Abstract: A resilient floor tile is described that comprises a base; a protective film layer; and a decorative layer disposed between the base and the protective film layer; wherein the resilient floor tile has a top surface and a convex edge along a perimeter of the top surface. In another embodiment, the resilient floor tile comprises a decorative layer comprising a printed ink forming a decorative pattern disposed between a base and a protective film layer; wherein the decorative pattern extends over at least a portion of a contoured edge of the tile such that the decorative pattern is substantially undistorted. The process for making a resilient floor tile comprises preheating a printed tile blank; cutting and molding the printed tile blank concurrently to form a resilient floor tile having a convex edge along a top, outer perimeter of the resilient floor tile.

Abstract: A resilient floor tile is described that comprises a base; a protective film layer; and a decorative layer disposed between the base and the protective film layer; wherein the resilient floor tile has a top surface and a convex edge along a perimeter of the top surface. In another embodiment, the resilient floor tile comprises a decorative layer comprising a printed ink forming a decorative pattern disposed between a base and a protective film layer; wherein the decorative pattern extends over at least a portion of a contoured edge of the tile such that the decorative pattern is substantially undistorted. The process for making a resilient floor tile comprises preheating a printed tile blank; cutting and molding the printed tile blank concurrently to form a resilient floor tile having a convex edge along a top, outer perimeter of the resilient floor tile.

Abstract: A resilient floor tile is described that comprises a base; a protective film layer; and a decorative layer disposed between the base and the protective film layer; wherein the resilient floor tile has a top surface and a convex edge along a perimeter of the top surface. In another embodiment, the resilient floor tile comprises a decorative layer comprising a printed ink forming a decorative pattern disposed between a base and a protective film layer; wherein the decorative pattern extends over at least a portion of a contoured edge of the tile such that the decorative pattern is substantially undistorted. The process for making a resilient floor tile comprises preheating a printed tile blank; cutting and molding the printed tile blank concurrently to form a resilient floor tile having a convex edge along a top, outer perimeter of the resilient floor tile.

Abstract: In one embodiment the present invention provides a coated substrate comprising a substrate, a radiation-cured coating or a thermally-cured on at least a portion of the substrate, wherein the coating comprises an inherent macroscopic texture. In another embodiment, the present invention provides a pre-cured coating mixture comprising a radiation-curable resin and an initiator, or a thermally-curable resin and thermal initiator, wherein the radiation- or thermally-curable resin and the respective initiator form a pre-cured coating mixture capable of forming a macroscopic texture upon application of the mixture on a substrate. In another embodiment the present invention provides a pre-cured coating mixture comprising a radiation- or thermally-curable resin, an initiator, and texture-producing particles having an effective size to provide a macroscopic texture upon application of the mixture on a substrate.

Abstract: A resilient floor tile is described that comprises a base; a protective film layer; and a decorative layer disposed between the base and the protective film layer; wherein the resilient floor tile has a top surface and a convex edge along a perimeter of the top surface. In another embodiment, the resilient floor tile comprises a decorative layer comprising a printed ink forming a decorative pattern disposed between a base and a protective film layer; wherein the decorative pattern extends over at least a portion of a contoured edge of the tile such that the decorative pattern is substantially undistorted. The process for making a resilient floor tile comprises preheating a printed tile blank; cutting and molding the printed tile blank concurrently to form a resilient floor tile having a convex edge along a top, outer perimeter of the resilient floor tile.

Abstract: In one embodiment the present invention provides a coated substrate comprising a substrate, a radiation-cured coating or a thermally-cured on at least a portion of the substrate, wherein the coating comprises an inherent macroscopic texture. In another embodiment, the present invention provides a pre-cured coating mixture comprising a radiation-curable resin and an initiator, or a thermally-curable resin and thermal initiator, wherein the radiation- or thermally-curable resin and the respective initiator form a pre-cured coating mixture capable of forming a macroscopic texture upon application of the mixture on a substrate. In another embodiment the present invention provides a pre-cured coating mixture comprising a radiation- or thermally-curable resin, an initiator, and texture-producing particles having an effective size to provide a macroscopic texture upon application of the mixture on a substrate.

Abstract: In one embodiment the present invention provides a coated substrate comprising a substrate, a radiation-cured coating or a thermally-cured on at least a portion of the substrate, wherein the coating comprises an inherent macroscopic texture. In another embodiment, the present invention provides a pre-cured coating mixture comprising a radiation-curable resin and an initiator, or a thermally-curable resin and thermal initiator, wherein the radiation- or thermally-curable resin and the respective initiator form a pre-cured coating mixture capable of forming a macroscopic texture upon application of the mixture on a substrate. In another embodiment the present invention provides a pre-cured coating mixture comprising a radiation- or thermally-curable resin, an initiator, and texture-producing particles having an effective size to provide a macroscopic texture upon application of the mixture on a substrate.

Abstract: In one embodiment the present invention provides a coated substrate comprising a substrate, a radiation-cured coating or a thermally-cured on at least a portion of the substrate, wherein the coating comprises an inherent macroscopic texture. In another embodiment, the present invention provides a pre-cured coating mixture comprising a radiation-curable resin and an initiator, or a thermally-curable resin and thermal initiator, wherein the radiation- or thermally-curable resin and the respective initiator form a pre-cured coating mixture capable of forming a macroscopic texture upon application of the mixture on a substrate. In another embodiment the present invention provides a pre-cured coating mixture comprising a radiation- or thermally-curable resin, an initiator, and texture-producing particles having an effective size to provide a macroscopic texture upon application of the mixture on a substrate.

Abstract: In one embodiment the present invention provides a coated substrate comprising a substrate, a radiation-cured coating or a thermally-cured on at least a portion of the substrate, wherein the coating comprises an inherent macroscopic texture. In another embodiment, the present invention provides a pre-cured coating mixture comprising a radiation-curable resin and an initiator, or a thermally-curable resin and thermal initiator, wherein the radiation- or thermally-curable resin and the respective initiator form a pre-cured coating mixture capable of forming a macroscopic texture upon application of the mixture on a substrate. In another embodiment the present invention provides a pre-cured coating mixture comprising a radiation- or thermally-curable resin, an initiator, and texture-producing particles having an effective size to provide a macroscopic texture upon application of the mixture on a substrate.

Abstract: An improved process and means are disclosed for continuously forming tiles that are embossed in register with a printed design. In this process a base layer is formed on a continuously moving support surface and moved by the surface through printing, laminating and embossing stages wherein a printed design is applied to the base layer, a wear coat is laminated over the design, and the design is embossed. In accordance with the invention, the base layer is adhered to the support surface prior to transfer of the printed design thereto.

Abstract: An improved means is disclosed for continuously forming tiles that are embossed in register with a printed design. A printed design is first applied to a base coat and a wear coat is laminated over the design. Advantageously, the wear coat is applied to the printed web before it is heated for lamination. Before embossing occurs, the laminated product is cooled until partial setting occurs, and the embossing roll is sprayed with water in order to minimize the likelihood that the laminated product will adhere to the embossing roll. To avoid distorting the web during lamination and embossing, proper web tension is maintained by controlling the rotational speeds of the laminating drum and the embossing roll so that a desired ratio is preserved. The web is then cut into oversized tiles that shrink to size during annealing.

Abstract: An improved process suitable for continuously producing tiles which have the sharp and vivid coloring characteristics of ceramic tiles. In accordance with this process, a release paper is coated with a clear liquid plastisol layer. The clear liquid plastisol layer is given a completely smooth upper surface. A decorative design is then applied to the smooth upper surface by transfer printing. The printed plastisol is then covered with an opaque plastisol backing layer to form a cast wear layer comprising the clear plastisol layer, the printed pattern, and the opaque plastisol backing layer. The cast wear layer is then transferred to a continuous plastic base web that has been made previously so that the backing layer is in contact with the base web. The cast wear layer is laminated onto the base web, and this laminate is embossed using an engraved roll having raised sections which are images of the printed design.

Abstract: An improved process is disclosed for forming tiles that are embossed in register with a printed design. A printed design is first applied to a base coat and a wear coat is laminated over the design. Advantageously, the wear coat is applied to the printed web before it is heated for lamination. Before embossing occurs, the laminated product is cooled until partial setting occurs, and the embossing roll is sprayed with water in order to minimize the likelihood that the laminated product will adhere to the embossing roll. To avoid distorting the web during lamination and embossing, proper web tension is maintained by controlling the rotational speeds of the laminating drum and the embossing roll so that a desired ratio is preserved. The web is then cut into oversized tiles that shrink to size during annealing.

Abstract: A method is described for the continuous manufacture of inlaid vinyl sheeting using different colored plastisols and rotary screen printing equipment. The printing equipment comprises an unwind stand, an accumulator, a plurality of printing stations, a coating station, an oven, a second accumulator, and a wind up stand. Optionally an embossing station may also be used. Each printing station comprises (i) a rotary screen through which a different colored plastisol is squeezed to form a colored pattern on a base layer and (ii) a hot air dryer for partially drying the plastisol deposited on the base layer. In accordance with the invention, the viscosity of the plastisol and the rate of drying is such that plugs of plastisol are deposited on the base layer by each screen to form discrete portions of the total pattern created. Several different rotary screens are used to deposit these plugs of colored plastisols on the base layer so as to build up a pattern from the different colored plastisols.

Abstract: This controller may be used to direct operations of a remote station impact line printer whose data source is a host computer. The controller includes a microprocessor (CPU), a memory large enough to accomodate a plurality of lines of textual data, and host computer and printer interfaces arranged in a firmware implementation. A multiline buffering feature includes capability for receipt of incomplete lines and printing of partial lines. An overstrike feature includes capability for printing more than one character at the same print point (e.g., underlining, or "0") without intervening horizontal escapement commands such as backspace or carriage return.

Abstract: A method is described for the continuous manufacture of inlaid vinyl sheeting using different colored plastisols and rotary screen printing equipment. The printing equipment comprises an unwind stand, an accumulator, a plurality of printing stations, a coating station, an oven, a second accumulator, and a wind up stand. Optionally an embossing station may also be used. Each printing station comprises (i) a rotary screen through which a different colored plastisol is squeezed to form a colored pattern on a base layer and (ii) a hot air dryer for partially drying the plastisol deposited on the base layer. In accordance with the invention, the viscosity of the plastisol and the rate of drying is such that plugs of plastisol are deposited on the base layer by each screen to form discrete portions of the total pattern created. Several different rotary screens are used to deposit these plugs of colored plastisols on the base layer so as to build up a pattern from the different colored plastisols.

Abstract: Distortions during printing and laminating are minimized by printing the design on a stable base, preferably release paper, and then transferring the printed design to a hot plastic web made continuously by an extruder. A stress relieved hot plastic film is then laminated to the printed web to provide a protective wear coat. To emboss in register with the printed design, the laminated product is first aligned by means of registration marks that are printed along with the design. Embossing is then made using a conventional engraved roll having raised sections which are images of the printed design. After embossing, the web is partially cooled and annealed. It is then aligned with a die cutter using the same registration marks as used for alignment during embossing. As a result, individual tiles can be cut automatically in register to the printed and embossed pattern.

Abstract: A tile having pre-formed edges and an exposed decorative relief surface with high areas subject to greater than average wear and low areas subject to less than average wear is provided with a protective coating which is thicker on the high areas than on the low areas. The coating covers the exposed surface without covering the pre-formed edges. Such coatings are provided in high volume production apparatus by the steps of (a) providing a continuous succession of base tiles with abutting front and back edges; (b) spraying a first coating of protective material onto the exposed surface of the tile from one or more points vertically within the side edges; (c) at least partially curing the first coating; (d) applying a second coating of protective material primarily onto the high areas on the exposed surface by roller coating; and (e) curing the protective coating. In preferred embodiments, the protective coating material is cured by exposing it to ultraviolet radiation.