Abstract: A data storage medium is provided which is suitable for production or replication by moulding, casting, embossing or a similar process against a tool. The method for manufacturing a data storage medium has a surface or a surface region which is strongly absorbent of at least a predetermined band of wavelengths of electromagnetic radiation. The surface or surface region includes a layer of a heat sensitive material which has a textured surface pattern the pitch of which is smaller than the shortest wavelength of the predetermined band of wavelengths, and the depth (peak-to-trough) of which is at least 100 nm. The surface pattern is free from undercutting, and can comprise an array of protuberances or one or more sets of grooves (which may be intersecting). The textured surface pattern is further coated with a thin film of a high-opacity material, e.g. gold, the thickness of the overcoating preferably being such as to give no more than 10% transmission of incident radiation.

Abstract: A printing blanket construction and method and apparatus for making the same are provided, the blanket construction comprising an outer layer formed mainly of polymeric material and having an outer printing surface for carrying liquid printing ink or the like for printing purposes or the like, the outer printing surface having a plurality of separate ink wells interrupting the same in a closely spaced apart generally uniform pattern thereof throughout substantially the entire printing area thereof and with a relatively large number of the wells each having a mouth opening at the printing surface that has a substantially straight-line length across the largest portion thereof of approximately 3 microns to approximately 65 microns.

Abstract: The process for making a dimensionally stable, embossed, ornamented surface covering suitable for use as a floor or wall tile, involving, laminating and embossing a resinous thermoplastic top layer having a plurality of openings extending through its thickness to allow the escape of air and extending to a base material or substrate of pre-formed, low-density, reinforced, porous thermoplastic material. The composite structure is subjected to heat and pressure in a flatbed press to emboss the structure without deformation, fuse the resins and render the top layer substantially impermeable. The improvement comprises the use of a rigid vinyl wear layer in a two step embossing operation involving a first embossing step in a heated press and immediately thereafter a second embossing step in a cooled press.

Abstract: A process is disclosed for the continuous embossing of the surface of flexible (i.e., soft-elastic) sheets or lengths of foam material optionally laminated to a synthetic resin film or a flat textile form or facing wherein the sheet of foam material is superficially plasticized by heating and is exposed to an embossing pressure by means of a perforated metallic embossing belt or band in accordance with a desired embossing pattern. The belt is removed after cooling and solidification of the embossed surface of the sheet of foam material.

Abstract: An absorptive laminated sheet material having improved, moisture-resistant, pressure bonded spots for locking the lamination layers together. During fabrication of the laminated product, a thermoplastic low-viscosity wax-like substance, such as melted wax or paraffin, hot melt plastic or the like, is applied in minute amounts onto juncture lines of pressure bonded spots formed in the pads. The thermoplastic material penetrates the layers of the laminated product so that, on cooling, it forms a "wax rivet" at each bonded spot, thus providing added strength for the juncture lines and rendering the layers impervious to absorbed liquid at the points of application.

Abstract: A carpet tile assembly which resists lateral movement and a process of producing the same are disclosed, the carpet tiles having a tufted carpet layer or similar surface and a second layer of elastomeric material vulcanized to the carpet layer. The second layer has a plurality of protrusions formed therein and a plurality of spikes on the protrusions which together engage a base layer which may be either a mirror image of the second layer or a needle-punched or felt-like fiber mat to resist lateral movement of the applied tiles. The process involves tufting carpet yarn into a substrate and then vulcanizing the second, elastomeric or resilient layer to the substrate. In the vulcanization process, heat and pressure are applied to soften the elastomeric material and force the material through cavities in a perforated sheet to form the protrusions.

Abstract: A process for manufacturing a trim cover assembly constituting the surface of an automotive seat or airplane seat is disclosed and comprises the step of forming a covering material and a foam wadding with a plurality of recessed grooves on the surface thereof. The process also includes the step of forming the covering material in the trim cover assembly by a thermal press or the like into a predetermined uneven configuration. Then, the thus-formed covering material is adhesively bonded to the surface of the foam wadding so that various kinds of uneven configurations are available for use as the surface of the trim cover assembly.

Abstract: A fabric-surfaced fiber board having pressed and non-pressed portions. The board includes a low density fiber board composition having a re-activatable binder therein and having a fabric bonded thereto to form a laminate therewith. The laminate has peripheral portions wherein said fiber board composition has been compressed and reformed to have a reduced height, a higher density and a greater strength as compared to the non-pressed portion of the board.

Abstract: A base web is prepared which has two parallel layers of nonwoven fiber glass webs, each impregnated with a solidified resinous composition and separated from each other by a core layer of an expandable solidified resinous composition which is bonded to the resinous composition used to impregnate the fiber glass webs by a thin integral layer of nonexpandable resinous composition. Additional layers of resinous material, expandable and nonexpandable, and decorative effects may be supported by the base web. The composite web is subjected to heat processing to expand the core layer and other expandable layers that may be present and to fuse the resinous composition used in the construction of the product. The processes are particularly adaptable for the production of shapes such as floor tiles and decorations that employ chemical embossing.

Abstract: A process for producing an expanded or foamed polyolefin panel with a decorative surface wherein a polyolefin or a mixture of a polyolefin with rubber and/or a synthetic resin miscible therewith is blended homogeneously with a crosslinking agent and a blowing agent and shaped into a panel-like matrix below the decomposition temperature of the blowing agent and the activation temperature of the crosslinking agent; a film of a thermoplastic synthetic resin, imprinted in accordance with a pattern with printing ink on one surface side, is applied unilaterally or bilaterally to the matrix, with the imprinted surface side facing the matrix; and then the matrix, with the film applied, is crosslinked and expanded by heating to a temperature above the activation of the crosslinking agent and the decomposition temperature of the blowing agent.

Abstract: An improved foil for stained glass assembly is disclosed. This improved foil is unique in that it includes an indexing reference to assist in the precise placement of the foil on the edge of a piece of stained glass. After foiling of numerous pieces of stained glass, they are butted to one another and soldered together along their contiguous seams. The precise placement of the foil on the edge of the glass insures that the solder bead between such contiguous pieces is uniform, thus insuring an esthetically attractive and structurally superior article.

Abstract: A method of manufacturing a container cap with a concealed mark is disclosed. The mark is provided to the central portion of one of both the inside face of the top panel and one side of a seat member made of a thermoplastic material. The seat member is then placed on the inside face of the top panel so that the one side of the seat member faces the inside face of the top panel. The seat member is thereafter heated for softening. The other side of the seat member, heated and placed on the inside face of the top panel, is depressed to form a manually tearable line surrounding the mark in the other side of the seat member, thus defining a gasket portion in the seat member outside the tearable line and a manually removable portion, overlying the mark, inside the tearable line, and to attach a gasket portion to the top panel.

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: A nonwoven fabric is disclosed which comprises at least two layers of nonwoven web adjacent to and bonded to each other. Each web comprises a plurality of monofilaments of a thermoplastic material. In one of the webs, the thermoplastic material is polypropylene. In another of the layers, the thermoplastic material is polyethylene. Advantages of this combination of nonwoven webs comprising these polymers in layers in a multilayer nonwoven fabric are disclosed which include increased softness and tensile strength.

Abstract: The invention provides a process for manufacturing optical disks by pressing and disks obtained by such a process, for improving the inherent flatness of the optical disk of the thick type, obtained by a process of pressing between a recorded master and another master, recorded or not depending on whether it is a question of a single or double side disk, this latter being formed from a stack of at least two thin sheets of thermoformable material subjected to a pressure-temperature cycle after which bonding together of the sheets and duplication of the information from the masters for information recording are obtained.

Abstract: The present invention contemplates a method of manufacturing a laminated sheet having a non-skid surface. In a preferred embodiment a method of manufacturing a decorated unitary laminated tray having a thermoplastic non-skid layer is disclosed.

Abstract: A decorative button for use in the surface of an automotive seat and method for making same are disclosed. In the method, a button core member is set on the back side of a trim cover assembly comprising a top cover member, a wadding and a wadding cover, and the button core member is covered by a reinforcing member. The peripheries of the button core member are then pressed and heated to weld the top cover member, wadding, wadding cover and reinforcing member around the button core member to one another into an integral body and, at the same time, to form a deep-valley-shaped recessed portion in the surface of the top cover member around the button core member.

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: Two or more webs (11 and 12) of highly bulked substrate are passed into a nip formed between a gravure roller (14) and an impression roller (15). The impression roller has raised areas defining an interconnected network of lines such that the webs are compressed only under the raised areas; as a result, the binding liquid applied by the gravure roller (14) to the laminate of the two webs is absorbed substantially through the webs in the compressed areas. The gravure roller (14) may have a uniform surface, such that a light coating of binding liquid is applied to the surface of the uncompressed areas in the laminate, or the gravure roller may have a pattern of etched grooves or cells which matches and registers with the pattern of raised areas on the impression roller. In the latter embodiment, binding liquid will be absorbed into the laminate only in the compressed areas.

Abstract: A method of manufacturing a shoe which comprises forming a foamed outsole in a mold cavity and cementing an insole to the formed outsole during molding. The mold is made of a silicone rubber and has a deeper cavity for forming the outsole and a shallow cavity for receiving an insole. An upper with multi-colors is fabricated by cementing differently colored plastic segments and a lining cloth by high frequency sealing.

Abstract: The barrier in a closure liner can be formed with a distinctive design or logo when the closure liner is inserted in the cap by placing a male embossing die against the sealing layer of the closure liner with sufficient force to emboss an image in the foil layer. The embossing of indicia into the liner at the time the cap is to be placed on the container provides the manufacturer with his own distinctive logo which cannot be readily duplicated thus making the container closure tamper-resistant.

Abstract: A laminated material comprises a layer (2) of a microcellular material capable of changing color upon the application of heat and pressure and having a layer of adhesive (3) bonded thereto. The laminated material can be used in a method of applying a decorative layer or motif (13) to a substrate (11) using a die (5). The die includes shaped projections (10) for heating and compressing the discrete areas of the microcellular material in order to change its color, and includes severing edges (9) for cutting the decorative layer or motif (13) from the laminated material.

Abstract: A method of bonding a label to a tag within a garment after the garment is manufactured is provided and consists of placing jaws of a heat activating press tool over the tag having a heat activated bonding agent thereon and the label and squeezing the jaws of the heat activating press tool so that the tag and the label will bond together.

Abstract: The present invention relates to a credit card or identification card fabricated from amorphous polyester sheet material wherein at least the area of said card containing embossed numerical or letter characters and the characters themselves are composed of substantially crystalline polyester. Such characters can not readily be altered by either heat treatment or by shaving them off.

Abstract: A decorative laminate having a differential texture and a differential gloss, and a method of manufacture therefor, are provided wherein the laminate has an embossed surface comprising raised segments which contain PVC resin particles adjoining recessed segments which do not contain PVC resin particles whereby the raised and recessed segments impart a relief pattern on the surface of the decorative laminate, and the raised segments have a rougher surface texture and a lower gloss than the recessed segments. The decorative article is useful as a floor covering.

Abstract: A laminating film product for applying a sealed protective cover to a document such as an identification card has a cover film of an unoriented polyester resin extruded onto a surface of a transfer film of an oriented thermoset polyester resin that has been coated with a release agent such as a soap; a film of a thermoplastic adhesive resin may be extruded onto the exposed surface of the cover film. In use, the laminating film product is laminated to a document under heat and pressure, the transfer film is stripped away, and the exposed cover film is embossed. Magnetic strips, pigment strips, and the like may also be applied to the cover film by hot stamp transfer.

Abstract: In accordance with a preferred embodiment, a dielectrically embossed automotive seat cover assembly is formed by providing a laminate of a decorative cover material, a first, relatively thin, polyurethane foam layer that is dielectrically heatable and a second thicker polyurethane foam layer that is not dielectrically heatable, and thereafter impressing a desired embossment pattern into the upper polyurethane and dielectrically fusing said upper layer of polyurethane to bond the cover layer to the lower polyurethane layer, thus forming the embossed pattern in the laminate structure.

Abstract: The present invention relates to a credit card or identification card fabricated from amorphous polyester sheet material wherein at least the area of said card containing embossed numerical or letter characters and the characters themselves are composed of substantially crystalline polyester. Such characters can not readily be altered by either heat treatment or by shaving them off.

Abstract: Low cost decorative award plaques are provided which use a plastic laminate article capable of being hot stamped with desired lettering or designs. The plaque is made by a process of repeatedly imprinting with different colors and surface effects. The process includes forming and cutting the plastic on a rigid backing, especially one simulating a fine, hardwood panel.

Abstract: A method for fabricating a molecular matrix print head for use in nonimpact electrolytic printers. Green ceramic sheets are stacked and laminated, then embossed with insulators and screened with ruthenium dioxide. The assembly is then co-sintered at less than 1000.degree. C. and the resulting structure smoothed by lapping and finished in a convention fashion.

Abstract: Laminated artificial leather is disclosed having in between a face layer selected from an ordinary PVC or PU sheet and a bottom layer of a foamed abraded PVC, at least one intermediate layer selected from a fabric cloth or foamed PVC, and ideally a second intermediate layer of ordinary PVC sheet. The laminate is formed by adhesion, foaming and embossing, the final product having the feel of genuine leather. In practicing the invention, fabric cloth is not used either as the bottom of the laminate or as a backing for the bottom layer.

Abstract: A plastic foam-forming mixture (31), e.g. a polyurethane or polyisocyanurate foam mix, deposited from one or more static dispensers (19) is metered through two spaced opposed members 14 and 18 forming between them a metering gap. At least one of the members is deformable in a controlled manner such that the profile of the metering gap can be variously defined. Reduces "crowning" of foam boards while permitting foam boards of different thicknesses to be made without having to replace metering bars.

Abstract: Production of high bulk nonwoven materials particularly useful as wipers and the like having a varying pattern of bonds and cloth-like feel. In one embodiment the method includes opposed, varying, high density bonding patterns on opposite sides of the materials formed by contact with surfaces having varyingly shaped or sided lands and grooves. Where both surfaces are contacted by such lands and grooves, increased spacing in the unbonded areas permits high loft, essentially unbonded fiber portions between the bond points. Construction of the individual land areas is preferable with tapered sides with vertical so as to permit engraving and high bond density and pattern depth while reducing wear. Resulting products have unique softness and absorbency characteristics for improved wipers because of the bond constructions. In addition, a wide variety of attractive patterns may be obtained.

Abstract: A process of making raised line imprinted display mounts utilizing a foam polymer sheet having a thin polymer laminate covering includes the step of selecting a foam polymer sheet having a thin polymer laminate covering. The laminate covering surface is foil stamped with a die under predetermined pressure at predetermined temperatures and for elected dwell time to produce a raised line imprinted lettering or designs on the surface resembling an embossed surface stamping.

Abstract: A self-supporting, decorative, armor panel having: a central armor core consisting of layers of fiberglass bonded together with resin; an outer, decorative, non-ricocheting laminate on each side of the armor core. Each laminate has an outer, decorative cover layer and a plurality of paper layers bonded together with resin. In a process of making the same the laminates are bonded to the armor core simultaneously with the bonding together of all the layers.

Abstract: A non-woven material is applied to the surface of a woven scrim. The non-woven material is needle-bonded to the scrim. The composite structure is then embossed, and during the embossing operation, a uniform coloring is provided in the areas of the embossing. The embossed pattern is placed by a heated embosser on the composite structure and in the embossed areas, the heat of embossing causes the non-woven material to partially melt and assume a textured effect which mirrors the texture of the woven scrim.

Abstract: A device is disclosed for determining the ionic analyte activity in liquids, e.g. aqueous solutions, by the use of electrodes and an internal capillary bridge which promotes ionic migration between the electrodes. This device includes an electrically insulative frame in which the electrodes are mounted, liquid access holes aligned with the electrodes on a capillary bridge formed of a porous material, and a cover sheet element formed of a nonporous cover sheet. The cover sheet element extends over the electrodes and encapsulates the elongated capillary bridge. Located in the cover sheet directly over and generally along the capillary bridge is one or more substantially continuous stretch lines typically provided by mechanically deforming the cover sheet. This deformation allows shorter junction times when liquids are introduced into the liquid access holes.

Abstract: A sheet of debossable plastic material is bonded to a backing plate, which may be a metal plate preferably pre-formed in a coin die. A polished surface on the edges of the metal plate projects beyond the plastic sheet material. The combined effect of the debossable plastic material, with a brushed metallic appearance, and the backing plate with polished edges greatly enhances an appearance of an engraved metal plate. This basic unit may be used in combination with other structures to form plaques, frames, name badges, and the like. When used in some combinations, such as a picture in a frame of the plastic sheet, for example, the components may be pre-assembled into a complete packet before attachment to a stand.

Abstract: A composite laminate material and a process for making the same are provided, the process comprising the steps of providing an unbonded fibrous batt of desired thickness having a thermosetting binder material dispersed therethrough, applying a layer of desired thickness of a curable latex to at least one side of the fibrous batt, drying the layer to a predetermined moisture level to provide a dried composite material, and heating and compression molding the dried composite material to simultaneously mold the composite, cure the layer and cure the binder material by embossing a pattern into the exposed side of the layer before the layer and the binder material are cured to cause the layer to be contoured with the pattern substantially throughout the thickness thereof and thereby cause the pattern to be substantially impressed into one side of the batt so that the resulting embossed and cured layer has a substantially uniform thickness and the one side of the cured batt substantially conforms to the embossed co

Abstract: This application discloses a process for producing a non-woven fabric which comprises applying a crosslinkable bonding agent to a portion of the surface of a fiber assembly, applying heat and pressure to drive the crosslinkable bonding agent into the fiber assembly and to densify the fiber assembly and subsequently crosslink the bonding agent.

Abstract: Methods are provided for producing a laminate particularly useful in producing warm moisture-resistant wearing apparel for industrial applications and sportswear. The laminate is superior in flexibility and comfort when worn while still providing appropriate moisture protection. In addition, the method includes procedures for providing a combined textured and creped surface for varying the appearance and degree of flexibility and "feel" to garments comprised of the laminate. The methods include joining a non-woven fibrous web such as a needled felt to a foamed synthetic resin web, such as polyurethane foam, and thereafter, through controlled tension, temperature and roll pressure, joining a film, such as a synthetic resin film, to the exposed foam surface through a heated roll nip, followed by embossing. The degree of "crepe" and texture or embossing imparted to the laminate varies inversely to each other, as desired, to provide a variety of different appearing and appealing fabric surfaces.

Abstract: Disclosure is made of a new and novel method of producing upholstered panels having a plurality of different textile surfaces. The panels are useful to upholster the interior of transportation vehicles.

Abstract: A method of forming a structural column wherein a plurality of formed inner and outer column layer halves are integrally constructed from flat sheets of wooden laminate simultaneously bonded together and molded into a triangularly shaped wave pattern.

Abstract: A process for preventing the counterfeiting of valuable documents through use of photography, photocopying techniques, or other methods of counterfeiting. The process includes laminating an extremely thin metallic film to the substrate of the valuable document before the document is printed with the area of the metallic film being small in comparison to the area of the document. The metallic film can be located anywhere on the face of the document and a "latent image" is embossed on the metallic film when the document is printed. Embossing the latent image on the metallic film, rather than on the document substrate, provides many advantages not possible in the prior art.A photocopy of a document containing the embossed metallic film does not include the latent image and a color photocopy will be different in color than the original document. Therefore, a lay observer can readily differentiate between a genuine document and a counterfeit document.

Abstract: A method for producing a flocked web by applying a layer of a thermosetting plastic foam onto a carrier sheet which foam penetrates into the surface of the carrier, flocking the uncrosslinked layer and then thermally hardening the layer and wherein prior to complete crosslinking of the flocked layer, the partially crosslinked flocked layer is submitted to heat pressing. In a preferred embodiment, the heat pressing can include an embossing step. The process of the present invention is not only easy to carry out, it avoids the presence of air bubbles as well as other inconsistancies in the product. The product obtained with the present invention is also disclosed.

Abstract: An improved process is provided for making tufted carpets having bonded nonwoven fabric secondary backings. After the secondary backing has been laminated to a back-sized and tufted primary backing to form a carpet composite, the composite is passed through a nip to emboss the secondary backing and provide a less stiff, easier to install carpet.

Abstract: A dual-purpose backerboard member is provided which has a weakening line dividing it longitudinally into two sections, and which has a barrier sheeting bonded to one face of the cellular backerboard except along the weakening line. The panel member can readily be split along the weakening line without damage to the barrier sheeting laminated thereto, due to the provision of the unbonded zone. The backer member can be used intact for a single-lap siding panel; alternatively it can be split and assembled with a double-lap panel, in which assembly the two sections are overlapped and hingedly interconnected by the bridging web of the sheeting, and are installed against the offset wall portions of the panel.

Abstract: A laminated thermosetting decorative sheet has on its surface glossy protruding parts and matted recessed parts, and the recessed parts are preferably colored. This laminated thermosetting decorative sheet is manufactured using a press plate with an enamel layer having protruding parts whose enamel surfaces are matted.

Abstract: A soft permeable material, such as a foamed plastics material or a fibrous material is shaped, and optionally provided with one or more facing layers, by applying to the faces thereof a polyurethane based prepolymer composition under such conditions that a non-tacky coating having latent adhesive properties is formed. The coated material may be stored for a period of several months and subsequently shaped by the application of heat and pressure sufficient to cure the pre-polymer. Facing layers can be bonded thereto simultaneously without the application of additional adhesive substance. The latent adhesive substance may be applied to the permeable material in solution or in the form of a dry film. In the latter case the film may be applied initially to a facing layer. The latent adhesive substance may be used to form reclaimed waste material into a coherent mass which can subsequently be shaped and faced without the application of further adhesive substance.

Abstract: An absorbent impervious barrier fabric in the form of a laminate has a fibrous section including a mat of polymeric melt blown microfibers and an impervious polymeric film adjacent said mat, said fibrous section and film being united in compacted bond regions formed by the application of heat and pressure and comprising pillars of bonds extending completely through the fabric from the outer surface where the fibrous elements are fused to the interface between the mat and the film where microfibers are fused to the film without disrupting the imperviousness of the film, the bond intensity tapering from said fused regions toward the essentially unbonded central plane of said mat to provide a double gradient in bond intensity in said pillars of bonds. One embodiment of the fabric has a fibrous section with a surface layer web of continuous and randomly deposited filaments and a microfiber mat with the web having intermittently discrete prebonded regions in addition to the compacted bond regions.