Abstract:
A process is provided for manufacturing an imbedded flooring product having a skeletal frame in the form of a mesh at least partially imbedded into a vinyl sheet substrate. The method provides for the mesh to create a pattern visible from above the sheet.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a vinyl flooring product having a design visible from a top surface of the product, and more particularly to a vinyl flooring product having an imbedded web creating a pattern visible from above. 
     Vinyl is often applied to the back of carpet tile. Vinyl is also utilized to create flooring products. Textures have been added to the surface of some vinyl flooring products as described in U.S. Pat. No. 4,379,185. However, a need still exists to provide an improved flooring product, especially one with superior aesthetics. 
     SUMMARY OF THE INVENTION 
     Consequently, it is an object of the present invention to provide a vinyl flooring product having improved aesthetics, and particularly such a product which utilizing a mesh, screen or scrim, hereafter a skeletal framework, which is imbedded into a top surface of the vinyl and then cured in an oven. The finished product produces a pattern which has a top portion of the skeletal framework exposed through a top surface of the cured vinyl or has valleys in a top surface of the vinyl where the mesh has been imbedded which resembles the skeletal framework. 
     Vinyl at least partially fills the voids, or openings, between runners in the skeletal framework. Anticipated skeletal framework material include metal and nylon. Further processing may be performed on the imbedded vinyl including, but not limited to, cutting into squares, and/or coating with a clear protective coating. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which: 
     FIG. 1 is a top elevational view of a skeletal framework in the form of a mesh utilized in the present invention; 
     FIG. 2 is a top elevational view of a first embodiment of the mesh imbedded vinyl product of the present invention utilizing the mesh of FIG. 1; 
     FIG. 3 is a top elevational plan view of a second embodiment of the present invention utilizing the mesh of FIG. 1; 
     FIG. 4 is a cross sectional view of the second embodiment of FIG. 3; 
     FIG. 5 is a cross-sectional view of a first portion of the first embodiment of FIG. 2; 
     FIG. 6 is a cross-sectional view of a second portion of the first embodiment of FIG. 2; and 
     FIG. 7 is a diagramic view of a process of making the mesh imbedded vinyl of FIGS.  2  and  3 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 shows a skeletal framework in the form of a mesh  10  for use in imbedding into a vinyl substrate. The mesh  10  has limbs or runners  32  which circumscribe openings  34 . The runners  32  meet at one or more junctures  35 , 37 . The runners  32  have top surfaces  36  and bottom surfaces  37  as shown in FIG.  4 . While FIG. 1 shows one design of a metal skeletal framework in the form of a mesh, or screen, many other designs could be utilized including those with round openings, square openings, or other shaped openings. Furthermore, all openings  34  need not be identically shaped in a particular mesh. The mesh  10  could also be nylon or other appropriate material. 
     FIGS. 2 and 3 show the mesh  10  installed in vinyl flooring products  12 , 14 . FIGS. 4-6 show cross sectional portions of FIGS. 2 and 3 at various locations. 
     Vinyl is often utilized to back carpet tile. Vinyl forms a relatively thin layer which is adhered to a back side of carpet to form tile. The thin layer is usually formed by pouring liquid vinyl onto a conveyor belt which is then transported through an oven to cure as a sheet of vinyl or the back of a tufted carpet. 
     FIG. 7 shows a diagram of a method of imbedding a mesh into a vinyl substrate. A conveyor  20  is utilized to transport a film of liquid vinyl provided from the supply  22 . Before entering the oven  24  to cure into a solid form, a mesh  26  is placed on a top surface of the liquid vinyl. Imbedders, such as rollers  28 , may be utilized to selectively adjust the depth of the mesh  26  relative to the top surface exposed vinyl portions during the imbedding process. The various designs produced will be explained in more detail below depending upon the depth and contour, such as provided by multi-depths. The composite unit is then transported by conveyor  20  into the oven  24  and cured. Curing at 250-275 degrees Fahrenheit has been found to adequately cure the liquid vinyl into a solid vinyl sheet as it passes through the oven  24 . After leaving the oven  24 , the composite product with the vinyl cured, and at least mechanically connected to the mesh  26 , may then be further processed, such as by rolling into rolls, cutting into tiles, adding additional layers or colors, etc. . . 
     The depth at which the mesh  10  is imbedded into the liquid vinyl has a large influence on the design of the flooring product after curing in the oven  24 . FIGS. 3 and 4 represent a first product  14  and a cross sectional portion of the first product  14  respectively. 
     The first product  14  enters the oven  24  with the mesh  10  only slightly depressed into the liquid vinyl. The bottom surface  37  of the runners  32  is below the top surface  44  of the vinyl. The vinyl forms a vinyl bottom layer  42  which forms a non-porous sheet surface which extends below the mesh  10 . Slight wicking of vinyl may be observed on walls  30  of runners  32  of the first mesh  10  within the openings  34  between runners  32 . The first product  14  may have vinyl which wicks up toward a top surface  36  of the first mesh  10  and forms a bubble  38 , or well, within the openings  34 . The top surface  36  of the first mesh  10  is not obscured from view by cured vinyl  40 . A bottom vinyl layer  42  extends below the bubbles  38 , or wells, and first mesh  10 . It is possible that the bubbles  38  may extend above the top surface  36  of the mesh, but they do not overhang to obscure the first mesh  10  from view in this embodiment. In other embodiments, overhanging occurs. 
     A second vinyl product  12  is shown in FIGS. 2,  5  and  6 . The second product  12  is constructed in a similar manner as the first product  14 , except that the imbedder  28  places the mesh at a greater depth than is done in the first product  14 . In the second product  12 , the vinyl extends through the openings  34  and extends over at least some of the top surface  36  of the first mesh  10  as an overhang. FIG. 5 shows a cross section of second product  12  such as taken along the left side of FIG. 2, while FIG. 6 shows a cross section of product taken along the middle of FIG.  2 . 
     In FIG. 5, the top surface  44  extends above the top surface  36  of the first mesh  10 , however at least a portion of the top surface  36  is still visible. The bubble  46  with the top surface  44  may, or may not, have an overhang  48  which extends over a portion of the top surface  36  of the mesh. This creates the look illustrated in FIG. 2 at the left side of that Figure. If more pressure is applied during the imbedding process, and/or if the first mesh  10  is applied at a deeper depth, then the product of FIG.  6  and certain portions of the center of FIG. 2 may be created. 
     In FIG. 6, the bubbles  46  once again extend above the top surface  36  of the first mesh  10 . However, in this embodiment, the top surface  36  of the first mesh  10  is no longer visible. Nevertheless, valleys  50  are created between the bubbles  46  where the first mesh  10  has been imbedded into the vinyl. Both embodiments of FIGS. 5 and 6 have vinyl throughout the openings  34  intermediate the runners  32 . 
     At the center of FIG. 2, due to the change in thickness of where the runners  32  meet relative to the arms  32  themselves, parts of the cross section would resemble FIG. 5, while parts would resemble FIG.  6 . This also creates a possible design choice. With other mesh designs, other designs can be created. Additionally, the depth of imbedding the mesh  10  may vary across different portions of the flooring product to create still further design choices. 
     Numerous alternations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.