US4052236A — Method of preparing imitation sheet material

Claim 1

Independent Claim 171 words

A process of preparing a polymeric sheet material with a three-dimensional surface design thereon, which process comprises: a. applying to depressed areas of an embossed release sheet having a design effect thereon a first polymer characterized by a high modulus of elongation in psi. at 100% elongation of about 2000 to 8000 psi.; b. applying a continuous layer of a second polymer characterized by a low modulus of elongation in psi. at 100% elongation over the first polymer in the depressed areas, the difference in the modulus of elongation between the first and second polymers being no less than 800 psi.; c. removing the release sheet to provide a polymeric sheet material composed of a continuous layer of a low modulus polymer, with raised areas composed of a high modulus polymer secured thereto; and d. flexing the low modulus polymer in the intervening low areas between the raised high polymer areas to the polymeric sheet to form a weak-hinge effect, thereby providing a sheet material with an accentuated design effect thereon.

Claim 2

Dependent Claim 171 words

A process of preparing a polymeric sheet material with a three-dimensional surface design thereon, which process comprises: a. applying to depressed areas of an embossed release sheet having a design effect thereon a first polymer characterized by a high modulus of elongation in psi. at 100% elongation of about 2000 to 8000 psi.; b. applying a continuous layer of a second polymer characterized by a low modulus of elongation in psi. at 100% elongation over the first polymer in the depressed areas, the difference in the modulus of elongation between the first and second polymers being no less than 800 psi.; c. removing the release sheet to provide a polymeric sheet material composed of a continuous layer of a low modulus polymer, with raised areas composed of a high modulus polymer secured thereto; and d. flexing the low modulus polymer in the intervening low areas between the raised high polymer areas to the polymeric sheet to form a weak-hinge effect, thereby providing a sheet material with an accentuated design effect thereon.

Claim 3

Dependent Claim 23 words

The process of claim 1 wherein the second polymer has a modulus of elongation at 100% elongation from about 300 to 3,000 psi.

Claim 4

Dependent Claim 27 words

The process of claim 1 wherein the first or second polymers are selected from a group consisting of aliphatic urethane elastomers, vinyl chloride resins and combinations thereof.

Claim 5

Dependent Claim 25 words

The process of claim 1 wherein the raised areas of the first polymer represent over about 80% of the surface area of the polymeric sheet.

Claim 6

Dependent Claim 26 words

The process of claim 1 which includes the step of securing a fibrous sheet material to one surface of the continuous layer of the second polymer.

Claim 7

Dependent Claim 21 words

The process of claim 1 wherein flexing the low modulus polymer includes subjecting the polymeric sheet to an oscillating-type tumbling action.

Claim 8

Dependent Claim 63 words

The process of claim 1 which includes applying to the continuous layer of the second polymer a woven fabric sheet material, and flexing the low modulus polymer by subjecting the woven fabric surface of the polymeric sheet to moisture and heat and to a mechanical action, so as to flex the low-modulus second polymer in the intervening low areas of the polymeric sheet.

Claim 9

Dependent Claim 26 words

The process of claim 1 which includes coating the top surface of the raised area with a polymeric layer to enhance further the surface design effect.

Claim 10

Dependent Claim 45 words

The process of claim 1 which includes coating a layer of an adhesive material onto the surface of the continuous layer of the second polymer, and placing onto the adhesive material and bonding to the continuous layer of the second polymer a flexible sheet material.

Claim 11

Dependent Claim 29 words

The process of claim 1 wherein the difference in the modulus of elongation at 100% elongation between the first and second polymers ranges from about 4300 to 5300 psi.

Claim 12

Dependent Claim 18 words

The process of claim 1 wherein the continuous layer of the second polymer is a flexible foam layer.

Claim 13

Dependent Claim 37 words

The process of claim 11 wherein the step of flexing the low modulus polymer layer includes subjecting the polymeric sheet to moisture and heat to provide for shrinkage of a fabric sheet bonded to the continuous layer.

Claim 14

Dependent Claim 232 words

A process of preparing a polymeric imitation leather-type material having an enhanced grain-like surface appearance, which process comprises: a. casting into the depressed valley areas of a preembossed paper release sheet having a design effect embossed therein a liquid composition of a first polymer of an aliphatic polyester urethane elastomer or a vinyl chloride resin, the polymer characterized by a high modulus of elongation in psi. of 100% elongation of from about 2000 psi. to 8000 psi.; b. casting a continuous layer of a liquid composition of a second polymer of an aliphatic polyester urethane elastomer or a vinyl chloride resin over the first polymer, the second polymer characterized by a low modulus of elongation in psi., and having a modulus of at least 800 psi. lower than the first polymer; c. heating the polymers to effect the solidification thereof; d. laminating a shrinkable fibrous supporting sheet material to one surface of the second polymer; e. stripping the paper release sheet to provide a laminated sheet material with slightly raised areas composed of the high modulus polymer, the raised areas representing a substantial part of the surface area; and f. subjecting the laminated sheet material to a combination of heat and moisture and mechanical means to provide flexing and fractioning of the low modulus polymer in the valley areas to form a weak hinge in such areas, thereby accentuating the design effect.

Claim 15

Dependent Claim 232 words

A process of preparing a polymeric imitation leather-type material having an enhanced grain-like surface appearance, which process comprises: a. casting into the depressed valley areas of a preembossed paper release sheet having a design effect embossed therein a liquid composition of a first polymer of an aliphatic polyester urethane elastomer or a vinyl chloride resin, the polymer characterized by a high modulus of elongation in psi. of 100% elongation of from about 2000 psi. to 8000 psi.; b. casting a continuous layer of a liquid composition of a second polymer of an aliphatic polyester urethane elastomer or a vinyl chloride resin over the first polymer, the second polymer characterized by a low modulus of elongation in psi., and having a modulus of at least 800 psi. lower than the first polymer; c. heating the polymers to effect the solidification thereof; d. laminating a shrinkable fibrous supporting sheet material to one surface of the second polymer; e. stripping the paper release sheet to provide a laminated sheet material with slightly raised areas composed of the high modulus polymer, the raised areas representing a substantial part of the surface area; and f. subjecting the laminated sheet material to a combination of heat and moisture and mechanical means to provide flexing and fractioning of the low modulus polymer in the valley areas to form a weak hinge in such areas, thereby accentuating the design effect.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1980-10-03	1981-04-04	1981-10-04	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1984-10-03	1985-04-04	1985-10-04	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1988-10-03	1989-04-04	1989-10-04	$7700.00	Window Closed / Lapsed

Method of preparing imitation sheet material

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