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: 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: An asbestos free composition suitable for the manufacture of vinyl floor tile comprises a substantially uniform mixture of a minor portion of vinyl polymer resin and a major portion of mineral filler consisting essentially of calcium carbonate and Kaolin clay. Formulations using such a mineral filler have been found processible into floor tile using the same basic production equipment and process line used in the manufacture of vinyl asbestos tile.

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.