE WITH A FLUID COATING COMPOSITION CONTAINING ESSENTIALLY 100% ACTIVE INGREDIENTS AND COMPRISING AT LEAST ONE ORGANIC COMPOUND HAVINF AT LEAST TWO PHOTO-POLYMERIZABLE ETHYLENICALLY UNSATURATED GROUPS PER MOLECULE, SAID COATING HAVING A THICKNESS OF FROM ABOUT 0.001 INCH TO ABOUT 0.005 INCH AND BEING CAPABLE OF CURING UPON EXPOSURE TO ULTRAVIOLET LIGHT TO FORM A HARD, CLEAR LAYER ADHERING TO SAID SHEET; D. EXPOSING THE THUS-COATED SHEET TRAVELING ESSENTIALLY AT SAID RATE IMMEDIATELY TO ULTRAVIOLET LIGHT HAVING WAVELENGTHS WITHIN THE RANGE OF FROM ABOUT 2500 A TO ABOUT 4000 A IN A-NON-OXIDIZING ATMOSPHERE AT A TEMPERATURE OF FROM ABOUT 110*F TO ABOUT 220*F. THE RADIATION INTENSITY LEVEL BEING SUFFICIENT TO INITIATE THE DESIRED CURING OF THE COATING WITHIN AN ULTRAVIOLET EXPOSURE TIME OF FROM ABOUT 0.2 SEC. TO ABOUT 15 SEC; AND E. PASSING THE THUS-TREATED SHEET TRAVELING ESSENTIALLY AT SAID RATE TO A CUTTING ZONE AND THEREIN CUTTING THE THUS PRINTED, COATED AND TREATED SHEET AT A TEMPERATURE OF NOT LESS THAN ABOUT 120*F TO FORM INDIVIDUAL PRINTED TILES HAVING A CLEAR WEAR LAYER THEREON, THE ABRASION AND SCRATCH RESISTANCE PROPERTIES OF SAID COATED TILE BOTH BEING SIGNIFICANTLY ENHANCED OVER SAID PROPERTIES OF THE UNTREAATED BASE TILE, THE DIMENSIONAL STABILITY CHARACTERISTICS AND RESISTANCE TO CURLING OF SAID COATED TILE BEING COMPARABLE TO THOSE OF THE UNTREATED BASE TILE, WHEREBY THE PRINTED TILE IS PRODUCED WITH ENHANCED WEAR PROPERTIES OBVIATING THE NEED FOR FREQUENT WAXING AND PROTECTING THE PRINTED EXTERIOR PLANAR SURFACE OF THE TILE.
Claim 2
Dependent Claim
349 words
A PROCESS FOR PRODUCING AN IMPROVED VINYL ASBESTOS OR ASPHALT FLOOR TILE PRODUCT COMPRISING: A. CALENDERING A UNIFORM MIX OF VINYL ABSETOS OR ASPHALT FLOOR TILE INGREDIENTS TO FORM A CONTINUOUS SHEET DISCHARGED FROM THE CALENDERING ZONE AT A TEMPERATURE OF FROM ABOUT 110*F TO ABOUT 180*F AND AT A TRAVEL RATE OF FROM ABOUT 80FT./MIN. TO ABOUT 200FT./MIN. B. PRINTING A PREDERTERMINED IMAGE ON THE EXTERIOR PLANAR SURFACE OF THE SHEET DURING PASSAGE OF SAID SHEET THROUGH A PRINTING ZONE ESSENTIALLY AT THE INDICATED TRAVEL RATE, C. COATING THE CONTINUOUS SHEET HAVING THE DESIRED IMAGE PRINTED THEREON AND TRAVELING ESSENTIALLY AT SAID TRAVEL RATE WITH A FLUID COATING COMPOSITION CONTAINING ESSENTIALLY 100% ACTIVE INGREDIENTS AND COMPRISING AT LEAST ONE ORGANIC COMPOUND HAVINF AT LEAST TWO PHOTO-POLYMERIZABLE ETHYLENICALLY UNSATURATED GROUPS PER MOLECULE, SAID COATING HAVING A THICKNESS OF FROM ABOUT 0.001 INCH TO ABOUT 0.005 INCH AND BEING CAPABLE OF CURING UPON EXPOSURE TO ULTRAVIOLET LIGHT TO FORM A HARD, CLEAR LAYER ADHERING TO SAID SHEET; D. EXPOSING THE THUS-COATED SHEET TRAVELING ESSENTIALLY AT SAID RATE IMMEDIATELY TO ULTRAVIOLET LIGHT HAVING WAVELENGTHS WITHIN THE RANGE OF FROM ABOUT 2500 A TO ABOUT 4000 A IN A-NON-OXIDIZING ATMOSPHERE AT A TEMPERATURE OF FROM ABOUT 110*F TO ABOUT 220*F. THE RADIATION INTENSITY LEVEL BEING SUFFICIENT TO INITIATE THE DESIRED CURING OF THE COATING WITHIN AN ULTRAVIOLET EXPOSURE TIME OF FROM ABOUT 0.2 SEC. TO ABOUT 15 SEC; AND E. PASSING THE THUS-TREATED SHEET TRAVELING ESSENTIALLY AT SAID RATE TO A CUTTING ZONE AND THEREIN CUTTING THE THUS PRINTED, COATED AND TREATED SHEET AT A TEMPERATURE OF NOT LESS THAN ABOUT 120*F TO FORM INDIVIDUAL PRINTED TILES HAVING A CLEAR WEAR LAYER THEREON, THE ABRASION AND SCRATCH RESISTANCE PROPERTIES OF SAID COATED TILE BOTH BEING SIGNIFICANTLY ENHANCED OVER SAID PROPERTIES OF THE UNTREAATED BASE TILE, THE DIMENSIONAL STABILITY CHARACTERISTICS AND RESISTANCE TO CURLING OF SAID COATED TILE BEING COMPARABLE TO THOSE OF THE UNTREATED BASE TILE, WHEREBY THE PRINTED TILE IS PRODUCED WITH ENHANCED WEAR PROPERTIES OBVIATING THE NEED FOR FREQUENT WAXING AND PROTECTING THE PRINTED EXTERIOR PLANAR SURFACE OF THE TILE.
Claim 3
Dependent Claim
41 words
The process of claim 1 in which the mix subject to calendering comprises asbestos fiber, fillers, vinyl chloride copolymer, plasticizer, pigment and a conventional amount of light and heat stabilizers, the printed tile produced thus comprising printed vinyl asbestos floor tile.
Claim 4
Dependent Claim
21 words
The process of claim 2 in which said coating is applied to the sheet with a thickness of about 0.003 inch.
Claim 5
Dependent Claim
30 words
The process of claim 3 in which said continuous sheet discharged from the calendering zone and thereafter printed, coated and irradiation-treated travels at from about 125 to about 175 ft./min.
Claim 6
Dependent Claim
24 words
The process of claim 2 in which the temperature at which the coated sheet is exposed to ultraviolet radiation is at least about 130*F.
Claim 7
Dependent Claim
13 words
The process of claim 2 in which said fluid coating contains a photosensitizer.
Claim 8
Dependent Claim
74 words
The process of claim 6 in which said fluid coating contains a vinyl monomer copolymerizable under ultraviolet radiation with said photo-polymerizable, multi-functional organic compound, said vinyl monomer being sufficiently stable to prevent gelation with said compound prior to exposure to said ultraviolet radiation, said monomer being present in an amount within the range of from about 15% to about 60% by weight based on the total weight of said organic compound and said monomer.
Claim 9
Dependent Claim
26 words
The process of claim 7 in which said monomer is employed in an amount within the range of from about 15% to about 45% by weight.
Claim 10
Dependent Claim
26 words
The process of claim 8 in which said monomer is employed in an amount within the range of from about 30% to about 35% by weight.
Claim 11
Dependent Claim
18 words
The process of claim 8 in which said photo-polymerizable ethylenically unsaturated groups are acrylyl groups of the structure
Claim 12
Dependent Claim
39 words
The process of claim 10 in which the image printed on the exterior planar surface of the sheet is preformed on the surface of a printing plate for transfer to said sheet as it passes through the printing zone.
Claim 13
Dependent Claim
27 words
The process of claim 10 in which said photo-polymerizable compounds contain polar groups taken from the group consisting of urethanes, ureas, amides, esters, epoxy and combinations thereof.
Claim 14
Dependent Claim
13 words
The process of claim 12 in which said polar groups comprise urethane groups.
Claim 15
Dependent Claim
13 words
The process of claim 12 in which said polar groups comprise ester groups.
Claim 16
Dependent Claim
22 words
The process of claim 12 in which said coating is exposed to ultraviolet light at a temperature of at least about 130*F.
Claim 17
Dependent Claim
34 words
The process of claim 15 in which said ultraviolet light exposure temperature is from about 130*F to about 180*F, said sheet being cut into individual tiles at a temperature of at least about 130*F.
Claim 18
Dependent Claim
19 words
The process of claim 16 in which said exposure time is from about 0.2 sec. to about 10 sec.
Claim 19
Dependent Claim
21 words
The process of claim 15 and including embossing or valley printing said sheet prior to coating with said fluid coating composition.
Claim 20
Dependent Claim
30 words
The process of claim 1 in which the mix subjected to calendering comprises asbestos, binder materials, fillers, antioxidant and pigments, the printed tile thus produced comprising printed asphalt floor tile.
Claim 21
Dependent Claim
24 words
The process of claim 19 in which the temperature at which the coated sheet is exposed to ultraviolet radiation is at least about 130*F.
Claim 22
Dependent Claim
16 words
The process of claim 20 in which the thickness of said coating is about 0.003 inch.
Claim 23
Dependent Claim
13 words
The process of claim 19 in which said fluid coating contains a photosensitizer.
Claim 24
Dependent Claim
74 words
The process of claim 22 in which said fluid coating contains a vinyl monomer copolymerizable under ultraviolet radiation with said photo-polymerizable, multi-functional organic compound, said vinyl monomer being sufficiently stable to prevent gelation with said compound prior to exposure to said ultraviolet radiation, said monomer being present in an amount within the range of from about 15% to about 60% by weight based on the total weight of said organic compound and said monomer.
Claim 25
Dependent Claim
26 words
The process of claim 23 in which said monomer is employed in an amount within the range of from about 15% to about 45% by weight.
Claim 26
Dependent Claim
18 words
The process of claim 24 in which said photo-polymerizable ethylenically unsaturated groups are acrylyl groups of the structure
Claim 27
Dependent Claim
39 words
The process of claim 25 in which the image printed on the exterior planar surface of the sheet is preformed on the surface of a printing plate for transfer to said sheet as it passes through the printing zone.
Claim 28
Dependent Claim
27 words
The process of claim 25 in which said photopolymerizable compounds contain polar groups taken from the group consisting of urethanes, ureas, amides, esters, epoxy and combinations thereof.
Claim 29
Dependent Claim
13 words
The process of claim 27 in which said polar groups comprise urethane groups.
Claim 30
Dependent Claim
22 words
The process of claim 27 in which said coating is exposed to ultraviolet light at a temperature of at least about 130*F.
Claim 31
Dependent Claim
21 words
The process of claim 29 in which said ultraviolet light exposure time is from about 0.2 sec. to about 10 sec.
Claim 32
Dependent Claim
21 words
The process of claim 30 and including embossing or valley printing said sheet prior to coating with said fluid coating composition.
Claim 33
Dependent Claim
348 words
A process for producing an improved vinyl asbestos or asphalt floor tile product comprising: a. calendering a uniform mix of vinyl asbestos or asphalt floor tile ingredients to form a continuous sheet discharged from the calendering zone at a temperature at least about 110*F to about 180*F and at a travel rate of at least about 80 ft./min.; b. printing predeterMined image on the exterior planar surface of the sheet during passage of said sheet through a printing zone essentially at the indicated travel rate; c. coating the continuous sheet having the desired image printed thereon and traveling essentially at said travel rate with a fluid coating composition containing essentially 100% active ingredients and comprising at least one organic compound having at least two photopolymerizable ethylenically unsaturated groups per molecule, said coating having a thickness of from about 0.001 inch to about 0.005 inch and being capable of curing upon exposure to ultraviolet light to form a hard, clear layer adhering to said sheet; d. exposing the thus-coated sheet traveling essentially at said rate immediately to ultraviolet light having wavelengths within the range of from about 2500 A to about 4000 A in a non-oxidizing atmosphere at a temperature of from about 110*F to about 220*F, the radiation intensity level being sufficient to initiate the desired curing of the coating within an ultraviolet exposure time of from about 0.2 sec. to about 15 sec.; and e. passing the thus-treated sheet traveling essentially at said rate to a cutting zone and therein cutting the thus printed, coated and treated sheet at a temperature of not less than about 120*F to form individual printed tiles having a clear wear layer thereon, the abrasion and scratch resistance properties of said coated tile both being significantly enhanced over said properties of the untreated base tile, the dimensional stability characteristics and resistance to curling of said coated tile being comparable to those of the untreated base tile, whereby the printed tile is produced with enhanced wear properties obviating the need for frequent waxing and protecting the printed exterior planar surface of the tile.
Claim 34
Dependent Claim
348 words
A process for producing an improved vinyl asbestos or asphalt floor tile product comprising: a. calendering a uniform mix of vinyl asbestos or asphalt floor tile ingredients to form a continuous sheet discharged from the calendering zone at a temperature at least about 110*F to about 180*F and at a travel rate of at least about 80 ft./min.; b. printing predeterMined image on the exterior planar surface of the sheet during passage of said sheet through a printing zone essentially at the indicated travel rate; c. coating the continuous sheet having the desired image printed thereon and traveling essentially at said travel rate with a fluid coating composition containing essentially 100% active ingredients and comprising at least one organic compound having at least two photopolymerizable ethylenically unsaturated groups per molecule, said coating having a thickness of from about 0.001 inch to about 0.005 inch and being capable of curing upon exposure to ultraviolet light to form a hard, clear layer adhering to said sheet; d. exposing the thus-coated sheet traveling essentially at said rate immediately to ultraviolet light having wavelengths within the range of from about 2500 A to about 4000 A in a non-oxidizing atmosphere at a temperature of from about 110*F to about 220*F, the radiation intensity level being sufficient to initiate the desired curing of the coating within an ultraviolet exposure time of from about 0.2 sec. to about 15 sec.; and e. passing the thus-treated sheet traveling essentially at said rate to a cutting zone and therein cutting the thus printed, coated and treated sheet at a temperature of not less than about 120*F to form individual printed tiles having a clear wear layer thereon, the abrasion and scratch resistance properties of said coated tile both being significantly enhanced over said properties of the untreated base tile, the dimensional stability characteristics and resistance to curling of said coated tile being comparable to those of the untreated base tile, whereby the printed tile is produced with enhanced wear properties obviating the need for frequent waxing and protecting the printed exterior planar surface of the tile.
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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) | 1978-12-01 | 1979-06-02 | 1979-12-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-12-01 | 1983-06-02 | 1983-12-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-12-01 | 1987-06-02 | 1987-12-02 | $7700.00 | Window Closed / Lapsed |