Abstract: Disclosed is a method of manufacturing a mechanically and chemically embossed surface covering having selectively textured surfaces. The method includes forming a web coated with a wear layer. The coated web is heated to a temperature at which the wear layer is cured, the foam layer expands, and the pattern is chemically embossed to form a surface covering having foamed regions and nonfoamed regions. The temperature gradient of the surface covering is adjusted such that there is a temperature gradient difference between the foamed and nonfoamed regions. A surface texture is then mechanically embossed into the wear layer and selectively set onto the wear layer substantially overlying the non-foamed regions.

Abstract: A preglued underlayment assembly comprises a substantially rigid underlayment having an upper and a lower surface, a pressure sensitive adhesive layer disposed on the upper surface, and a release layer disposed on the adhesive layer. Another pressure sensitive adhesive layer and another release layer optionally are provided on the lower surface of the preglued underlayment. One or more performance enhancing layers, such as foam and solid layers, can be disposed between the underlayment and the adhesive layer to modify and/or enhance various properties of the preglued underlayment. Mechanical fasteners, such as staples, penetrate the preglued underlayment assembly and engage a structural support member to attach the preglued underlayment assembly thereto.

Abstract: Improved durability and sharper chemical embossing images are obtained in a thick foamed thermoplastic floor structure by the use of an unfoamed inner layer. The floor covering is formed on a release paper and includes an unfoamed thermoplastic base coat, lower foamed thermoplastic layer, an unfoamed thermoplastic inner layer, an upper foamed thermoplastic layer and a clear coat. The enhanced chemical embossing is achieved by printing an inhibitor containing ink on the inner layer and below the upper foamed layer. Multilevel embossing is obtained by embossing both foamed thermoplastic layers or applying a growth-controlling agent to both surfaces of one foamable thermoplastic layer. The preferred embodiment includes a pearl platelet containing layer above the upper foamed layer to give the illusion of deeper embossing. The preferred embodiment also includes a wear coat of the reaction product of an aminoplast, a urethane and a polyol.

Abstract: Improved durability and sharper chemical embossing images are obtained in a thick foamed thermoplastic floor structure by the use of an unfoamed inner layer. The floor covering is formed on a release paper and includes an unfoamed thermoplastic base coat, lower foamed thermoplastic layer, an unfoamed thermoplastic inner layer, an upper foamed thermoplastic layer and a clear coat. The enhanced chemical embossing is achieved by printing an inhibitor containing ink on the inner layer and below the upper foamed layer. Multilevel embossing is obtained by embossing both foamed thermoplastic layers or applying a growth-controlling agent to both surfaces of one foamable thermoplastic layer. The preferred embodiment includes a pearl platelet containing layer above the upper foamed layer to give the illusion of deeper embossing. The preferred embodiment also includes a wear coat of the reaction product of an aminoplast, a urethane and a polyol.

Abstract: A vinyl floor covering to accommodate wood subfloor contraction and expansion as well as rolling load incorporates a foamed plastisol encapsulated glass mat which may be cut to form pivot points and expanded under a controlled pre-stressed condition. The glass mat serves as a carrier during manufacture and an "elastic glass" reinforcing layer during use as either tension or loose-lay flooring. The floor covering may be a true hybrid surface covering which is capable of accommodating the dimensional change of a target subfloor by utilizing the characteristics of both tension floorings and loose-lay floorings.

Abstract: A vinyl tension floor covering includes a reinforcing layer, preferably disposed below the neutral bending plane. The floor covering elongates in at least one direction due to a controlled pre-stressed condition and tends to return to its original pre-elongated dimension. Reinforcing layers expand in the across machine direction as well as machine direction in response to a tensile stretching force in the machine direction or roll-up growth.

Abstract: A vinyl floor covering to accommodate wood subfloor contraction and expansion as well as rolling load incorporates a foamed plastisol encapsulated glass mat which may be cut to form pivot points and expanded under a controlled pre-stressed condition. The glass mat serves as a carrier during maufacture and an "elastic glass" reinforcing layer during use as either tension or loose-lay flooring. The floor covering may be a true hybrid surface covering which is capable of accommodating the dimensional change of a target subfloor by utilizing the characteristics of both tension floorings and loose-lay floorings.

Abstract: A method of manufacture for producing a decorative laminate which exhibits through-color printing is provided in which a layer of absorptive PVC resin particles of substantially only one particle thickness is printed with, for example, three differently colored vinyl plastisol printing inks. The decorative article is useful as a floor covering.

Abstract: The present invention relates to structures exhibiting unique appearances resulting from the presence of crinkled chip materials. A reflective and/or nacreous platelet or flake material is intermixed with a plasticizer and a general purpose resin, and the mixture is formed into a reflective sheet. The reflective sheet is pulverized to provide a chip material which is then used alone or in combination with other chips to form a mottle comprising a vinyl chloride resin and a plasticizer. Upon consolidating the mottle into a decorative surface, the nacreous and/or reflective chips are found to surprisingly exhibit an enhanced crinkled appearance, thereby exhibiting unique aesthetic properties.

Abstract: The present invention relates to structures exhibiting unique appearances resulting from the presence of crinkled chip materials. A reflective and/or nacreous platelet or flake material is intermixed with a plasticizer and a general purpose resin, and the mixture is formed into a reflective sheet. The reflective sheet is pulverized to provide a chip material which is then used alone or in combination with other chips to form a mottle comprising a vinyl chloride resin and a plasticizer. Upon consolidating the mottle into a decorative surface, the nacreous and/or reflective chips are found to surprisingly exhibit an enhanced crinkled appearance, thereby exhibiting unique aesthetic properties.

Abstract: A decorative laminate is provided which includes a printed layer of absorptive PVC resin particles of substantially only one particle thickness which can be printed with, for example, three differently colored vinyl plastisol printing ink compositions, and which exhibits through-color printing. The decorative article is useful as a floor covering.

Abstract: The present invention relates to superior wear layer-coated embossed surface coverings which are prepared by depositing a cross-linking inhibitor on at least a portion of the surface of a cross-linkable foam formed on a backing and containing a cross-linking initiator. Preferably a wear layer is applied at this point and cross-linking of the affected areas is accomplished by heating the sheet. The sheet of material is either uniformly or differentially heated and then uniformly compressed to a desired embossing depth using a non-patterned press or roll. The noncross-linked regions remain depressed upon removal of the compressing force whereas the cross-linked regions return essentially to their original height. The wear layer remains in contact with all of the foam regions so that the resulting sheet of material has a wear layer which is uniformly adhered to the contour of the foam layer. The surface of the sheet has an embossed or textured finish.

Abstract: A decorative laminate and method of manufacture therefor are provided wherein the laminate has a differential texture and a differential gloss wherein the textured regions contain PVC resin particles and have a lower gloss than adjoining regions without PVC resin particles. The decorative article is useful as a floor covering.

Abstract: The present invention relates to polyvinyl chloride resin particles which are colored with cationic dyestuffs, to a process of making them, and to plastisols produced therefrom. Resin particles are preferably heated in a solvent medium which preferably is water or comprises water, the solvent medium being suitable to dissolve the cationic dyestuff. The dye penetrates and dyes the particles. Particulate material can be produced having diverse characteristics.

Abstract: A decorative laminate and method of manufacture therefor are provided wherein the laminate has a differential texture and a differential gloss wherein the textured regions contain PVC resin particles and have a lower gloss than adjoining regions without PVC resin particles. The decorative article is useful as a floor covering.

Abstract: The present invention relates to superior wear layer-coated embossed surface coverings which are prepared by depositing a cross-linking initiator on at least a portion of the surface of a cross-linkable foam formed on a backing. Preferably a wear layer is applied at this point and cross-linking of the affected areas is accomplished by heating the sheet. The sheet of material is either uniformly or differentially heated and then uniformly compressed to a desired embossing depth using a non-patterned press or roll. The noncross-linked regions remain depressed upon removal of the compressing force whereas the cross-linked regions return essentially to their original height. The wear layer remains in contact with all of the foam regions so that the resulting sheet of material has a wear layer which is uniformly adhered to the contour of the foam layer. The surface of the sheet has an embossed or textured finish.

Abstract: A process of forming an embossed surface covering is disclosed. The process comprises forming a crosslinkable foam on a backing, depositing an activator composition to initiate cross-linking on at least a portion of the crosslinkable foam, and heating the resulting crosslinkable foam-containing sheet to a temperature sufficient to crosslink the portions of the foam affected by the deposition of activator composition and melt the portions of the foam not affected by the deposition of activator composition.

Abstract: A process of forming an embossed surface covering is disclosed. The process comprises forming a cross-linkable foam comprising at least one polymer and having a first phase region and a second phase region; heat the foam to a temperature at least equal to the flow temperature of the first phase region; compressing the heated foam and cooling the foam while compressed; cross-linking a portion of the compressed foam; and reheating the compressed foam to permit the noncross-linked portion of the foam to return or "pop back" to substantially its precompressed shape and thus form an embossed surface covering.

Abstract: A process of forming an embossed surface covering is disclosed. The process comprises forming a crosslinkable foam on a backing, depositing a deactivator composition to inhibit cross-linking on at least a portion of the cross-linkable foam, and heating the resulting crosslinkable foam-containing sheet to a temperature sufficient to crosslink the portions of the foam not affected by the deposition of deactivator composition and melt the portions of the foam affected by the deposition of deactivator composition.

Abstract: A process of forming a surface covering having decorative effects is disclosed. The process comprises forming a foam comprising at least one polymer having at least a first phase region and a second phase region on a backing, heating the foam to the flow temperature of the first phase region of the foam, compressing the heated foam and cooling the foam while in the compressed shape, thus facilitating coating the surface of the foam which remains in the compressed shape, and reheating the foam to permit the compressed foam to return to substantially its precompressed shape.