Patent GB-1409295-A (GB)
Title: Surface covering materials
IPC: B32B5/20
Filed: 1972-07-28
Abstract: 1409295 Laminates MARLEY TILE CO Ltd 10 April 1973 [28 July 1972] 35507/72 Heading B5N [Also in Division B2] Surface covering materials having a textured effect are produced by (a) applying foamable resin composition(s) containing a blowing agent and foamable throughout, in the form of a plastisol, on to selected areas of a substrate, (b) applying at least one overall layer as a preformed layer of an essentially non-foaming composition over the substrate and the foamable resinous composition(s) thereon, and (c) heating to effect foaming of the foamable resin composition(s), a decorative pattern being provided by printing on to the surface of the overall layer(s) and/or by use of a pigmented substrate and/or pigmented foamable resin composition(s) together with a transparent or translucent overall layer(s). The substrate may comprise a non- woven or woven fabric or preformed film, e.g. asbestos paper, woven glass-fibre fabrics and glass fibres bonded, e.g. with synthetic resins. The substrate may be impregnated with a resin composition and/or may have one or more layers of resin composition bonded either to the side on to which the foamable resin composition is applied or to the reverse side thereof, said layer(s) being foamable or non-foamable. The substrate may also be a film casting support, e.g. a release paper and subsequent to step (c) the film casting support may be removed and subsequently a backing material applied to the product. The backing material may comprise a polyvinyl chloride layer applied either by adhesion of a preformed calendered film or by spreading a polyvinyl chloride plastisol. The foamable resin composition may be applied by rotary screen printing and is preferably a polyvinyl chloride plastisol which contains a blowing agent. The polyvinyl chloride may be a homopolymer or copolymer, e.g. a copolymer of vinyl chloride with vinyl acetate or vinylidene chloride. The plastisol may also contain a stabilizer, e.g. dibasic lead phthalate, fillers, e.g. calcium carbonate, viscosity modifiers, e.g. hexylene glycol and volatile additives such as white spirit. Multi-level texturing may be achieved by second and subsequent applications of the foamable resin composition either in register or only partly in register and optionally using compositions containing differing amounts of blowing agent. A non-foamable resin composition may also be applied on to selected areas of the substrate, e.g. before application of any foamable resin composition and the foamable resin composition applied in register or partly in register with a non-foamable composition. The foamable resin composition may be first applied directly on to selected areas of the substrate and non-foamable resin composition applied in register or partly in register with the foamable composition. Successive applications of foamable composition, non-foamable composition and then foamable composition or successive applications of non-foamable composition, foamable composition and then non-foamable composition can be effected. The overall layer in step (b) may be applied as a pre-formed film but is preferably applied in the form of a polyvinyl chloride plastisol by doctor blade or air-knife or rotary screen printing. Where a decorative pattern is provided by printing on the surface of the overall layer(s), the printing ink, e.g. polyvinyl chloride plastisol or water-based acrylic resin emulsion can be applied by rotary screen, gravure or block printing in or in and out of register with the valleys (corresponding to areas in which no foamable resinous composition has been applied). The printing ink may also contain a blowing agent and differently coloured plastisols may be applied to different portions of the overall layer surface. The thickness of the printing ink can also be varied. Preferably an overall transparent wear layer is applied to the surface covering material, preferably a polyvinyl chloride composition applied as a preformed film or as a plastisol. The use of acrylic based compositions to provide coating, forming part of the substrate and polyurethane-based compositions to provide flexible wear layers are mentioned. The products may be used as flooring materials, or wall and ceiling coverings.