Abstract: Texturing the surface wood comprising moving randomly positioned, rigidly mounted shredding points along the surface of the wood, orienting the direction of movement of the shredding points generally in the direction of the grain but slightly at variance with the grain, bearing down to engage the shredding points into the grain of the wood, ripping and shredding fragments of the grain as the shredding points cross the grain in the direction slightly at variance with the grain while leaving the shredded fragments still attached to the wood surface at one end, lifting and randomly orienting the shredded fragments of grain still attached to the wood surface as the shredding points move along the surface thereby imparting a rough appearance of randomly oriented grain fragment separations covering the surface.

Abstract: A sheet material finished on at least one side with a coherent surface layer is formed by electrostatically spraying a solution or dispersion of plastics producing fibers from 0.1 to 30 microns in diameter. Then the mat is consolidated with heat and pressure, whereby the fibers form a tight bond with the surface of the support material which is thus finished.

Abstract: A method of producing covering materials of leather for the upholstery and cushions of furniture, wherein the raw material or stock, if desired following evening-out by splitting, while possessing a thickness of at least 3 millimeters is converted by tanning and post-tanning into a loose-fibrous, soft and pliable condition suitable for use.

Abstract: A method of mounting a shed snake skin. The shed snake skin is saturated in water to render it limber and free of folds with at least some foreign particles being removed. The skin is subjected to flowing water to remove the remaining foreign particles. A pool of water is placed on a plastic substrate. The saturated skin is placed on the pool of water, cut longitudinally, flattened on the pool of water and caused to dry to form a unitary structure, with the shed skin adhered to the substrate.

Abstract: A diagonal bias-stretching device and a method of enhancing surface grain of imitation-leather material with such device, which device comprises a reciprocating roller moving between lateral positions on either side of a line of advance of an imitation-leather material, to provide for alternating diagonal stretching and relaxing of the material as it moves under tension in the line of advance.

Abstract: A decorative laminated structure having on its surface a pattern composed of concaves and convexes which are formed by local heat shrinkages of a layer of a heat-shrinkable resin sheet employed. Such decorative laminated structure can be obtained by laying a base, a heat-shrinkable resin sheet and a picture layer containing at least a plurality of heat sensitive picture areas in a predetermined order to form a composite material, said heat sensitive picture areas being contiguous and closely adherent to said heat-shrinkable resin sheet; and irradiating the resulting composite material with a heat ray to cause said heat-shrinkable resin sheet at its portions corresponding to said heat sensitive picture areas to cave in, thus forming concaves.

Abstract: There is provided a non-woven textile composite which simulates the strength, durability, appearance, temper, smooth surface, hand and feel of natural leather and a method of producing the same. The composite includes a non-woven needled textile fabric substrate having a coherent network of randomly entangled textile fibers with an as needled overall bulk density of at least 6 pounds/cubic foot and having a face surface and a back surface, and a geometric center therebetween. A shape-sustaining immobilized polymeric composition is differentially disposed in the substrate such that there is at least 25% more polymeric composition between the face surface and the geometric center than between the back surface and the geometric center. A moldable skin coat layer may be disposed on the face surface. The substrate and the immobilized polymeric composition are in a co-compacted state such that the thickness of the co-compacted substrate and immobilized polymeric composition are less than 0.

Abstract: The invention relates to a process for preparing thermoplastic sheets or webs suitable for use as surfacing materials.Sheets of thermoplastic polymers are known as surfacing materials and, when foamed, as substitutes for wood, but available materials do not closely resemble natural wood in appearance. The present invention provides a process whereby sheets or webs are obtained which can provide a wide variety of decorative finishes and which can approximate the appearance of such natural products as wood and marble.The process of the invention comprises the extrusion of a foamable mixture of immiscible thermoplastic polymers, one of which is crystalline and of higher melting point than another, stretching the resulting foamed extrudate, compressing the stretched extrudate and then cooling the stretched and compressed extrudate. The resulting product is substantially impermeable and has integral patterning and can be used as a surfacing material in a variety of applications.

Abstract: A simulated stained glass article and method for its production comprises a sheet of transparent or translucent material having at least one surface provided with an optically distorting characteristic and a thermosetting or thermofluid composition suitably colored and disposed on at least one surface to provide a desired leaded effect.

Abstract: This invention provides a decorative laminated structure having on the surface a pattern composed of concaves, at least one of said concaves having an opening at its bottom portion formed by local heat shrinkage of a layer of a heat-shrinkable resin sheet employed. Such decorative laminated structure is prepared by a method comprising forming a composite layer structure including a base, a heat-shrinkable resin sheet, a picture layer containing heat insensitive picture areas and another picture layer having heat sensitive picture areas, said heat sensitive picture areas being contiguous and closely adherent to said heat-shrinkable resin sheet; and irradiating the composite layer structure with a heat ray in an amount sufficient for making an opening in the heat-shrinkable resin sheet to thereby cause the heat-shrinkable resin sheet to shrink locally and form concaves, at least one of said concaves having an opening at its bottom portion at portions corresponding to the heat sensitive picture areas.

Abstract: A counter stiffener for shoes is made from a thermoplastic base sheet, specifically a copolymer of ethylene and a vinyl monomer, laminated to a liner sheet. The liner sheet is a cross-linked copolymer of ethylene and a silane to which color has been added. The liner sheet is colorfast and wear-resistant.

Abstract: A layered material for linings or coatings is made of a paste consisting principally of wood powder having a fineness similar to flour and vinylic glue, said paste being convertible into a foil by rolling cylinders, a press or other means.The layered material may be engraved, printed, painted or may withstand any finishing work as wood.To engrave or emboss the layered material an embossing belt or an embossing cylinder can be employed.To manufacture the embossing cylinder a method is disclosed in which even the model itself which has to be imitated can be used as matrix for the cylinder.

Abstract: A decoratively branded plasterboard product having a pattern of recesses formed in the paper-like outer surface of the plasterboard is disclosed. The recesses are charred to discolor the same, and the pattern is preferably a wood grain simulating pattern.

Abstract: A wood based composition board product, either hardboard, particleboard or fiberboard, having an intricate pattern of recesses formed in the relatively hard outer surface of the product is disclosed. The recesses are charred to discolor the same, and the pattern is preferably a wood grain simulating pattern.

Abstract: A process for producing an artificial leather having excellent touch, appearance and full-hand similar to that of natural leather and having further excellent softness and surface strength, which comprises coating a composition comprising an urethane prepolymer, a combination of catalysts and a foam stabilizer and including a plurality of extremely fine cells (foams) of an inert gas, onto a release paper or a layer of a surface treating agent coated on a release paper in a specified thickness; subjecting the resultant to a steam treatment under a specified atmosphere; laminating a base sheet onto the coating layer under pressure; subjecting the laminated product to a heat treatment at a specified temperature, and then peeling off the release paper, and optionally further treating the product with a surface treating agent.

Abstract: Resilient wood replication especially suited for use as floor covering is provided by a thick resilient elastomeric polyurethane base having a wood-stained molded textured wood-grain surface which is overcoated with a clear, tough, abrasion-resistant, flexible, water-resistant polyurethane protective coating. A preferred configuration of the resilient wood replication is a floor tile having opposed mating ends and two parallel sides and a surface configuration having a grain appearance of a plurality of parqueted natural wood pieces. A multiplicity of the tiles can be applied to the floor with complimentary ends fitted together to provide a continuous mass of tile having the actual lines between separate tiles virtually indistinguishable to the casual observer.

Abstract: Upholstery material and shoe upper material made from a base sheet of criss-crossing elastomeric polyurethane fibers running parallel to the surfaces of the sheet, said fibers being bonded together at their points of contact. In one preferred form the product has a preformed skin whose thickness is less than about 100 microns and preferably less than about 50 microns, such as about 20 to 40 microns and the skin is joined to the fibers of the base sheet by spaced fingers of a binder.

Abstract: A multi-layer front plate for furniture, especially, but not exclusively, for kitchen cabinet doors, and method of making same, according to which a core plate, preferably of pressed material, has its front side and its confining edges covered with a synthetic material, especially with a soft integral foam of polyurethane or another elastomeric material, while those sections of the cover where the front side of the cover merges with the cover edges include a rounded section.

Abstract: The flame spread rating of Lauan plywood panels is reduced significantly by incorporating, just prior to application, a quantity of sodium bicarbonate in dry powder form or slurry and a quantity of a saturated aqueous solution of sodium tetraborate, respectively, in the water base filler and the water base basecoat used to finish the surface thereof.

Abstract: A floral base is made by hot wire cutting a foam of expanded polystyrene beads, thereby forming a smooth skin over the cells at the cut surface; differentially wire brushing the hot wire cut surface, lightly in some areas so that the wires only slice the surface skin and more deeply in adjacent areas so that the wires gouge out beads to form cavities and roughly parallel channels; then coating the surface with a latex paint. The resultant material surprisingly simulates the appearance of rough weathered lumber.

Abstract: This invention relates to a process for producing finished and/or irreversibly embossed microporous sheet structures by coagulation of a polyurethane solution, in which prior to the coagulation of the polyurethane solution a finishing agent is mixed into it or a finishing agent is applied to the free surface of the polyurethane solution which has been spread out flat and embossing is then carried out during or shortly after the coagulation or after the washing, but still before the drying, or else the microporous sheet structure obtained and into which the finishing agent has been mixed previously is, after drying, pressed between two plates or passed under pressure between at least two oppositely rotating rolls, at least one of which is highly polished.

Abstract: An embossed plastic sheet material having a surface design effect thereon, and the process of preparing such material which comprises: applying to compressed areas of an embossed release sheet having a design effect thereon a first polymer characterized by a high modulus of elongation; applying a continuous layer of a second polymer characterized by a low modulus of elongation over the first polymer in the depressed areas; removing the release sheet to provide a polymeric sheet material composed of a continuous layer of a low modulus polymer, with raised areas composed of a high modulus polymer secured thereto, the raised areas of the high modulus polymer forming a substantial part of the sheet surface; and flexing the low modulus polymer in the intervening low areas between the raised high polymer areas to the polymeric sheet to form a weak-hinge effect, thereby providing an imitation leather-type material with an accentuated design effect thereon.

Abstract: An embossed plastic sheet material having a surface design effect thereon, and the process of preparing such material which comprises: applying to compressed areas of an embossed release sheet having a design effect thereon a first polymer characterized by a high modulus of elongation; applying a continuous layer of a second polymer characterized by a low modulus of elongation over the first polymer in the depressed area; removing the release sheet to provide a polymeric sheet material composed of a continuous layer of a low-modulus polymer, with raised areas composed of a high modulus polymer secured thereto, the raised areas of the high modulus polymer forming a substantial part of the sheet surface; and flexing the low modulus polymer in the intervening low areas between the raised high polymer areas to the polymeric sheet to form a weak-hinge effect, thereby providing an imitation leather-type material with an accentuated design effect thereon.

Abstract: A plate block includes a decorative plate which includes a substratum and a face veneer joined to the substratum by adhesive means. The substratum has a front face and a rear face with inclined edge portions disposed between the front face and the rear face such that the rear face is larger than the front face. The face veneer is joined to the front face and to the edge portions. A base plate is disposed in spaced parallel relationship relative to the decorative plate, and an intermediate member is disposed between the base plate and the decorative plate with the base plate having at least one edge portion projecting beyond an edge of the decorative plate to facilitate assembly of a plurality of plate blocks in juxtaposed array.

Abstract: The invention contemplates expanded-plastic coated fabric wherein the exposed surface of the expanded plastic is characterized by a random distribution of torn cellular pockets and by a random distribution of projecting free ends of flock elements which are rooted to the plastic at their other ends. Various methods of making the fabric are described, with different "hand" or "feel" depending upon the method and upon the materials and their dimensions.

Abstract: An imitation leather material which comprises in combination: a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; the napped surface of the base sheet impregnated with a crosslinked polymeric material; the napped impregnated surface of the base sheet characterized by a smooth, buffed, flesh-like surface; an open-cell flexible polymeric foam layer bonded to the other unnapped surface of the base sheet material; a thin polymeric skin layer bonded to the surface of the foam layer; and the thin polymeric skin layer characterized by an imitation leather-like surface.

Abstract: A decorative laminate material exhibiting stability to heat at temperatures used to bond such laminates to metal surfaces is prepared by bonding a calendered vinyl film to a vinyl plastisol.

Abstract: A unitary, heat and pressure consolidated laminate comprising at least one paper sheet, a decorative sheet and a coating on said decorative sheet, said paper sheet and said decorative sheet being impregnated with an acrylic resin-melamine/formaldehyde resin composition and said coating comprising an acrylic resin-alkoxymethylated melamine composition.

Abstract: A process for the manufacture of artificial leather which has a napped, suede or nubuck surface finish by contacting a natural, synthetic of semi-synthetic backing member with a polymeric system comprising a mixture of a heat-reactive latex and a carboxylated latex and which contains at least one dyestuff. Each of the latices is cross-linked in sequence while the contacted backing member is dried. The migration of non-polymeric components in the system of latices is suppressed during drying. The backing so treated is mechanically altered on the grain side of the backing member to provide an irregular leather-like surface thereto.

Abstract: A unitary, heat and pressure consolidated laminate comprising at least one paper sheet, a decorative sheet and a coating on said decorative sheet, said paper sheet and said decorative sheet being impregnated with an acrylic resin-melamine/formaldehyde resin composition and said coating comprising an acrylic resin-alkoxymethylated melamine composition containing pyrophyllite, andalusite or mixtures thereof.

Abstract: A synthetic suede is disclosed comprising a flexible backing having a multiplicity of upstanding flock fibers adhered to the base, and a fatty acid radical cationic softener substantially uniformly distributed over at least portions of the fibers at or near their ends. Typical cationic softeners include the fatty acid quaternary ammonium softeners.

Abstract: A diallyl phthalate resin-containing aqueous emulsion containing an aqueous emulsion of a diallyl phthalate resin of a rate of polymerization of 30 - 75 weight % consisting of 50 - 100 weight % of diallyl phthalate and 50 - 0 weight % of an alkyl acrylate, and an aqueous emulsion of a thermosetting vinyl resin consisting of 10 - 1 weight % of a vinyl compound containing a thermosetting functional group and 90 - 99 weight % of a vinyl compound not containing a thermosetting functional group, the content of said diallyl phthalate resin component to said thermosetting vinyl resin component being in a proportion of 10 - 70 weight % of the former to 90 - 30 weight % of the latter.

Abstract: A decorative laminated structure having on its surface a pattern composed of concaves and convexes which are formed by local heat shrinkages of a layer of a heat-shrinkable resin sheet employed. Such decorative laminated structure can be obtained by laying a base, a heat-shrinkable resin sheet and a picture layer containing at least a plurality of heat sensitive picture areas in a predetermined order to form a composite material, said heat sensitive picture areas being contiguous and closely adherent to said heat-shrinkable resin sheet; and irradiating the resulting composite material with a heat ray to cause said heat-shrinkable resin sheet at its portions corresponding to said heat sensitive picture areas to cave in, thus forming concaves.

Abstract: A simulated wood panel comprising a substrate with rigid elongated reinforcing members and foamed polymer coating which is molded to simulate the appearance of wood grain. The method for making the simulated wood panel comprises the steps of providing a substrate, providing elongated reinforcing means for said substrate, and covering said substrate and said reinforcing means with a foamed polymer.

Abstract: A smooth-surfaced textile fabric, suitable for use in artificial leather, is prepared by needling staple fibers into a coherently-entangled structure. The structure has a base layer which carries a major portion of planar loading and a top layer which carries a minor portion of planar loading. Disposed on the top layer is a polymeric finish having a smooth surface. The base layer and the top layer are connected by connecting fibers having segments disposed in each of the said layers and the connecting fibers only loosely connect the top layer to the base layer.

Abstract: A web of indeterminate length carrying thermally transferable material, usually referred to as hot stamp tape, is structured to provide an improved simulated wood grain pattern on a substrate after transfer to the substrate of transferable portions of the tape. The web or tape may be provided in sheet form. The structure comprises "ticks" or discrete linearly oriented spots of material having low specular reflectivity coated on a matte carrier sheet, as by printing, and a layer coated thereon to provide the top layer of the transferred material, which replicates the surface of the carrier sheet and the coated "ticks" or spots.

Abstract: There is provided a needled textile fabric having high bulk density, entangled fibers, a controlled axis of flexure and a bulk density gradient wherein the bulk density increases from the back surface to the face surface thereof. The products are made by needling layers of fibers having a needle pick-up gradient into a dense structure, with a bulk density gradient. The needled fabric is coated with a polymeric coating on the face surface of the structure where the thickness of the coating is from 4 to 20 mils. The fabric is suitable for use as an artificial leather.

Abstract: A textile fabric with a dense intensely entangled reticular fibrous structure and process for manufacture thereof are provided wherein staple fibers are needled into a high bulk density structure with a bulk density gradient wherein the bulk density increases from the back surface to the face surface of the structure. The needled structure is impregnated with a liquid phase filler and capillary action preferentially disposes the liquid phase filler toward the more dense face surface. The filler is coagulated and dried, cured, etc., into particles which are at most loosely bonded to the fibers. The preferential disposition of the filler increases the bulk density gradient of the filled fabric.

Abstract: An improvement in a process for preparing a foamed thermoplastic article in which a foamable thermoplastic resin is passed through an orifice of a die and is permitted to expand after passing through said orifice. The improvement includesA. passing the foamable thermoplastic resin through an orifice, the outer periphery of which contains a plurality of recesses,B. allowing the resin to expand to form a soft-surfaced porous shaped article having peaks and valleys corresponding to the recesses of the orifice, andC. pressing the surface of said article so as to level the peaks.A smooth-surfaced shaped article is produced having a surface structure characterized by high density portions corresponding to the peaks and low density portions corresponding to the valleys and resembling natural wood.

Abstract: Dry leather is dyed with azoic dyes without wetting the leather with water by incorporating into the leather the required diazonium component and any required coupling component in a substantially non-aqueous volatile low-viscosity solvent and incorporating into the leather any other materials required for the coupling reaction in such a solvent or as a vapor. The coupling component can be a natural or synthetic phenolic tanning agent employed in tanning the leather. Dye patterns can be applied to the surface of the leather by using a light-sensitive diazonium component and photo-imaging the surface before effecting coupling. Dry leather is dyed by such processes without significant change in properties.