Method and apparatus for manufacturing sheet flooring by simultaneous multi-layer die coating
AssigneeAWI Licensing LLC
InventorsR. Suter Hudson, Robert E. Waters, Lowell E. West
Life of this patent
Estimating the term…
Abstract
Surface coverings and surface covering components and methods for forming them using slot die coating are disclosed. The methods involve applying a plurality of wet layers to a substrate simultaneously or in sequence using a slot die coater, wherein a plurality of wet layers can be applied before any of the individual layers are dried, gelled, cured and/or fused. The layers remain separate and distinct before and after drying, gelling, curing and/or fusing, and can be dried, gelled, cured and/or fused together or separately after wet on wet application to the substrate. The surface coverings may be decorative surface covering, including floor coverings.
Claims54
A method of forming a surface covering or surface covering component on a substrate, wherein the surface covering or surface covering component prior to curing comprises a plurality of superposed, separate and distinct fluid coating compositions, the method comprising:
- a) obtaining a plurality of curable fluid coating compositions, wherein at least one fluid coating composition comprises a 100 percent solids composition, and
- b) applying each fluid coating composition onto a substrate to form a plurality of separate and distinct layers directly or indirectly overlying the substrate.
A method of forming a surface covering or surface covering component on a substrate, wherein the surface covering or surface covering component prior to curing comprises a plurality of superposed, separate and distinct fluid coating compositions, the method comprising:
- a) obtaining a plurality of curable fluid coating compositions, wherein at least one fluid coating composition comprises a plastisol, and
- b) applying each fluid coating composition onto a substrate to form a plurality of separate and distinct layers directly or indirectly overlying the substrate.
A method of making a decorative surface covering or decorative surface covering component comprising a wear layer and top coat, the method comprising;
- a) applying wet-on-wet at least one wear layer composition and at least one topcoat composition to the surface of a decorative surface covering element;
- and
- b) curing each of the at least one wear layer composition and at least one topcoat composition.
A method of making a decorative surface covering comprising a high performance topcoat, the method comprising:
- a) applying a plurality of topcoat compositions in wet state to a decorative surface covering component comprising a wear layer;
- and
- b) curing the plurality of topcoat compositions to form a high performance topcoat on a decorative surface covering.
A method of forming a floor covering or floor covering component on a substrate, wherein the floor covering or floor covering component prior to curing comprises a plurality of superposed, separate and distinct fluid coating compositions, the method comprising:
- a) obtaining a plurality of curable fluid coating compositions, and
- b) applying each fluid coating composition onto a substrate with a die coater to form a plurality of separate and distinct layers directly or indirectly overlying the substrate.
Dependencies are inferred from the claim text.