Abstract: A decorative laminate having registered color and embossing is produced by effecting a simultaneous embossing and laminating using a three-dimensional press plate acting against a release sheet having a colored ink layer on the surface thereof adjacent the uppermost laminate surface and a color bearing sheet over which is coated, colored flowable resin.

Abstract: A flocked foam having an embossed pattern provided by a high-frequency welder is disclosed. The foam comprises a partially cross-linked foam substrate (10 to 75% gel fraction in boiling toluene for 15 hours) formed from a 1,2-polybutadiene resin or a polymer blend including a 1,2-polybutadiene resin as one component thereof, and modacrylic pile fibers or a mixture thereof with other pile fibers flocked on the surface of the foam substrate.

Abstract: A cap visor defined by upper and lower layers of material having an insert board therebetween in a sealed relationship. A flow mold technique patterns one of the layers of material, as, for example, to simulate stitching. In that the insert board is sealed within the layers of material, any damage, as that from water passing through conventional stitching, is prevented.

Abstract: A method of manufacturing an electret device which comprises the step of causing a pressure deformation jig whose surface is provided with numerous minute convex and concave regions to abut against the surface of a raw dielectric material for an electret and later be removed therefrom, thereby forming minute stretched and contracted region on the surface of said dielectric material.

Abstract: A system for the manufacture of leatherlike materials, particularly for shoe uppers, which avoids pollution, toxicity and fire hazards and makes it possible for the shoe manufacturer to make his shoe upper materials as required with a minimum of investment in inventory of raw materials and with simple, relatively inexpensive equipment.

Abstract: It has been found that a layered recording disc having an inexpensive core layer and high quality recording groove-accepting outer layers can be made in a relatively simple manner through an application of the technique known as coextrusion, wherein a common die, e.g. a coextrusion die (10) having a die orifice (11) for a plurality of streams (13, 23, and 33) provides a multilayer coextrudate (60) having a plurality of layers (64, 74, and 84). The coextrudate (60) can be cut into segments (60a) with a suitable cutting means (20). The coextrudate segments can be substantially of record thickness with a circular periphery. Alternatively, coextrudate segments (60b) can be much thicker than a record and much smaller in surface area. In either case, segments can be compression molded into discs (100) having the desired profile and/or grooves.

Abstract: A method of and an apparatus for producing a seat cushion member by laminating a sheet of decorative surface material, a sheet of usual polyurethane foam material and a reinforcing web of fabric material in the above order, and subjecting the laminate to heating by a conventional heating unit and, at the same time, to high-frequency dielectric heating by a high-frequency welder to locally fuse required portions of the sheet of usual polyurethane foam material thereby welding the three layers into an integral structure.

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 process for producing decorative articles having patterns of surface concavities and convexities (unevennesses) comprises the steps of:(1) placing into mutual contact and laminating a hardenable decorative material layer and an expansion-contraction deformable sheet provided with regions susceptible to expansion-contraction deformation and regions not susceptible to said deformation;(2) causing the deformable sheet to undergo said deformation under pressure thereby to impart a pattern of unevennesses to the decorative material layer in contact with the sheet; and(3) causing the hardenable decorative material layer to fully harden.The sheet deformed under pressure imparts a unique pattern of surface unevennesses corresponding to the two kinds of regions to the decorative material layer. Decorative articles thus obtained can be applied to a wide variety of uses as materials for decorating architectural exteriors and interiors and as decorative boards.

Abstract: An improved method for the construction of tire liners (19) incorporating a core strip (10) of high temperature and pressure (HPT) molded and vulcanized rubber or another tread supporting material which allows low temperature and pressure (LPT) vulcanizable rubber to flow and to bond the core in place in the liners is described. The tire liner preferably includes LPT vulcanized rubber (16, 17 and 18) surrounding the HPT strip (10) with flexible wings (16) on the side resulting from the flow of vulcanizable LPT rubber during molding of the tire liner. The LPT rubber as vulcanizable sheets 11 and 12 is preferably wrapped around the strip of HPT rubber in such a manner that during molding the rubber flows to the short sides (10b) of the HPT core to form the flexible LPT wings on the tire liner. The tire liner is adapted for mounting inside pneumatic tires adjacent the tread (102) to provide protection against objects penetrating the tread and to stabilize the tread.

Abstract: A resinous material suitable for the fabrication of laminated structures comprising a first layer of resin and at least one second layer of filled resin contiguous with the first layer, the second layer being flowable under a compressive force. In the manufacture of a reticulated laminated structure of substantially uniform thickness, the thickness of the second layer varies in accordance with the number of first layers overlying one another at crossover nodes in the reticulated structure, with the second layer flowing from between the plies of the first layer at the nodes due to compressive forces applied to achieve such substantially uniform thickness.

Abstract: A contrasting color is imparted to the decorative surface of a decorative laminate by inserting a pigment coated release sheet between the molding caul and the decorative surface during the molding operation, with the pigment facing the decorative surface. Upon application of heat and pressure during the formation of the laminate, color is transferred from the release sheet to the decorative surface. A suitable technique is also used to emboss or impart surface texture to the decorative surface during molding. Thereafter, the textured surface is subjected to rubbing or brushing to remove more color from the embossed or raised areas than the debossed areas, thereby highlighting or imparting a shaded effect to the textured surface.

Abstract: A reactive polyurethane mixture is applied by a high pressure airless spray applicator directly onto the primary backing of a moving substrate such as a carpet web. The applied reactive mixture is allowed to foam to an approximate predetermined thickness and density. While the blown or foamed backing layer still possesses substantial residual tackiness, it is compressed or regauged to a precise uniform thickness and simultaneously is provided with either an embossed or a smooth surface. The tack of internal cell walls of the blown backing layer retains the layer at the regauged thickness. Curing of the regauged backing layer by externally applied heat and/or by the heat of the exothermic reaction in the applied mixture is completed. Detackifying agents are applied to the regauging devices and/or to the applied backing layer to prevent adherence of the layer to the regauging devices. A surface skin formed of the detackifying agents is cured on the regauged backing layer.

Abstract: A method of making a differential gloss product which comprises: forming a foamable base resinous plastisol on a substrate; gelling the base resinous plastisol; applying to the base resinous plastisol various printing ink compositions in a predetermined pattern, some portions of which contain a blowing inhibitor and a polymerization temperature-lowering promoter, either in the same or different portions; applying to the printed base resinous plastisol a resinous wear layer containing a polymerizable and/or cross-linkable monomeric material and a free radical polymerization catalyst; gelling the wear layer; mechanically dull mat embossing the entire surface of the wear layer at a temperature below the normal decomposition temperature of the catalyst but which is sufficient to decompose the catalyst in those portions of the wear layer lying directly over the polymerization temperature-lowering promoter present in some portions of the printed pattern, whereby the polymerizable monomeric material polymerizes to b

Abstract: Decorative sheet type material and process for making same. The material comprises a substrate, an embossed foamed plastic layer, a translucent layer having raised portions corresponding to embossed portions of the embossed layer and preferably a wear layer. The process involves forming an embossed foamed plastic layer on a substrate, covering the embossed layer with a layer of heat curable translucent plastic and then heating the materials sufficiently to cure the translucent plastic and also to allow embossed portions of the embossed layer to partially expand to create raised portions of the translucent layer corresponding to embossed areas of the embossed layer.

Abstract: A novel method of releasing from one another in a press pack, a plurality of heat and pressure consolidated resin-impregnated laminates, including those pressed back-to-back, e.g. decorative laminates, metal clad laminates, veneer backs and the like, which method comprises utilizing, as a separator sheet, a web of phenol-formaldehyde resin-free paper having a water absorption of at least about 200 seconds which has been sized on at least one side thereof, from an aqueous solution, with a water-soluble, alkaline earth or earth metal salt, e.g. a calcium salt such as calcium chloride, and then coated on said sized side with a film of a salt of alginic acid, such as sodium alginate.

Abstract: A laminate of tissue-like materials having a liquid absorbing agent fixed in position between lamina.

Abstract: A process for solvent bonding blended nonwoven fabrics is disclosed. The fabric is obtained by forming a web from a blend of fibers selected from the group consisting of acrylic fibers, modacrylic fibers and mixtures thereof and polyester fibers, applying a controlled amount of solvent to the web, and then bonding contiguous fibers at their cross-over points by the application of heat and pressure so as to activate the solvent. The fabric thereby obtained is characterized by improved elongation and tear strength.

Abstract: A system for the manufacture of leatherlike materials, particularly for shoe uppers, which avoids pollution, toxicity and fire hazards and makes it possible for the shoe manufacturer to make his shoe upper materials as required with a minimum of investment in inventory of raw materials and with simple, relatively inexpensive equipment.

Abstract: Resinous polymer sheet materials having selective, surface decorative effects comprising:(1) a base layer or substrate, such as a fibrous backing sheet material and/or a blown or unblown resinous polymer composition having either an embossed or a relatively smooth surface;(2) a pattern or design printed or otherwise deposited on and adhered to the base layer or substrate, certain portions of the printed pattern or design having certain colors, and other portions of the printed pattern or design having other colors; and(3) a wear layer having an embossed or a relatively smooth surface and containing reactive polymerizable monomers and having certain surface portions provided with a certain texture or effect, such as a flat, dead or dull mat finish, and other surface portions provided with another texture or effect, such as a sleek, glossy or lustrous finish, the interior portions of the wear layer lying under the flat, dead or dull mat finish having a relatively high melt viscosity and containing relatively hi

Abstract: An improved thermoforming process for the production of formed articles of corrugated plastic board having small radius curvatures and deep drawings, which comprises heating said corrugated plastic board at the portions to be formed into small radius curvatures or deep drawings more intensively than at the other portions, and applying pressure to said portions thereby crushing the rib structure in said portions without crushing the rib structure in said other portions.

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 method for making a dimensionally stable decorative floor covering product. A sheet is first formed, and this is then provided with a decorative design. A clear wear layer is applied thereon, mechanically embossed-in-register, and then the sheet is cut into a plurality of individual tile units.

Abstract: Resinous polymer sheet materials having selective, surface decorative effects comprising:(1) a base layer or substrate, such as a fibrous backing sheet material and/or a blown or unblown resinous polymer composition having either an embossed or a relatively smooth surface;(2) a pattern or design printed or otherwise deposited on and adhered to the base layer or substrate, certain portions of the printed pattern or design having certain colors, and other portions of the printed pattern or design having other colors; and(3) a wear layer having an embossed or a relatively smooth surface and containing reactive polymerizable monomers and having certain surface portions provided with a certain texture or effect, such as a flat, dead or dull mat finish, and other surface portions provided with another texture or effect, such as a sleek, glossy or lustrous finish, the interior portions of the wear layer lying under the flat, dead or dull mat finish having a relatively high melt viscosity and containing relatively hi

Abstract: Resinous polymer sheet materials having selective, surface decorative effects comprising:(1) a base layer or substrate, such as a fibrous backing sheet material and/or a blown or unblown resinous polymer composition having either an embossed or a relatively smooth surface;(2) a pattern or design printed or otherwise deposited on and adhered to the base layer or substrate, certain portions of the printed pattern or design having certain colors, and other portions of the printed pattern or design having other colors; and(3) a wear layer having an embossed or a relatively smooth surface and containing reactive polymerizable monomers and having certain surface portions provided with a certain texture or effect, such as a flat, dead or dull mat finish, and other surface portions provided with another texture or effect, such as a sleek, glossy or lustrous finish, the interior portions of the wear layer lying under the flat, dead or dull mat finish having a relatively high melt viscosity and containing relatively hi

Abstract: Laminates comprising at least one reinforcing layer, for example of metal or of fiber-reinforced duroplast resin, bonded to a foamed polyimide layer are disclosed, wherein the particular nature of the polyimide foam imparts high temperature strength properties to the laminates and permits them to be made by methods, also disclosed, employing more extreme conditions of temperature, pressure, and time than are otherwise operable for making conventional laminates.

Abstract: Identification plates are produced by applying retroreflective material upon a male die member and subsequently pressing a plate blank over the retroreflective material to adhere the material to the blank. The blank is then lifted from the male die member and the retroreflective material, in the form of characters to be formed upon the identification plate, has pressure applied thereto to remove air bubbles. The blank is then replaced on the male die member which is formed with male die elements also in the form of the characters to be produced, and by applying a compressive force to the plate blank, an identification plate is formed with indented retroreflective characters devoid of air bubbles or the like.

Abstract: Resinous polymer sheet materials having selective, surface decorative effects comprising:(1) a base layer or substrate, such as a fibrous backing sheet material and/or a blown or unblown resinous polymer composition having either an embossed or a relatively smooth surface;(2) a pattern or design printed or otherwise deposited on and adhered to the base layer or substrate, certain portions of the printed pattern or design having certain colors, and other portions of the printed pattern or design having other colors; and(3) a wear layer having an embossed or a relatively smooth surface and containing reactive polymerizable monomers and having certain surface portions provided with a certain texture or effect, such as a flat, dead or dull mat finish, and other surface portions provided with another texture or effect, such as a sleek, glossy or lustrous finish, the interior portions of the wear layer lying under the flat, dead or dull mat finish having a relatively high melt viscosity and containing relatively hi

Abstract: Disclosed is a method for making a laminated thermoplastic sheet from which can be cut one or more embossed straps having a loop at least at one end for receiving the cross-pin of a watch, buckle or the like.

Abstract: A consolidated man-made board, such as hardboard, is "post-press" embossed with a contoured embossing plate at a pressure of at least about 1000 psi, at a temperature in the range of about 400.degree.-550.degree. F. and for a period of time sufficient to permanently re-shape the surface of the consolidated board.

Abstract: A method of producing a wall or ceiling covering that is dry-stripable from the wall, is flexible and has good opacity, and will fully retain an embossed pattern even when the sheet is soaked with a water based adhesive. A sheet is provided containing 10 to 90% by weight of cellulose pulp fibres and 10 to 90% by weight of discontinuous fibres of two different synthetic thermoplastic polymeric materials. Staple fibres may also be added. The sheet is then heated to a temperature intermediate the temperature of plasticity of the two different thermoplastic materials so that the fibres of one of the thermoplastic materials are rendered plastic and fused together, the other thermoplastic material retaining its fibre structure.

Abstract: A specially constructed solid core door is disclosed having a solid core material of particleboard or other suitable material, wood stiles bonded around the periphery of the edges of the core material, a hardwood skin having a minimum thickness of 1/8 inch bonded to the front and rear surfaces of the core material and a phenolic resin-impregnated paper overlay overlying and bonded to the exposed faces and backs of each of the hardwood veneers. The exposed face of the resin-impregnated paper is preferably deeply embossed during bonding of the paper to the veneer with a texture such as a wood grain texture. The door has twice the warp resistance of standard wood doors. The resin impregnated overlayed surfaces provide excellent dent resistance, easy repairability, resistance to checking or crazing, and long paint life (approximately 2 to 3 times that of the standard wood faced door).

Abstract: A method is provided for forming a unique embossed laminated board product. A hard core is covered with a soft wood veneer and this is then covered with a resin treated wood fiber sheet. The composite structure is embossed, the embossing occurring in the resin fiber sheet and soft wood veneer. The hard core provides structural rigidity to the finished product and good definition to the embossed product.

Abstract: Production of a wall or ceiling covering comprising an embossed laminate of a first printable embossable ply, and a second supporting ply. The first ply consists of a paper sheet containing 60-100% by weight of cellulose wood pulp fibers and 0-40% discontinuous fibers of a synthetic thermo-plastic polymeric material. The second ply consists of a sheet of 10-60% cellulosic wood pulp fibers, and 40-90% of thermoplastic fibers (either the same as or different than those in the first ply). A fused three dimensional network is formed by heating the laminate to a temperature at which the thermoplastic fibers are rendered plastic.

Abstract: This invention relates to a method and an apparatus for flattening wood based panels such as plywood, flake board or fiber board panels, which have an undesirable curvature, due to an imbalanced construction, or due to a certain production process. In particular this invention relates to the flattening of a panel as described in U.S. Pat. No. 3,878,017.

Abstract: A nonwoven, self-sustaining, absorbent fabric comprising a batt of randomly arranged, intermingled cellulosic fibers has a plurality of high loft, loosely compacted regions separated from each other by highly compressed regions. An adhesive material penetrates through the compressed regions to form bonded fiber networks extending completely through the batt, and said adhesive material only partially penetrates through said high loft regions whereby the fibers in the interiors of said high loft regions are unbonded by said adhesive so that said regions are highly absorbent. A method of manufacturing the above-described nonwoven fabric by moistening opposed surfaces of a loosely compacted, randomly oriented cellulosic fiber batt, embossing said moistened batt for providing a pattern in said surfaces, applying an adhesive to the patterned surfaces of the batt and setting said adhesive.

Abstract: The process herein is used for achieving multilevel mechanical embossing of a sheet material having a fused or cured wear layer. An embossed pattern is provided in register with a printed design under the wear layer. A two stage embossing is carried out. In the first stage embossing, a texturing is placed on the raised areas of the finished product. The second stage embossing provides deep embossing, which would be in register with the printed design under the wear layer.

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: In the production of a trim board such as an automobile roof trim board using a corrugated paperboard substrate which is bulged or dented in a comparatively small area and has an aperture in this area for the installation of a separate article, at least one linear notch is formed in a flat board of corrugated paperboard so as to extend transversal to the ridges of the corrugated medium and be entirely included in the area of the aperture as a preparatory procedure to press-forming of the corrugated paperboard. The presence of the notch allows some deformation of a tensioned liner also in the same direction as the ridges and hence precludes the appearance of cracks in the bulged or dented area. The notched region of the shaped board is thoroughly cut away as the result of the formation of the intended aperture.

Abstract: A highly absorbent and fragile composite sheet normally used as a throwaway domestic wiper is quickly and easily converted to a strong and attractive colored wallcovering. Thus, a composite layer comprising a net material sandwiched between and bonded to a pair of cellulosic-fleece (wadding) layers has a carrier sheet of paper bonded thereto, has colorant applied thereto, and is impregnated with a synthetic resinous bonding medium so that the fleece layers are bonded together at the mesh openings of the net material. In a preferred construction, the carrier sheet of paper has an internal cohesion inferior to that of the composite layer so that with the covering on the wall the composite layer is peelable from the carrier sheet adhering to the wall.

Abstract: A process for making composite contoured sound insulating panels of a type suitable for use adjacent to structural panels of automobile vehicle bodies, which in accordance with one embodiment of the present invention, comprises forming a fibrous pad incorporating controlled amounts of heat curable thermosetting binder and a heat softenable thermoplastic binder distributed in a controlled manner therethrough.

Abstract: An embossed film-to-foam laminate is provided having minute perforations through the film selectively distributed essentially along the sidewalls and valleys of the embossed pattern. The integrity of the laminated film material is retained on the crowns of the embossed patterned surface, since the perforations in the film material are mainly distributed on the sidewalls and valleys of the embossed pattern. The laminated product has a water-resistant and abrasion-resistant upper surface imparted by the film material on the crowns while the small perforations in the sidewalls and valleys permit sound to pass through the film and be exposed to the acoustical matrix of the open cell foam component of the laminate while impeding the penetration of liquids (e.g. water) through the film into the foam under the action of gravity. The film and/or the foam material are heated to supply adhesive material by melting or softening which serves to bond the film material to the foam.

Abstract: A plywood panel is provided with a durable and highly weather-proof surface and a plurality of embossed parallel grooves therein for enhancing its appearance. A metal caul plate is formed with the series of spaced apart ridges corresponding to desired grooves in the panel. A moist, spongy fibrous web is placed between the surface of the plywood panel and the surface of the caul plate, with an adhesive coating on either the panel or on the web surface facing the panel. The assembly of the caul plate and the plywood panel with the web therebetween is inserted into a hot press and subjected to heat and pressure and the web is firmly adhesively secured to the panel. The web, as well as the adhesive used for securing the web onto the panel, contains a quantity of thermo-setting phenolic resin so that the covered surface of the panel is durable and highly weather-proof. The original plywood panel may be of low quality and grade, having surface defects and blemishes, all of which are concealed by the covering web.

Abstract: The present invention provides a process for the manufacture of shaped articles, especially films and sheets, having an increased white fracture effect. These articles are obtained with the use of molding compositions on the basis of vinyl chloride polymers containing from 5 to 25% by weight of elastomers and from 3 to 10% by weight of plasticizers, each relative to the total mixture.

Abstract: A method of making a display folder is disclosed. The method comprises the steps of providing a sheet of display material having an area to be viewed on one side thereof and then adhering the side of the sheet of display material opposite the viewed side to a base sheet of substantially rigid material. A top sheet of substantially rigid material is then adhered to the viewed side of the sheet of display material by means of an adhesive material, the adhesive material being disposed solely on a portion of the sheet outward of the area to be viewed, thereby sandwiching the sheet of display material between the base and the top sheets to define a panel assembly. The top sheet is then die-cut to form the outline of an aperture, the outline being interior of the adhesive material and outward of the area to be viewed for permitting removal of the portion of the top sheet interior of the outline.

Abstract: The process herein is used for achieving multilevel mechanical embossing of an expanded foam having a fused or cured wear layer in register with a print on the foam. The expansion of the decorative foam and fusion of the wear layer are carried out and then the back of the foam is cooled by back wetting with or without drum cooling. The wear layer is maintained at a high temperature for embossing and is embossed with registry between the embossed pattern and the printed pattern on the foam.

Abstract: A process of preparing textured, decorative laminates is disclosed wherein the laminate assembly is heat and pressure consolidated in conjunction with a press plate having a specific roughness and gloss comprising its textured surface.

Abstract: Retroreflective sheeting having improved resistance to delamination is prepared by imparting a grid pattern to a monolayer of glass spheres having a light reflecting layer thereon, applying a sphere binder layer over the grid pattern imposed on the monolayer of glass spheres so as to adhere to the reflective layer on the monolayer of glass spheres, and pressure consolidating the resulting composite against a clear, protective overlay film, wherein the overlay film bonds to the sphere binder layer in the grooves formed by the grid pattern.

Abstract: An embossed film-to-foam laminate is provided having perforations through the film selectively distributed essentially along the sidewalls and valleys of the embossed pattern. The integrity of the laminated film material is retained on the crowns of the embossed patterned surface, since the perforations in the film material are mainly distributed on the sidewalls and valleys of the embossed pattern. The laminated product has a water-resistant and abrasion-resistant upper surface imparted by the film material on the crowns while the perforations in the sidewalls and valleys permit sound to pass through the film and be exposed to the acoustical matrix of the open cell foam component of the laminate. The film and/or the foam material are heated to supply adhesive material by melting or softening which serves to bond the film material to the foam.

Abstract: a jig-saw puzzle comprises interfitting pieces (1, 2, 3, 4) which when fitted together side-by-side form a three-dimensional upper surface simulating for example hills and valleys. Each piece is formed of a molded open or closed cell thermoplastics foamed core 7 sandwiched between upper and lower thermoplastics skins 8a and 8b. A printed sheet 9 is stuck on to the upper skin 8a. The skins 8a and 9a may be made from any conventional moldable thermoplastics. A preferred thermoplastics is a copolymer of propylene with from 5 to 20% by weight of ethylene made by injecting ethylene into the final stages of an otherwise propylene homopolymerization. The core may be made of the same or different plastics as the skins. Polyurethane is a preferred core material. The printed sheet, which may be paper or fabric, may be stuck on to the upper sheet with adhesive or by penetration or fusing of the skin material into the sheet during molding of the pieces.