Abstract: Compression molded pigmented door skins fabricated by compression molding a pigmented, curable, unsaturated polyester sheet molding compound containing a co-curable unsaturated monomer, a low profile additive, and a microvoid-reducing thermoplastic polymer, exhibit uniform stainability while maintaining a low linear thermal coefficient of expansion. Such door skins are suitable for preparing wood grain textured exterior insulated doors which exhibit minimal thermal deflection when exposed to interior/exterior temperature differentials, even at eight foot door heights. The doors may be stained without first applying a seal coat.

Abstract: An improved stitchbonded nonwoven fabric having repeating patterns of stitches in a fibrous layer is prepared with a stitching thread that consists essentially of fiber of partially molecularly oriented synthetic organic polymer. The fabric can be stretched, shrunken, and/or heat set and is particularly suited for thermoforming operations.

Abstract: A plastic sheet is extruded and a layer of redwood, cedar or other bark which has been finely separated is hot rolled into the two faces. The bark is decorative and also protects the sheets from ultraviolet light destruction. The sheets can then be hot worked into corrugated, design-embossed sheets and into many tubular or other hollow or open-sided shapes.

Abstract: A grip tape 11 for applying to a handle 94 generally comprises an elongate tape having a top portion 60 comprised of shock absorbing and compressible material, such as polyurethane, bonded to a shock absorbing bottom portion 90, such as of open-pored textile material, such as of felt. The top includes a central portion 62, a right densified portion 70 adjacent the right side 50 and a left densified portion 80 adjacent the left side 40. Preferably, the tops 75, 85 of densified portions 70, 80 are below the top 65 of the central portion 62 by at least 10% of the thickness of the tape. Preferably, bottom bevels 77, 87 underlie densified portions 70, 80. Tape 11 is spiral wrapped around handle 94 such that right side 50 overlies top 85 of left densified portion 80 of the previous turn, preferably such that top 75 of right densified portion 70 is disposed below top 65 of central portion 62 of the succeeding wrap.

Abstract: The front surface of a wooden overlay sheet, having a wooden material on the front surface thereof, is subjected to a color treatment with a colorant comprising a primer resin; the wooden overlay sheet, which was subjected to color treatment, is positioned in a metal mold for molding, and a transparent resin layer is molded on the front surface thereof by means of injection-molding. Furthermore, a synthetic resin core material is molded on the rear surface of the wooden overlay sheet. A composite molded article is thereby produced, wherein a synthetic resin core material is molded on the rear surface of the wooden overlay material, and a transparent resin layer is molded on the front surface of the wooden overlay sheet. Thus, the present invention enables the enhancement of the outer appearance of the product and the enhancement of the adhesion of the wooden overlay sheet and the transparent resin layer.

Abstract: Casting paper of a desired surface texture or finish for use in the manufacture of artificial leather is produced by heating the polymer coating 1 of a polymer-coated paper 2 to a temperature sufficient to melt the polymer and then cooling the polymer coating from its molten state to a solid state as it passes through a nip between an embossing roll 3 having a surface configuration corresponding to said desired surface texture or finish and a backing roll 4, thereby to impart the surface configuration of the embossing roll to the polymer-coated paper. The polymer is preferably polyolefinic, for example poly (4-methyl-1-pentene) or a polypropylene/polyethylene blend. An anti-curl back-coat, for example of polyvinyl alcohol, can be applied after the embossing operation.

Abstract: A heat-transferable film and a method for providing a tick pattern on a film-decorated substrate is provided. The heat-transferable film comprises (1) a transfer layer in facing engagement with a substrate having a first gloss level, at least one color, and a heat-activatable adhesive layer; (2) a plurality of individual spaced-apart markings, the markings having a color different from the color or colors within the transfer layer and a second gloss level different from the first gloss level, the markings adhered to the top of the transfer layer; and (3) a carrier sheet adhered to the top of the individual spaced-apart markings. Heat and pressure are applied to the top of the carrier sheet such that the heat-activatable adhesive affixes the heat-transferable film to the substrate.

Abstract: An improved composite sheet suited for use as artificial leather is prepared by treating with an elastomeric resin a fabric having an interior yarn network and an outer layer of well separated fibers that loop in and out of the yarn network. The resin completely or partially impregnates the outer layer.

Abstract: A wood veneer laminated gypsum board comprises a gypsum core and lamination f a paper or a paper-like outer layer on both sides, an aluminum backed wood veneer bonded to the paper outer layer, and debossed designs on the wood veneer which penetrates beyond the surface of the gypsum board. The wood veneer laminated gypsum board is formed by spraying or applying a mixture of adhesive diluted with liquid softening agent, which may include water or water mixed with other materials, on the aluminum side of the aluminum-backed wood veneer. The paper or paper-like outer covering is lightly sprayed or coated with the softening agent. The coated aluminum backed wood veneer is placed on the lightly coated the gypsum board. The wood veneer is moistened with water. The wood veneer and the gypsum board is pressed with application of heat for a predetermined period.

Abstract: An instrument trim panel (12) includes a shell (14) made from a flexible plastic material. A textured section (18) is circumscribed by a simulated seam (20). A closed cell plastic block (28) is press fitted behind the textured section. An air pocket (26) is interposed between the block and textured section. A rigid substrate (22) is molded and cured behind the shell (14) and block (28). The air pocket allows the textured section to be deformed to simulate the appearance and feel of a leather applique.

Abstract: A highly glossy thick aesthetic laminate surface layer is achieved by using pre-cured particulates of the impregnating resin preferably along with an initial binder material and abrasion resistant mineral particles. The protective overcoating may be applied in a thick layer to give gouge resistance and a deep look in the glossy laminate. The overcoated decor sheet is pressed against a mirror plate in the laminate manufacturing process, and gives a gloss meter reading well over 100. Because the impregnating resin and the pre-cured particulates have the same index of refraction, the transparency of the coating and the resultant clarity of the underlying decor sheet are excellent.

Abstract: A method of preparing a stainable resin material includes compounding 100 parts by weight of a resin material with from about 10 to about 30 parts by weight of a filler material being a plurality of individual filler particulate; and, heat polishing the surface of the material at a temperature sufficient to remove a portion of the material surface such that at least a portion of the filler particulate proximate to the surface is at least partially exposed. The filler material is selected from the group consisting of stainable materials. Products made using such a material may include striations to simulate the appearance of wood.

Abstract: A powdered leather which is composed of at least 85% by weight of cortex, at most 2% by weight of oil and fat, and at most 0.5% by weight of Na.sup.+ and Ca.sup.2+ ions capable of being eluted by water and which has an average particle size (D.sub.50) of at most 7 .mu.m, a standard deviation of the average particle size being at most 3 .mu.m. With this powdered leather, it is possible to thin films, coatings, fibers, etc. which would hardly be deteriorated with time.

Abstract: A grained artificial leather comprised of a sheet-form fibrous base, a porous polyurethane layer having interconnected open cells, formed on at least one surface of the base, and a non-porous polyurethane film formed on the porous polyurethane layer. A multiplicity of open cells are interspersed in the porous polyurethane layer, part of which are closed by the non-porous polyurethane film and the remainder of which are not closed and at least 70% in number of the non-closed opening cells have a diameter of 1-25 .mu.m.The artificial leather is made by adhering the porous polyurethane layer to the sheet-form fibrous base, applying a polyurethane/solvent mixed liquid as dots interspersed on the surface of the polyurethane layer to develop a multiplicity of open cells on the surface, and then applying a finishing polyurethane on the open cell-developed surface.

Abstract: A suede-like artificial leather which is composed of fiber bundles and an elastomeric polymer, has fibrous nap on its surface and is dyed, said fiber bundles being composed of fine fibers (A) having a finess of 0.02-0.2 denier and microfine fibers (B) having a fineness not more than 1/5 of the average fineness of said fine fibers (A) and also less than 0.02 denier, said fibers (A) and (B) being substantially uniformly dispersed in cross sections of the fiber bundles, the ratio between the strand numbers of fibers (A) to fibers (B) ranging from 1/2 to 2/3, said fiber bundles not substantially containing the elastomeric polymer in the interspaces among the individual fibers constituting each of the fiber bundles, and the ratio of the number of fibers (A) to that of fibers (B) in the nap-constituting fibers being at least 3/1, is provided.

Abstract: Described herein are artificial leather sub-composite and composite materials which are prepared with minimal or no use of solvents and which exhibit improved resistance to the phenomenon of "read through". The sub-composite and composite materials each include a thermoplastic film facing layer thermally embossed with a simulated leather texture and a barrier layer thermoplastically bonded to the facing layer. The composite material includes a flexible backing layer adhesively bonded to the barrier layer.

Abstract: A decorative sheet comprises a transparent or translucent base sheet having a rear surface on which protrusion and recess patterns are formed and a bright set-solid print layer or bright pattern print layer formed on a side of the protrusion and recess patterns of the base sheet. Each of the protrusion and recess patterns is composed of parallel lines, continuous curved lines or a combination of the parallel lines and the curved lines each composed of protruded and recessed portions each in form of a groove having a width of 1 to 100 .mu.m. The base sheet has a front surface on which a transparent resin layer may be formed. The transparent resin layer is formed of a hardenable resin. The decorative sheet also comprises the base sheet having a rear surface on which protrusion and recess patterns are formed, grain patterns formed on a side of the protrusion and recess patterns of the base sheet, and a bright set-solid print layer formed on a rear side of the grain patterns.

Abstract: Natural and artificial animal skins are provided with randomly spaced protuberances which simulate natural quill marks of ostrich skins. The protuberances are created from die formed depressions into which is adhered an individual glob of hot melt material. The glob has a generally semi-spherical mass extending above the inner surface of the animal skin. During manufacture of articles therefrom, the globs have the tendency to accentuate the appearance of the quill marks.

Abstract: A shingle is provided that is especially adapted for application to hips or ridges of a roof. In a preferred embodiment, the shingle is a laminated multi-layer shingle, bent or curled into a preformed shape that is reasonably close to the shape that it will have in the installed condition. The shingle layers are connected together in more than one zone, or in one large zone after sliding relative to one another as the shingle is bent or curled. Preferably, such connection is by means of an adhesive.

Abstract: There is a need for polymers which are utilized in automotive interiors which offer increased heat and ultraviolet light resistance. It is particularly critical for polymers which are utilized in making skin compounds for automotive instrument and door panels to display excellent heat and ultraviolet light resistance. This invention discloses a rubbery polymer which can be blended with polyvinyl chloride to make leathery compositions having good heat and ultraviolet light resistance, said rubbery polymer being comprised of repeat units which are comprised of (a) butyl acrylate, or optionally a mixture of butyl acrylate and 2-ethylhexyl acrylate containing up to about 40% 2-ethylhexyl acrylate, (b) at least one member selected from the group consisting of methyl methacrylate, ethyl methacrylate, methyl acrylate, and ethyl acrylate, (c) acrylonitrile, (d) styrene, (e) a half ester maleate soap, and (f) a crosslinking agent.

Abstract: A finished leather comprising a leather to which has been applied a fat liquoring and/or water repellant agent, and a particularly formulated polyurethane adhesive improving bottoming coat composition applied thereto.

Abstract: A novel display panel (10) has a high fidelity visual pattern with a full range of grey scale values, for instance, a marble or leather pattern, which is produced via a novel methodology (20). In accordance with the novel methodology (20), a high resolution visual pattern (31) and a mask pattern (32) are produced and separately printed. The patterns (31, 32) are then superimposed and exposed to a camera (33) which generates an enlarged photograph positive. A silk screen is produced from the enlarged photograph positive and used to print a high fidelity visual pattern onto a glass substrate (13). The glass substrate (13) and visual pattern (14) are then heated in a tempering oven to derive the display panel (10).

Abstract: This invention involves an artist's working support or panel that is durable, of high quality, and long lasting. The structure has a planar core material usually balsa wood with a stressed-skin layer or sheet adhered to its front and back surface. Specific adhesives are used to enhance the quality of the working support. The panel is completed by adhering a finishing material such as canvas or paper to at least one surface of the panel.

Abstract: A thick aesthetic laminate surface layer is achieved by using pre-cured particulates of the impregnating resin along with an initial binder material and preferably also abrasion resistant mineral particles. The protective overcoating may be applied in a thick layer to give gouge resistance and a deep look. Because the impregnating resin and the pre-cured particulates have the same index of refraction, the transparency of the coating and the resultant clarity of the underlying decor sheet are excellent.

Abstract: Compositions are provided for forming a coating on metal, plastic or wood substrate wherein the coating has the appearance and texture of wood, conceals joints on the surface of the substrate and is capable of accepting conventional wood stain.

Abstract: Compositions and a method are provided for forming a coated wood, plastic or metal product having the appearance and texture of wood grain. The joints on a wood surface are concealed by the coating and the coating is capable of accepting conventional wood stain.

Abstract: A synthetic wood board comprised of an extrusion of plastics material having opposed elongated top and bottom flat parallel walls spaced apart by transverse walls. A wood grain simulation pattern is formed in at least one of the top or bottom surfaces of the board. Two of the transverse walls are end walls, and each have integrally formed elongated connectors which interconnect with connectors of an adjacent one of the synthetic wood boards. A central fastener receiving channel extends longitudinally in the top and bottom walls and aligned back to back. A transverse wall is provided on each side of the fastener receiving panel. The fastener receiving channel of at least the top wall is provided with a cover strip which is removably connectable across a top opening thereof to conceal fastener heads of fasteners secured therein.

Abstract: Polyvinyl chloride articles are chemically embossed by placing a pattern thereon with a composition of vinyl ink containing silicone oil wherein the quantity of silicone oil is from about 2.5% to 5% by weight of the composition and then top coating the article with a fluid coating of an aromatic-hydroxyl functional polyester and a multi-isocyanate curing agent which is cured in the presence of a vaporous tertiary amine catalyst to form an adherent film over said substrate and whereby the fluid coating retracts from over the siliconized ink prior to curing to form a concave pattern on the cured film which is in registry with the siliconized ink.

Abstract: A decorative sheet comprises a transparent or translucent base sheet having a rear surface on which protrusion and recess patterns are formed and a bright set-solid print layer or bright pattern print layer formed on a side of the protrusion and recess patterns of the base sheet. Each of the protrusion and recess patterns is composed of parallel lines, continuous curved lines or a combination of the parallel lines and the curved lines each composed of protruded and recessed portions each in form of a groove having a width of 1 to 100 .mu.m. The base sheet has a front surface on which a transparent resin layer may be formed. The transparent resin layer is formed of a hardenable resin.

Abstract: Compositions and a method are provided for forming a coated wood product having the appearance and texture of wood grain, which conceals joints on the wood surface and which is capable of accepting conventional wood stain.

Abstract: An interior finish surface material for automobiles having good heat moldability such as high stretchability, low shrinkability after molding, good feeling of touch and good retainability of embossed pattern and comprising a surface layer and at least one of a base layer and a foam layer provided between said surface layer and said base layer, said surface layer being made from a composition comprising (A) 100 parts by weight of a vinyl chloride resin, (B) 20 to 200 parts by weight of at least one of a plasticizer and a thermoplastic elastomer, (C) 2 to 150 parts by weight of an AMBS resin and (D) 0 to 100 parts by weight of an inorganic filler.

Abstract: A decorative material in which two layers, i.e., a delustering printed layer and a lustering printed layer are combined together in a particular manner to obtain rugged feeling close to that of a natural tree. The lustering printed layer is formed on the grain trachea pattern portion so as to cover the trachea pattern, in order to obtain appearance that resembles natural tracheae, yet improving abrasion resistance and durability.

Abstract: A leather-like sheet material resembling natural leather is provided which has a microporous surface and comprises a fibrous substrate layer (1) and a porous, skinless surface layer (2) having an apparent density of 0.25-0.48 g/cm.sup.3 with pores having an average diameter of 15-300 .mu.m being predominantly present therein. The surface layer (2) comprises polyurethane I in which the organic diisocyanate constituent is an aromatic ring-containing organic diisocyanate and the porous structure of at least the surface portion of the surface layer (2) is provided with polyurethane II prepared from an organic diisocyanate, which mainly comprises an aliphatic diisocyanate and/or an alicyclic diisocyanate, a polymer diol and a chain extender.

Abstract: Method for production of artificial wood veneer, according to which sheets of natural wood, spot stained by burnings and/or coloring substances, are used to form a block of precomposed wood from which sheets of wood veneer are sliced presenting grains imitating briar veneers.

Abstract: Compositions and a method are provided for forming a coated metal or plastic surface having the appearance and texture of wood grain, which conceals joints on the surface and which is capable of accepting conventional wood stain.The present method utilizes a basecoat composition for covering a metal or plastic surface comprising a combination of resins, pigments, solvents, and additives for suspension, dispersion, wetting, thickening, flowing and anti-marring. A printing composition is also provided comprising resins, pigments, solvents, and tinting and wetting agents.

Abstract: High quality agglomerated structural boards, lumber and other structural members such as I, U, T, L beams or corrugated plates or moldings are produced from engineered long, thin narrow green wood strands. Process, in which the parallel alignment of the strands to each other and their original starting orientation are maintained through their transportation, drying, blending, forming and pressing, preventing their intermingling, twisting, warping and breaking. The application of fungicides, pesticides, fire retarding and other chemicals during the blending process, impregnates or colors the agglomerated structural products throughout their cross section, making the products resistant against rot, insects, fire or aesthetically attractive for architectural applications.

Abstract: Molded composites, useful for manufacturing for example entry way doors, furniture components, building decorative or structural components, etc., are produced by a process in which a substrate and surface finishing film are placed in a mold, the mold is closed, and reactive polymeric precursors are injected between the substrate and the surface finishing film. The injection pressure and the autogenous pressure incident to the curing of the reactive polymeric precursors deform the surface finishing film into intimate contact with a surface of the mold cavity, and simultaneously the polymeric precursors chemically bond to the surface finishing film.

Abstract: An aqueous dispersed primer-sealer composition applied to a surface layer of overlay paper or surface mat provides an impregnated surface layer for use in manufacturing hardboard products by hot pressing in a molding operation. The primer sealer provides a finished surface as well as defect-free surface from the molding surface. The primer-sealer can be pigmented and is based on a polymeric binder composition containing melamine resin, carboxyl functional acrylic emulsion copolymer, vinyl-acetate-vinyl versatate copolymer, emulsified fatty acid, and polyvinyl alcohol.

Abstract: Door constructions are provided including a frame, a core, and on both the inner and outer faces of the core an iron plate at least 0.2 millimeters thick with a wooden layer adhesively secured to the outer surfaces thereof. Preferably the core provided is a material having superior heat insulating properties with a heat conductivity of between about 0.15 and 0.05 as well as a diffusion resistance at least 20 times greater than that of air. In a preferred embodiment, each of the iron plates has a wooden layer adhesively secured to both the inner and outer surfaces thereof.

Abstract: An improved material for finishing athletic court, commercial, and residential floor surfaces of wood, linoleum, terrazzo, concrete, or other smooth surface includes at least one elongated sheet having a layer of a uniform flexible film of clear plastic material of between about 1 mil and 25 mils thickness and a continuous layer of adhesive material releasably adhering the flexible film onto the floor surface. The elongated sheet is provided in a self-adhesive roll and is applied to the floor surface by unrolling the sheet from the roll, with the adhesive side down, aligning an end portion on a predetermined corresponding portion on the floor, and pressing the total length of the sheet against the floor to adhere the sheet to the floor surface. Additional sheets may be unrolled successively, with a slight overlap to assure an sealed joint.

Abstract: A dressed leather is provided at least on one side with depressions and have on this side absorbent protruding fibres. At this side the leather is bonded with a layer formed of an aqueous dispersion of synthetic plastics material, said layer fills the depressions and completely receives the protruding fibres and forms at least a part of the dressing, which dressing is provided with a structured surface at the side turned away from the leather.Preferably, the dressing consists of two layers, the inner layer, which is adjacent the leather and completely receives the protruding fibres, is formed of the aqueous dispersion of synthetic plastics material and the outer layer, which has the structured surface, consists of an aqueous dispersion of synthetic plastics material or of a liquid solution of synthetic plastics material.

Abstract: A flexible epoxy coated fabric has good hand, good wear resistance, good hydrolytic resistance, and good ultraviolet light resistance. An optional but desirable binder is a true coating and not an impregnation of the fabric in that at least 50 percent of the binder material resides on the surface of the fabric. A flexible epoxy material is utilized as a coating and generally has an intermediate hydrocarbon portion having at least 25 carbon atoms for each chain. The fabric is suitable as a substitute for leather in clothing, and upholstery as in automotive upholstery.

Abstract: A paste-the-wall wallcovering has a deep emboss paper ply (10a) adhered to a flat plastics ply (16) having perforations (22). The ply (16) can restrain the ply (10a) against any significant expansion in the course of hanging and paste drying. The perforations (22) are regulated on the one hand so that weight loss from the hanging paste is not so excessive that the paper ply becomes softened and, on the other hand, so low that tacking of the wallcovering to the surface on which it is to be adhered is not unduly delayed.In making the wallcovering the paper ply is moistened and embossed and allowed to dry just below ambient humidity prior to laminating it to the plastics ply. The wallcovering may be decorated in the course of manufacture or after hanging.

Abstract: A coated laminate in web form, having a fine-grained surface, consists of a nonwoven fabric with a coating, with a plain knit or woven fabric situated between the coating and the nonwoven fabric. Its production is performed by a reverse procedure on a release paper.

Abstract: A synthetic leather-like material includes a woven fabric base, an acrylic paint layer over the fabric, a clear polymer layer over the paint, and a silicone layer over the polymer.

Abstract: A plastics tile has a back ply having raised areas on one face which define at least one recess and a slug of facing material bonded in the or each recess. The slug or slugs are desirably either flush with or slightly proud of the raised areas of the back ply.

Abstract: A method of molding high definition skins of a photocurable polymers, to said skins and said skin filled with a foam to yield a cushion protective or decorative item.

Abstract: Covered polyurethane foam panels have incorporated in them an adhesion enhancer which is composed of a polyester polyol and a heteric polyether polyol. The polyester polyol is preferably an adduct of adipic acid with ethylene glycol and butanediol. The heteric polyether polyol contains from about 35 weight percent to about 75 weight percent ethylene oxide, the remainder being propylene or butylene oxide and has a functionality from about 2 to about 3.

Abstract: Artificial leather and a dyeing method therefor; the leather includes ultrafine polyamide fibers and is particularly a grained artificial leather having bright, deep color, good color fastness to dry cleaning with charged soap, a delicate touch free from any undesirable rubber-like feeling, as well as high durability.A super-entangled fiber base is provided comprising ultrafine polyamide fibers and/or bundles thereof; polyurethane including polyoxyethylene of molecular weight of 500-5,000 is applied. The polyamide ultrafine fibers are dyed with a metal-dye complex and a fixing agent.

Abstract: A dressed leather is provided which comprises a split leather having one side from which fibers protrude, a first layer of solidified aqueous dispersion having a thickness between 0.07 mm and 0.22 mm of a synthetic plastics material in which the fibers are completely immersed on the one side, and a second layer of a synthetic plastics material of generally the same thickness of the first layer bonded to the first layer and having turned away therefrom a textured or non-textured surface. Additionally, there may be a finish layer overlying the textured or non-textured surface of the second layer. The split leather is substantially free of the dispersion except at the fibers.