Patent GB-1062670-A (GB)
Title: Improvements in or relating to embossed sheet material
IPC: B32B27/00
Filed: 1963-12-19
Abstract: 1,062,670. Embossing. HICKS & OTIS PRINTS Inc. Dec. 19, 1963 [Dec. 24, 1962; Dec. 13, 1963], No. 60151/63. Heading B6J. [Also in Divisions B5 and D1] Embossed laminates, comprising a layer of open-cell foamed polyether-, or polyester-, polyurethanes, or foamed natural rubber, synthetic rubber, or vinyl polymers, having on one or both sides a layer of woven or knitted fabric or plastics material such as polythene, polypropylene or a vinyl chloride copolymer, are made by coating the foamed layer with a pattern of adhesive, applying the outer layer or layers, applying pressure while setting the adhesive, and releasing the pressure whereby the foamed layer remains compressed and adheres to the outer layer or layers, at those parts containing, and in the pattern of, the adhesive, the foamed layer being stretched longitudinally before compression, e.g., when in web form, by accelerating the advancement of the web, or being stretched both longitudinally and laterally, producing after retraction a puffed effect in the cover layer or layers. Alternatively the cover layer or layers may be rendered stretchable, e.g. by heating if not naturally stretchable, and may be stretched to conform to the increased surface area of the centre layer resulting from embossment. A woven fabric outer layer may be bias-cut. In Fig. 2 (not shown), a web (210) of foamed material is embossed on each side by engraved rollers (215), (216) supplied with adhesive respectively by a reservoir (217) and doctor blade (218), and a reservoir (211) and blade (212). The adhesive-patterned web is passed through a heating chamber (229) to partially set or dry the adhesive and is compressed between heated rollers (233), (234) which are driven at a speed which stretches the web and which apply upper and lower webs (235), (236). On emergence from the rollers the web recovers except at those points held by adhesive and exhibits an embossed pattern such as that of Fig. 3. If embossed on one side only the web may be supported on the other side by a web, e.g. of permeable fabric, and the heating chamber may be replaced by a hot-air nozzle on the fabric side. Two layers embossed on one side only may be laminated together back-to-back. The engraved roller or rollers may be replaced by rollers having projections arranged in a pattern and taking adhesive from a coated rubber roller formed with corresponding recesses. As shown in Fig. 10 a foam web 410 printed on both sides with a pattern of adhesive is stretched longitudinally, by adjustment of the speed of the forwarding rollers, and laterally by pairs of endless belts 509 between which the edges of the web are gripped. The belts pass around pulleys. 501 . . . 504, are engaged by driving pulleys 514, 515, and (see also Fig. 12), move within convergent cam surfaces 536 forming parts of frames 534, 535 which are spaced apart to the desired extent by bars including turnbuckles 516, 517. The stretched web is united with cover layers 435, 436 between heated pressure rollers 433, and on recovery after passing around chill rollers 439, 440 forms an embossed web with a puffy surface shown in section in Fig. 13. The adhesive used may be coloured, to be seen as a pattern through translucent outer layers when provided or alternatively when used in less viscous form, to appear by diffusion as a pattern on the surface of permeable cover layers. Specified adhesives are rubber, synthetic rubber, and cellulose cements, rubber latex, heat-sensitive adhesives, and thermosetting compounds such as epoxy resins. Examples given are (a) butadieneacrylonitrile copolymer and a vinyl chlorideacetate copolymer in organic solution, (b) a polyester-isocyanate mixture in organic solution, (c) a solution, containing TiO 2 , of an epoxy resin and a polyamide curing agent, (d) a solution of an acrylic ester resin in toluol, (e) a solution in toluol of a linear thermoplastic polyester resin with or without an isocyanate to give temperature and solvent resistance.