Note: Descriptions are shown in the official language in which they were submitted.
3~
1066/1142 -1-
~ecorative Surface Covering
And Process for its PreparatiOn
Background of the Invention
`~~, 5 Various methods have been suggested fox producing
a decorative surface covering containing reflective elements.
One such method is the lamination of a metalized mylar
. 7 sheet to a backing, printing a design on the surface of
` the metalized sheet and then applylng a transparent top
coating. Another method has ~een the applica~ion of an
adhesive to portions of a backing sheet, flocking meta-
~, llic parts onto the sheet and then coverlng wlth a
transparent top coating. Canadian patent 1,085,706
issued to L. E. Carpenter and Company is typical of such
a process.
The dlfficulty in such processes is the obtaining
of good adhesion between the top layer and backing and
the metalized areas. Further, aging causes a weakening
or complete destruction of the adhesive force. This can
be caused by the migration of the plasticizer from the
top laye~ into the adhesive layer. The process of the
invention overcomes the dlsadvantages of prior art processes.
Summary of the_Invention
In accordance with the invention a decorative
surface covering is produced utill~ing a metal foil
sheet. A surface covering product is printed with an
adhesive in spaced areas where it is desirable to have
reflective foil applied. A metal foil or film sheet is
; then super-imposed on the adhesive printed sheet with
the metal foil in contact with the adheslve. The ad-
hesive is then set to secure the metal foil to the base
and thereafter the metal foil is stripped from the base.
The portion of the metal foll in contact with the adhesive
remains adhered to the base and only the other portions
~, 35 of the metal foil are removed. The product can then
have a transparent wear layer applied over the adhered
, "~
1~66/1042 -2-
metal portions of the film and subjected to any other
type of processing including the fusion of the wear
layer. The wear layer readily adheres to the areas on
; 5 which there is no metal oil and thereby encapsulates
~,` each piece of metal foil securely binding the metal foil
piece to the base sheet. The resul~ing product has the
appearance of a complete metal layer although it is a
discontinuous sheet. The discontinuous nature of the
sheet has distinct advantages. The portions of the
' metal film and the wear layer are adhered securely to
the backing. Further it allows penetration of inhibitors
. to produce embos~ed products following the procPdure
~-~ of U.S. Patent 3,29~,094 which was issued December 20, 1966
~' 15 to Nairn et al.
Description of the Drawing
Figure 1 is a cross section view of a decorative
~ product made in accordance with the invention.
r Figure 2 is a schematic illustration of the
apparatus for carrying out the invention techniques
20 herein.
Fiqure 3 is a perspective view showing the
' location of the adhesive application.
Figure 4 is a cross section view of an intex-
25 mediate product showing metallic film pieces secured
to the adhesive.
Descri~tion of the Invention Including Preferred Embodiments
.
In one aspect the invention resides in a surface
covering and a process for the production the,reo*. The
surface covering comprises, in superimposed relationship,
(1) a backing sheet which can be a fibrous
felt or a polymer composition sheet,
(2) a background or coating atop of the backing,
~i (3) an adhesive, discontinued coating,
(4) portions of a metal film surface on one
side thereof adhered to the adhesive,
``~ (5) a printed decoration,
~ .
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~t73~
106611142 -3~
(6) a clear r transparent, or translucent wear
layer, through which the printed decoration and at least
some of the metal film portions are visable.
In a further aspect of the invention there is
~! provide~ a method for the production of the surface
~, covering as defined above which comprises
(a) coating a backing sheet with a resinous
composition,
(b) drying the resultant coated backing,
~j tc) applying by a rotogravure or silk-screen
.~~ method an adhesive composition in a discontinuous
pattern,
(d) drying said adhesive coating,
(e) adhering a metal film on one surface
thereof, to th~ adhesive coating,
--- (f3 setting the metal in the adhesive,
F (g) stripping the m~tal film from the backing
leaving portions of the metal film affixed to the adhesive
on tne base,
(h) applying a printed design,
(i) applying a wear layer to cover the
portlons of the metal film and prinked design,
(j) heating to fuse the wear layerO
Referring to the drawings, in one embodiment
of the invention, a decorative sheet is produced,
generally indicated at 10, haviny a backing 12 which can
be asbestos fiberous sheet, a resinous composition foam
layer 14 having depressed areas, generally indicated at
16 and raised areas, generally indicated at 18, a dis-
continuous adhesive layer 20 on the upper surface of the
foam layer~ comprising small areas of adhesive, a metal
sheet 22, adhering to the surface of the adhesive layer,
and coextensive with each of the small areas of adhesive,
a printed design 24, coveriny the metal areas and the
surface of fo~m layex, and a resinous composition wear
is
3f~2
1066/1142 -~-
layer 26, covering the printed design and if desired
the top coating 28 of polyurethane composition~
One o~ the embodiments for producing the decora-
tive product o the invention is shown in Figure 2. A
felt backing sheet is coated with a vinyl chloride resin
composition containing a blowing agent 13. The coating
is passed through an oven generally indicated at 15,
which heats the coating to solidify. The gelled coating
31, is then passed through one station press generally
indicated at 17, which applies adhesive 20, on the
surface of the gelled coating in the form of a roto-
gravure print of fine separate dots, squares or other
shapes 32, of adhesive which can be in the form of a
pattern, i.e. only on some areas of the gelled sheet.
This can be seen by referring to Figure 3. The printing
inks can utilize pigments or dyes (transparent, trans-
lucent or opaque) for colorationO The adhesive coated
sheet 33, is then passed through an oven generally indicated
at 1~ to tackify the adhesive. A vacuum metalized film 35,
more fully described hereinafter is unwound from a supply
roll 35' and brought into contact with the adhesive by
means of pressure roll 36. The composition 37 is then passed
through a cooling zone generally indicated at 21 to solidify
the adhesive. The metal film is then stripped from~the
base sheet by passing around take-off roll 39 and
winding on collector roll 41. Portions of the metal
film adhering to the adhesive remain in contact with the
adhesive and the stripping action removes only the portions
of the metal film which are not in contact with the
adhesive. The sheet 43, with the adhering metal portions
of the sheet are passed through a rotogravure press
generally indicated at 45 for applying a decorative
design to the surface of the sheet. the decorated
sheet 47 is then coated with a wear layer 26 by use of
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1066/1142 -5-
a reverse roll coater or doctor blade 48, and passed
throu~h an o~en generally indicated at 51. This latter
oven is heated to fuse the wear layer and decompose the
- 5 blowing agent to produce the finished product which is
collected on xoll 53. As an alternate procPdure a
~; decoratlon can be printed on the base prior ~o application
~_ of the metal film.
, The Backin~ Sheet Material
A relative flat, backing web or sheet material
may be used, if so desired or required, as the fibrous
backing sheet material or substrate 12, the most common
in the industry being a fibrous, felted asbestos or
cellulosic sheet. Many other types and forms of fibrous
backing sheet materials are, of course, utilizable within
the scope and spirit of the present invention and many
of these materials are described in the prior art t such
as in U. S. Patent 3,293,094. Such fibrous backing sheet
materials do not relate to the essence of the present
invention and may be omitted if so desired. The backing
can also comprise a resinous layer as hereinafter defined
or a fabric of natural or synthetic materials.
The Resinous Polymer Composition Layer
The resinous polymer composition layer 14 may
comprise a potentially foamable or non-foamable resinous
polymer composition which may be made by well-known
conventional and standard methods and techniques and may
contain sne or more synthetic resins, preferably a polymer,
copolymer, homopolymer, or terpolymer of vinyl chlorlde,
as the main constituent.
. ~ ~
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066/1142 -~-
Although polyvinyl chloride is the preferred and typical
resin, many other synthetic resins are equally applicable. The
specific synthe~ic resins which are used do not relate to the
essence of the present invention and many other suitable resins
are set forth in the previously ci~ed U.S. Patent 3,2~,094.
~i
Of partlcular use are the copolymers o vinyl chloride
with vinylidene chloride or with esters such as vinyl acetate,
vinyl propionate, vinyl butyrate, or alkyl substituted vinyl
esters. The copolymers of vinyl chloride with various acrylic
~! 10 compounds, such as acrylic acid and methacrylic acid and the
. esters thereof are also of use. Other resins such as poly-
strene, subs~ituted polystyrenes, polyolefins such as poly-
ethylene and polypropyle~e acrylates and methacrylates,
~i polyamides, polyesters etc., are ~lso applicable to the
principles of thP present invention.
Also, although such resins are preferably usP~d as plas-
tisols in the form of a dispersion or suspension of the resin
~IP`
in a plasticizer therefor, aquasols or aqueous latices and
organsols are of use in which th~ dispersing or suspending
, 20 medium is water or an organic solvent.
A few preferred and typical plasticizers used in the
formulation of such plas~isols are dibutyl sebacate, dioctyl
sebacate, butyl benzyl sebacate, dibenzyl sebacate, dioctyl
adipate, didecyl adipate, dihutyl phthalate, dicapryl phth-
alate, dioctyl ph~halate, dibutoxy ethyl phthalate, butyl
benzyl phthalate, dibenzyl phthalate, di (2-ethylhexyl)
,',.,s;
.,
....
~ 2
1066/1142 -7- -
phthalate, alkyl aryl modified phthalate esters, alkyl aryl
hydrocarbons, tricresyl phosphate, oc~yl diphenyl phosphate,
dipropylene glycol dibenzoate, dibasic acid glycol ester,
~ ~ epoxidiæed soya oil, epoxidized tall oil esters, and many
t~' 5 other primary and secondàry plasticizers.
Other consitituents of the resinous polymer composition
~ include: a blowing or foaming agent, such as azodicarbonamide,
51'
if a blowing or foaming procedure is desired; various accel-
erators, initiators, or catalysts such as diabasic lead ace-
tate, dibasic lead phosphate, etc.; various heat and light
stablilizers such as dibasic lead phosphite, phenyl phthalate,
etc.; UV absorbers; colorants such as dyes and pigments, par-
ticularly titanium dio~ide; solvents and diluents such as
methyl ethyl ketone, methyl isobutyl ketone 9 dodecyl benzene,
etc.; fillers such as clay, limestone, etc.; viscosity im-
provers; anti-oxidants; bacteriostates and bacteriocides; Ptc.
The specific nature and the particular physical prop-
erties and characteristics of the various constituents of
the resinous polymer composition do not relate ~o the essence
of the present inventive concept and further specific elabor-
ation of such additives is believed unnecessary and not re-
quired. All of these constituents are well known and con-
.
ventional in the industry and many are set forth in the
1 previously cited U.S. Patent 3,293,094.
D`- 25 The thickness of the resinous polymer composition, as
.~.
~ ,.c ~
., .
, ~
. .
31'~2
1066/11~2 -~-
t is applied to the backing sheet material and is still
wet, is in the range of from about 0.005 inch to about
0.060 inch.
After the resinous polymer composition has been
~'`', applied to the backing sheet material, i~ is then heated
in an oven or o~her suitable heating appara~us maintained
at an elevated tempera~ure of from about 240~ F. to about
450 F., and preferably from about 260 ~ to about 410 F.,
for a period of time of from about 1 minute to about 5
minutes, whereby lt gels and becomes firm. ~he tempera-
ture and the time are interdependent and the higher the
temperature, the shorter the time, and vice versa. The
elevated temperature, however, is not that high as to
.~15 activate or decompose any blowing or foaming agent which
Yimay be included in the formulatiorl of the resinous poly-
mer composition as to cause blowing or foaming at this
time.
Adhesi~e Layer
The resultant material is next placed through a
printing apparatus such as a gravure printing machine, and
the adhesive is applied to the smoothed~ coated ~urface
of the base. A tint such as 0.5% of carbon black can be
added to the adhesive in order to assure by visual detec-
tion that this adhesive remains on the base during sub
sequent treatment. The adhesive is deposited using any
suitable cylinder such a~ a gravure cylinder having 55
l.p.i. quadrahelic etch at the required level and dried.
It is preferred to utilized a heat-sensitive
layer. Any adhesive whlch conforms to ~his definition
may be used with such materials as 85-88% vinyl chloride,
11-14% vinyl acetate, 0.8-1.2~ maleic acid terpol~mers
1 ~ and the like being exemplary.
The adhe~ive coated product is then preheated
by passing it through an oven or heated drum (e.g., at
about 320 F.) with the back uncoated portion of the
.~`
~ '73~3~
1066/1142 -
~sheet in contact with the drum. At a point about 1/3
around the circumference of the drum, the coated surface
of the article is brough~ into contact with the metalized
polyethylene terephthalate film, the coated face of the
~, base being in contact with ~he metalized film. The two
webs continue around the heated drum and are then fed
between the smooth rollers of a laminating nip press.
Web temperature is controlled at about 270F. and the
10 laminate is consolidated into a unitary structure at
about 40 pli pressure on the chilled nip rollers. The
film carrier is then cooled to ambient conditions and
stripped from the backing.
A design is then printed on the surface including
15 on the metal portions using conventional gravure printing
cylinders and vinyl inks if desired. The printed design
may form a background of a design different from that of
the metallic particles, an outline design or the same or
an independent design.
20 _he Metallic Layer
The metallic layer is preferably a polyethylene
~ terephthalate film ranging in thickness from about 0.0005
t to about 0.005 inch. It has a metal film of about 1 to
about 10 micron of which aluminum is preferred. Other
25 metals such as copper, nickel etc. can be used. The
~` metal film is thin and is applied onto the polyethylene
terephthalate by vacuum deposition as is known in the
art. Th~ polyethylene terephthalate film is preferably
biaxially oriented and is also known in the art. The
30 metal film can be colored.
The metallic carrier film, as described above,
r¦ is applied to the base with the metal side facing said
base by heat and/or pressure. As an alternative, the
adhesive can be applied to the metalized film rather
~` 35 than on the base layer and then laminated to the base.
~,
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1066/1142 -10-
Lamination and Stripping
The next step in ~he process is the lamination
of the metal sheet to the adhesive coated base with the
metal surface in contact wlth the adhesive. Prior to
~`~; this lamination the adhesive is tacktified. The system
for accomplishing this will depend on the nature of the
adhesive. If ~he adhesive is a thermoplastic or thermo
setting then the tacktificiation can usually take place
by applying heat. In any event the metal film is brought
~, into contact with the tacktified adhesive and passed
i through a compressor roller which forces the metal sheet
into contact with the adhesive. ~he adhesive is allowed
to solidify such as by cooling and then the carrier
~! 15 sheet is stripped from the base. Because of the adhesive
those areas of the metal film in contact with the adhesive
will remain on the sur~ace of the base, the carrier film`
removed ~herefore has areas of metal missing, corres-
~; ponding to the areas which remain adhered to the base.
The carrier sheet i5 wound on a collecting roller. Asindicated above, as an alternate procedure, the adhesive
can be applied to the carrier sheet and then the adhesive
coated metallic carrier ~rought into contact wi~h the
base. As a general rule the base sheet area covered
should not exceed 80% of the surface of the base.
Decorative Print
A print design can be applied to the surface
layer, utilizing any conventlonal gravure printing
~- equipment. The use of vlnyl inks is preferred, however,
any other type of ink which enables the design to be
`~ readily printed onto the polyester surface may be used
such as acrylic gravure printing inks and the like.
The Printing of the Resinous Polymer Composition
The gelled and firmed resinous polymer composition
after removal of the unwanted carrier film can then be
printed or coated with a printing ink composition
.~
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1066/1142 -11-
containing a colorant such as a dye or a pig~nent, if a
design or a pattern is desired or required to appear in
the final product. ~he p~inting composition may also
contain resins, plasticizers, stabilizers, anti-oxidants,
blowing or foaming inhibitors in selected areas, etc.
, Drying or hardening of the applied printing ink composi-
tion can be accomplished by air-drying, or by conventional
~I he~ting procedures. Preferred and typical printing ink
compositions are to be noted in the previously cited
U.S. Patent 3,293,094. The printing could be beneath
the metalized a~e~ for certain design effects.
The Wear Layer
The relatively flat, resinous pol~ner composi-
tion wear layer 16 has an average thickness of from about
; 15 0.002 inch to about 0.025 inch and is applied substantially
' uniformly to the surface of the printed, gelled and firmed
: resinous polymer composition 14. The wear layer 16, in
~, normal practice, is usually a clear, unpigmented ~esinous
polymer composition and its basic purpose is customarily
to give to the resilient floor covering improved wearing
qualities. Many of the constituents of the previously
described non-foamable resinous polymer compositions are
also present in the formulation of the wear layer 16,
notably the polyvinyl chloride polymers, or the other
previously mentioned polymers, as well as plasticizers,
stabilizers, etc. Blowing or foaming agents and pigments
or dyes are normally omitted. Typical formulations of
preferred and typical wear layers 16 are to be found in
i the previously cited U.S. Patent 3,293,094. After the
, 30 wear layer 16 has been applied to the printed, gelled
. ~ and firmed resinous polyme~ composition 14/ it is then
heated in an oven or other suitable heating apparatus
maintained at an elevated temperature of from about 240F.
to about 410~., and preferably from about 260F. to
about 410F. for a period of time of from about 1 minute
i~, to about 5 minutes, whereby it gels and becomes firm.
Again, the temperature and the time are interdependent and
no blowing or foaming may take place at this time.
``:
~'7~2
. lu~/il42 -12-
If desired, the preceding gelling and firming process
may be combined with a fusing and blowing or foaming process
by heating to a higher temperature, the specific temperatures
of each process : being dependent upon ~he chemical and
physical properties and characteristics of ~he resinous poly-
mer composition 14 and the wear layer 16, the specific syn-
r ~hetic resins therein, and the nature of ~he blowing or
foaming ag~nt employed. Under normal conditions, fusing and
blowing or foaming may take place by exposure to elevated
temperatures of from abou~ 2~0F. to abour 460~F. and pref-
erably from about 270F. to about 420F. for periods of time
. from about 2 minutes to about 10 minutes.
The resulting product is shown in Figure 1 wherein
there is illustrated a blown resinous polymer sheet ma~erial
generally indicated at 20 comprising a fibrous backing sheet
material or subs~rate 22 upon which has been deposited and
adhered a blown resinous polymer composition layer 24, on top
of:which has been deposited a now uniform layer of a metall-
ized sheet adhered by an adhesive and adhered another relative-
` 20 ly flat, resinous polymer composition wear layer 26, and a top
.
coating 28 to be described more fully hereinafter.
. ~ And, if blowing or foaming inhibitors were used in order
to modify the blowing or foaming effects, the resulting pro-
` duct is shown in ~igure 1 wherein there is illustrated a
L" blown and embossed resinous polymer sheet material generally
-~. !
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~ ~ ~ 7 3
1066/1142 -13-
indicated at 30 comprising a fi~rous backing sheet material
or substrate 32 upon which has been deposited and adhered
a blo~ resinous polymer composition layer 34, on top of
`-.ii which has been deposited and adhered another relatively flat,
but now embossed, resinous polymer composition wear layer
36, and a top coating 38 comprising lands or higher portions
37 and mortars or lower portions 39, which will be descirbed
-~ in greater detail hereinafter.
~ THE TOP COATING
? A top coating 28 or 38 which can be applied to ~he
firmed and gelled or fused surface of the wear layer 26
or 36 comprises a polyurethane composition lay~r to give the
product gr~ater gloss retention. Such a top coating is des-
cribed in U.S. Patent 4,059,709.
The following example is set forth for purposes of illus-
tration only and is not to be construed as a limitation on
the present inYentiOn. All parts and percentages are by
weight unless otherwise specified.
EXAMPLE 1
A relatively flat, fibrous felt backing sheet of 0.030
inch thick asbestos fibers i8 impxegnated with 5% of a urea-
formaldehyde resin and 25% of a copolymer of butadiene andacrylonitrile. The resin-impregnated asbestos fiber sheet
is then heated to cure the resin. In addition, the asbestos
fiber sheet is coated on one surface with a Bize of one-half
methyl methacrylate and one-half butyl acrylate in an amount
equal to 0.025 pounds per square yard, followed by a drying
of $he size coat.
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1066/11~2 -14-
A foamable plastisol coating composition is applied
substantial}y uniformly to the surface of the sized back-
ing sheet material at an average thlckness of about 0.010
inch. The plastisol has the following formulation:
~, Parts
Polyvinyl chlorlde, dispersion grade,
specific viscosity 0.6 50
Polyvinyl chloride, dispersion grade,
10 specific viscosity 0.4 50
Butyl benzyl phthalate plasticizer52
~' Alkyl aryl hydrocarbon secondary
plasticizer 18
Azodicarbonamide blowing agent 3
~ 15 Zinc oxide stabilizer-accelerator 2
`~, Titanium dioxide pigment 5
~~~ The plastisol coatlng composltion is heated and
~`, gelled to a firm condition in an oven maintained at an
elevated temperature of about 300 F. The exposure time
20 for the heatlng is about three minutes.
The sheet is then passed through one station of
a rotogravure press which applies an adhesive having the
following composition in designated areas:
Parts
~5 Nitril ~ynthetic rubber with phenolic
modification (22% solids) (G414 of
National Startch and Chemical Company/
- Bloomfield, N. ~.) 50
' Methyl ethyl ketone 50
- 3U Since the adhesive is applied by a rotogravure roll, it
~r is formed of a series of dots or squares of about 120
ne screen. Approximately 75% of the surface of the
base was covered with adhesive.
The adhesive coated sheet is then heated to
tacktify its adhesive and a metalized carrier film is
pressed with the metal side against the adhesive by
passing through pressure rollers which exert a pressure
of about 40 pounds. The metal carrier fllm consists
~,
3'7~2
1066/1142 -15-
of a 0.0005 inch biaxially oriented film of polyethylene
terephthalate having on one side theraof a thin, vacuum
deposited aluminum layer~ The adhesive is ~hen cooled to
solidify and adhere the metal side of the carrier film
~v to the base. The carrier film is then stripped from the
surface by passing around rollers. The metal in contact
; with the adhesive readings adhered to the base and the
remainder of the metallic surface is removed and the
carrier film wound on a take up roller.
' The sheet is then printed with ~ pattern
utilizing printing inks having the following formu-
lations with the parts by weight:
~- Inhibitor Pxinti~ InkParts
15 ~inyl chloride-vinyl acetate copolymer 8.5
Methyl ethyl ketone 51.5
Pigment tTitanium dioxide pigment
~, 55~ solids) 25.0
Trimetellitic anhydride inhibitor15.0
Printinq Ink Parts
Vinyl chloride-vinyl acetate copolymer 13.5
Methyl ethyl ketone 61.5
Pigm~nt 25.0
. No inhibitor 0.0
The applied printing ink compositions are dried.
-, A weax layer composition having the following
formulation by weight is then applied over the surface
- of the printed sheet, substantially uniformly to an
average thickness of about 0.015 inch.
Parts
Polyvinyl chloride, dispersion grade,
specific viscosity 0.5 95.0
Polyvinyl chloride, suspension grade,
. specific viscosity 0.35 5.0
Alkyl aryl modified phthalate ester plasticizer 38.0
Epoxidized tall oil ester secondary plasticizer 5.0
~, Stabilizer 3.0
3'~2
1066/1142 -16-
Parts
Viscosity control agent 1.2
Dibutyl tin dilaurate 0.11
The composite product is then heated in a fusion oven
~ maintained at an elevated temperature of about 385 F.
! ~' for a period of exposure time of about 2 minutes and
45 seconds. Fusion of the polyvinyl chloride resins
~i takes place, along with the decomposition or activation
of the azodicaxbonamide blowing or foaming agent and the
plastisol composition is blown or foamed and embossed in
~ accordance with the printed pattern or design containing
-~ designated areas with trimellitic anhydride inhibitor
therein and other designated areas not containing any
~s 15 inhibitor.
;' The resulting product has a metallic appearance
~j in the areas of metallic foil and transparent inks. The
`~ product is also found to possess good resistance to abrasion,
good flexibility and impact resistance, good toughness, good
i
high gloss retention, good surface texture
and improved adhesion of wear layer to metalized substrates.
EXAMPLE 2
The procedures of Example 1 were followed except
that the adhesive was applied to the metal side of the
metallic sheet instead of to the foamable base coating.
The adhesive utilized was a vinyl chloride-vinyl acetate
compound (86/14).
.
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1066/1142 -17
The procedures of Example 1 were followed except
that the adhesive is applied overall and a metallized
: 5 carrier sheet, which ha~ already been used ~removing
about 50% of the metal), is pressed against the adhesive.
This example, shows the multiple use of the me~allized
sheet to reduce costs. If only certain separated areas
- require high reflectivity, the metallized sheet can be
used several times.
! EXAMPLE 4
A foamable plastisol coating is applied
substantially uniformly to the surface of a 6 mil paper
of the type typically used for wall covering at an
average thickness of about 0.005 inch. The plastisol
has the following formulation:
Parts
Polyvinyl chloride, dispersion grade,
specific viscosity 0O5 50
20 Polyvinyl chloride, dispersion grade,
specific viscosity 0.36 25
Polyvinyl chloride, suspension grade
blending resin, specific viscosity 0.3 25
Bentyl benzyl phthalate plasticizer 37.5
Alkyl aryl hydrocarbon secondary plasticizer 12.5
Diethyl hexyl phthalate plasticizer 10
Azodicarbonamide blowing agent 4
Zinc oxide stabilizer-accelerator
Titanium dioxide pigment 8.5
The plastisol coating composition is heated and
~ gelled to a firm condition in an oven maintained at about
! 300 F. for about three minutes. The sheet is then
passed through a one station rotogravure press which
. ~ applies in designated areas an adhesive having the
following composition:
~,
. ~, .
~,
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3739~
1066~1142 -18-
Parts
BONDMASTER G414-22~ 50
Methyl ethyl ketone (used to adjust
5 to a workable viscosity - about) 50
~'~. *G414-22 is an amber-tan nitrile synthetic
rubber/phenolic resin composition
(22% solids) in methyl e~hyl ketone with a
viscosity of about 650 cps.
The adhesive coated sheet is dxied. It is then
heated to 250 F. 300 F. to ~ackify the adhesive and
a metallized carrier sheet is pressed with the metal
side against the adhesive by passing through pressure
rolls which exert about 40 pounds of pressure. After
cooling, the carrier sheet is stripped from its surface.
The metal adheres to the adhesive giving a discontinuous
metal film on ~he vinyl substrate. The sheet is then
printed as described in E~ample 1. Or, as i5 quite
common for wall coverings, it could be silk screen printed
in the desired design using silk screen printing inks.
A wear layer composition is then applied over
the surface of the printed sheet, substantially uniformly
to an average thickness of 2 mils. The wear layer has ~he
following formulation:
Parts
Polyvinyl chloride, dispersion grade,
sp~ci~ic viscosity 0.6 95
Polyvinyl chloride suspension grade,
specific viscosity 0.35 5
30 Bentyl benzyl phthalate plasticizer 30
Alkyl and hydrocarbon secondary plasticizer10
2,2,4-trimethylpentanediol-1,4 benzoate
isobutyoate 20
Epoxidized tall oil ester secondary plasticizer 5
Viscosity control agent
Stabiliæer 3 ~
:.
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1066/1142 -19-
The composite p~oduct is then heated in a~ oven at
about 385 F. for about 2~ minutes.
Fusion of the polyvinyl chloride resins takes
5 place, along with the decomposition or activation of the
.j azodicarbonamide blowing or foaming agent and the
plastisol composition is blown or foamed and embossed
in accordance with the printed pattern or design containing
designated areas with trimellitic anhydride inhibitor
10 therein and other designated areas not containing any
inhibitor.
The resulting product has a metallic appearance
~j in the desired areas. The product lS also found to
possess good resistance to abrasion and scuffing, good
15 flexibllity and toughness and good surface texture.
` Although the present ~nventlon has been described
in great particularity in the preceding specifi examples
~ wherein there are shown preferred and typical embodiments
L of the inventive concept, such is not to be construed as
20 limitative of the broader aspects of the inventive concept
but only illustrative thereof. The specific materials,
chemicals, patterns, designs and other particular aspects
of such examples are simply illustrative and do not limit
the broader scope o the invention which lS limited and
25 defined by the scope and the spirit of the appended
claims.
`
,
, ~
