Coated fabric sheet-type material having resilient backing and process for making same
AssigneeGAF Corporation
InventorsJesse Werner, Gordon R. Rugg
Life of this patent
Estimating the term…
Abstract
Sheet-type covering material having a decorative fabric base with a wear layer over the face of the fabric and a resilient backing adhered to the back of the fabric is prepared by first forming a plastic wear layer adhered to the face of a sheet of decorative fabric and then forming a resilient backing layer on the back of the fabric sheet. Preferred embodiments include the use of mechanically foamed plastic as the resilient backing layer and a conventional wear layer of polyvinyl chloride or polyurethane. The fabric is preferably textured so as to impart a textured surface to the wear layer.
Claims14
A flexible, decorative sheet-type covering material comprising:
- a. a decorative textured fabric base, said fabric having a height variation between about 4 and about 16 mils;
- b. a transparent, flexible polyurethane or PVC wear layer at least about 4 mils thick adhered to the face of the fabric and having a surface height variation of at least about 4 mils due to the texture of the fabric;
- and
- c. a resilient backing layer of foamed material between about 50 and about 250 mils thick and having a density between about 10 and about 40 lbs/ft.sup.3 adhered to the back of the fabric.
A process for making a flexible, decorative sheet-type covering material which comprises:
- a. forming a transparent, flexible, polyurethane or PVC wear layer at least about 4 mils thick adhered to the face of a sheet of decorative textured fabric having a height variation between about 4 and about 16 mils, the surface of the wear layer having a height variation due to the texture of the fabric of at least about 4 mils;
- and
- b. forming a resilient backing layer of foamed material between about 50 and about 250 mils thick and having a density between about 10 and about 40 lb/ft.sup.3 adhered to the back of the fabric sheet.
A process for making a flexible, decorative sheet-type covering material which comprises:
- a. coating the face of a sheet of decorative textured fabric having a height variation between about 4 and about 16 mils with a transparent latex emulsion seal coat between about 2 and about 5 mils thick and drying said seal coat;
- b. applying a transparent PVC plastisol or organosol wear layer having a thickness of at least about 4 mils over said seal coat and gelling said wear layer without curing same;
- c. heating the thus coated fabric to a temperature sufficient to cure the wear layer, the surface of the cured wear layer having a height variation of at least about 4 mils due to the texture of the fabric;
- d. applying a foam backing layer of mechanically foamed PVC between about 50 and about 250 mils thick and having a density between about 10 and about 40 lb/ft.sup.3 to the coated fabric;
- and
- e. heating the coated fabric sufficiently to cure the foam backing layer.
Dependencies are inferred from the claim text.