Printable composition for making embossed decorative sheets

Claim 2

A process for producing a thermoplastic resin sheet comprising the following steps: a. forming a first layer which comprises a gelled thermoplastic resin composition on a base web; b. applying a printable composition to the surface of the gelled thermoplastic resin layer which composition comprises an effective amount of a blowing agent; c. applying a second layer of a thermoplastic resin composition, which thermoplastic resin composition has a melt viscosity which differs from the melt viscosity of the thermoplastic resin composition of the first layer by at least 0.05 meter-kilograms, to form a composite structure; and d. heating the composite structure of step (c) to a sufficient temperature and for sufficient period of time to gel the first and second resin layers.

Claim 3

A process according to claim 1, in which the thermoplastic resin of the first layer is a vinyl polymer with a melt viscosity of about 0.15 meter-kilograms to about 0.75 meter-kilograms and the thermoplastic resin of the second layer is a vinyl polymer with a different melt viscosity, and the melt viscosities of the two layers is different by at least 0.05 meter-kilograms.

Claim 4

A process according to claim 1 or 2, in which the melt viscosities of the two thermoplastic layers differ by at least 0.2 meter kilograms.

Claim 5

A process for producing a thermoplastic resin sheet comprising the following steps: a forming a first layer of gelled thermoplastic resin composition with a melt viscosity of about 0.15 to about 0.85 meter-kilograms on a base web; b. applying a printable composition in a first design to the surface the gelled thermoplastic resin layer which composition comprises an effective amount of a blowing agent; c. applying a second layer of a thermoplastic resin composition with a melt viscosity of at least 0.05 meter-kilograms higher than the first resin layer to form a laminate; d. heating the laminate to gel the thermoplastic resin of the second layer; e. applying a third layer of thermoplastic resin composition with a melt viscosity of about 0.15 to about 0,85 meter- .-kilograms over the second resin layer; f. heating to gel the third thermoplastic resin layer; g. applying in a different design a second printable composition with an effective amount of a blowing agent; h. applying a fourth layer of a thermoplastic resin composition with a melt viscosity at least 0.05 meter-kilograms higher than the third thermoplastic resin layer to form a composite structure; and i. heating the composite structure sufficiently to gel the fourth resin layer.

Claim 6

A process for producing a thermoplastic resin sheet comprising the following steps: a forming a first layer of gelled thermoplastic resin composition with a melt viscosity of about 0.15 to about 0.85 meter-kilograms on a base web; b. applying a printable composition in a first design to the surface the gelled thermoplastic resin layer which composition comprises an effective amount of a blowing agent; c. applying a second layer of a thermoplastic resin composition with a melt viscosity of at least 0.05 meter-kilograms higher than the first resin layer to form a laminate; d. heating the laminate to gel the thermoplastic resin of the second layer; e. applying a third layer of thermoplastic resin composition with a melt viscosity of about 0.15 to about 0,85 meter- .-kilograms over the second resin layer; f. heating to gel the third thermoplastic resin layer; g. applying in a different design a second printable composition with an effective amount of a blowing agent; h. applying a fourth layer of a thermoplastic resin composition with a melt viscosity at least 0.05 meter-kilograms higher than the third thermoplastic resin layer to form a composite structure; and i. heating the composite structure sufficiently to gel the fourth resin layer.

Claim 7

A process according to claim 1 or 4 , which includes heating the gelled composite structure to a sufficient temperature and for sufficient period of time to fuse the first and second resin layers and decompose the blowing agent in the printable composition.

Claim 8

A process according to claim 1 or 4, which includes heating the composite structure of step (c) or (h) to a sufficient temperature and for a sufficient period of time to fuse the resin layers and decompose the blowing agent in the printable composition.

Claim 9

A process for producing a thermoplastic resin sheet comprising: a. forming a first layer of a gelled foamable thermoplastic resin composition on a backing web; b. applying a first printable composition in a desired design to the surface of the gelled foamable thermoplastic resin of the first layer, which first printable composition contains an effective amount of an inhibitor, to form a first printed resin layer; c. applying a second layer of thermoplastic resin, which resin has a melt viscosity in the range of about 0.20 to about 1.30 meter-kilograms, to the surface of the first printed resin layer to form a first printed composite; d. heating the first printed composite to a temperature and for a time period sufficient to gel the second layer of thermoplastic resin to form a gelled layer; e. applying a third layer of a thermoplastic resin composition over the second resin layer which thermoplastic resin composition has a melt viscosity of between 0.15 and 0.85 meter-kilograms; f. heating the printed composite to a temperature and for a period of time sufficient to gel the third layer of thermoplastic resin to form a gelled layer with a printable surface; g. applying a second printable composition to the printable surface of the third layer which second printable composition comprises an effective amount of a blowing agent; h. applying a fourth layer of a thermoplastic resin composition to the surface of the printed and gelled third layer, which thermoplastic resin composition has a melt viscosity of between about 0.20 to about 1.30 meter-kilograms and which melt viscosity is at least 0.05 meter-kilograms higher than the melt viscosity of the thermoplastic resin of the third layer to form a final composite structure; and i. heating the final composite structure of step (h) to a sufficient temperature and for a sufficient period of time to gel the fourth layer of thermoplastic resin.

Claim 10

A process for producing a thermoplastic resin sheet comprising: a. forming a first layer of a gelled foamable thermoplastic resin composition on a backing web; b. applying a first printable composition in a desired design to the surface of the gelled foamable thermoplastic resin of the first layer, which first printable composition contains an effective amount of an inhibitor, to form a first printed resin layer; c. applying a second layer of thermoplastic resin, which resin has a melt viscosity in the range of about 0.20 to about 1.30 meter-kilograms, to the surface of the first printed resin layer to form a first printed composite; d. heating the first printed composite to a temperature and for a time period sufficient to gel the second layer of thermoplastic resin to form a gelled layer; e. applying a third layer of a thermoplastic resin composition over the second resin layer which thermoplastic resin composition has a melt viscosity of between 0.15 and 0.85 meter-kilograms; f. heating the printed composite to a temperature and for a period of time sufficient to gel the third layer of thermoplastic resin to form a gelled layer with a printable surface; g. applying a second printable composition to the printable surface of the third layer which second printable composition comprises an effective amount of a blowing agent; h. applying a fourth layer of a thermoplastic resin composition to the surface of the printed and gelled third layer, which thermoplastic resin composition has a melt viscosity of between about 0.20 to about 1.30 meter-kilograms and which melt viscosity is at least 0.05 meter-kilograms higher than the melt viscosity of the thermoplastic resin of the third layer to form a final composite structure; and i. heating the final composite structure of step (h) to a sufficient temperature and for a sufficient period of time to gel the fourth layer of thermoplastic resin.

Claim 11

A process for producing a thermoplastic resin sheet comprising the following steps: a forming a first layer of gelled foamable resin composition on a base web; b. applying a first printable composition in a desired design to the surface of the gelled foamable thermoplastic resin layer which first printable composition contains an effective amount of an inhibitor, to form a first printed resin layer; c. applying a second layer of thermoplastic resin, with a melt viscosity of at least 0.05 meter-kilograms higher than the melt viscosity of the gelled resin of the first layer, to the printed surface of the first resin layer to form a first printed composite; d. heating the first printed composite to a temperature and for a time period sufficient to gel the second layer of thermoplastic resin, and form a gelled layer with a printable surface; e. applying a second printable composition to the printable surface of the second layer, which second printable composition comprises an effective amount of a blowing agent f. applying a third layer of a thermoplastic resin composition over the gelled second layer, which thermoplastic resin composition has a melt viscosity of at least 0.05 meter-kilograms lower than the melt viscosity of the thermoplastic resin composition of the second layer to form a composite structure; g. heating the composite structure of step (e) to a temperature and for a period of time sufficient to gel the third layer of thermoplastic resin; h. applying a fourth layer of thermoplastic resin material over the third printed resin layer, which thermoplastic resin has a melt viscosity of at least 0.05 meter-kilograms higher than the melt viscosity of the thermoplastic resin in the third layer, to form a final composite structure; i. heating the final composite structure of step (h) to a sufficient temperature and for a sufficient period of time to gel the fourth layer of thermoplastic resin.

Claim 12

A process for producing a thermoplastic resin sheet comprising the following steps: a forming a first layer of gelled foamable resin composition on a base web; b. applying a first printable composition in a desired design to the surface of the gelled foamable thermoplastic resin layer which first printable composition contains an effective amount of an inhibitor, to form a first printed resin layer; c. applying a second layer of thermoplastic resin, with a melt viscosity of at least 0.05 meter-kilograms higher than the melt viscosity of the gelled resin of the first layer, to the printed surface of the first resin layer to form a first printed composite; d. heating the first printed composite to a temperature and for a time period sufficient to gel the second layer of thermoplastic resin, and form a gelled layer with a printable surface; e. applying a second printable composition to the printable surface of the second layer, which second printable composition comprises an effective amount of a blowing agent f. applying a third layer of a thermoplastic resin composition over the gelled second layer, which thermoplastic resin composition has a melt viscosity of at least 0.05 meter-kilograms lower than the melt viscosity of the thermoplastic resin composition of the second layer to form a composite structure; g. heating the composite structure of step (e) to a temperature and for a period of time sufficient to gel the third layer of thermoplastic resin; h. applying a fourth layer of thermoplastic resin material over the third printed resin layer, which thermoplastic resin has a melt viscosity of at least 0.05 meter-kilograms higher than the melt viscosity of the thermoplastic resin in the third layer, to form a final composite structure; i. heating the final composite structure of step (h) to a sufficient temperature and for a sufficient period of time to gel the fourth layer of thermoplastic resin.

Claim 13

A process according to claim 7 or 8, which includes heating the gelled composite structure to a sufficient temperature and for sufficient period of time to fuse and blow the foamable first layer, fuse the second, third and fourth resin layers and decompose the blowing agent in the printable composition.

Claim 14

A process according to claim 7 or 8, which includes heating the composite structure of step (h) to a sufficient temperature and for a sufficient period of time to fuse and blow the foamable first layer, fuse the second, third and fourth resin layers and decompose the blowing agent in the printable composition.

Claim 15

A process according to any one of claims 4 to 10, in which at least one thermoplastic resin composition is a thermoplastic vinyl resin.

Claim 16

A process according to any one of claims 4 to 10, in which the blowing agent in the printable composition is p-toluene sulfonyl semicarbazide and the temperature for gelling the vinyl resin is about 140°C. to 160°C.

Claim 17

A process according to any one of claims 4 to 10, in which the blowing agent in the printable composition is azodicarbonamide.

Claim 18

A process according to claim 12, in which the temperature for fusing the vinyl resin and decomposing the blowing agent is about 190°C to 210°C.

Claim 19

A process according to claim 13, in which the temperature for fusing the vinyl resin and decomposing the blowing agent is about 190°C to 210°C.

Claim 20

A printable composition, having a viscosity of about 10 to 50 seconds using No. 3 Shell cup viscometer, for the production of an embossed thermoplastic resin sheet, comprising a. a blowing agent component comprising about 10% to about 30% by weight of the printable composition and further comprising one or more members selected from the group of compounds consisting of ammonium bicarbonate, sodium bicarbonate, sodium boron hydride, silicon oxyhydride, azodicarbonamide, p-toluene sulfonyl semicarbazide, p,p'-oxybis-(benzene sulfonyl) hydrazide, p,p'- oxybis-benzene sulfonyl semicarbazide, azobisisobutyronitrile, N,N'-dimethyl-N,N'- dinitrosoterephthalate, diazoaminobenzene, N,N'- dinitrosopentamethylenetetramine, aminoquanidine bicarbonate, p,p'-thiobis-(benzene sulfonyl hydrazide), p,p'- diphenylmethane disulfonyl hydrazide, benzene m-disulfonyl hydrazide, benzene sulfonyl hydrazide, terephthalazide, benzazide, p-t-butyl benzazide, phthalazide, isophthalazide, 1,3-diphenyltriazene, azohexahydrobenzonitrile, azodicarboxylic acid diethylester, naphthalene-1,5-disulfonyl hydrazide and biuret; b. a binder component comprising about 3% to about 70% by weight of the printable composition and further comprising a polymer resin binder; c. optionally an aqueous or non-aqueous solvent component comprising about 0 to about 65% by weight of the printable composition; and d. optionally, an accelerator component comprising an effective amount of an accelerator for the blowing agent selected from the group comprising dioctyl phthalate, dioctyl adipate, paraffin oil, calcium sulfate, magnesium sulfate, carbon black, stearic acid, barium sterate, stannous stearate, titanium oxide, citric acid, triethanol amine, dibutyl tin laurate, dibutyl tin bis isooctyl, thio glycolate, dibasic lead phosphite, dibasic lead stearate, dibasic lead phthalate, zinc laurate, zinc oxide, zinc stearate, zinc carbonate, zinc octoate, zinc naphtholate, zinc dust and zinc mercaptoben- zothiazote.

Claim 21

A printable composition, having a viscosity of about 10 to 50 seconds using No. 3 Shell cup viscometer, for the production of an embossed thermoplastic resin sheet, comprising a. a blowing agent component comprising about 10% to about 30% by weight of the printable composition and further comprising one or more members selected from the group of compounds consisting of ammonium bicarbonate, sodium bicarbonate, sodium boron hydride, silicon oxyhydride, azodicarbonamide, p-toluene sulfonyl semicarbazide, p,p'-oxybis-(benzene sulfonyl) hydrazide, p,p'- oxybis-benzene sulfonyl semicarbazide, azobisisobutyronitrile, N,N'-dimethyl-N,N'- dinitrosoterephthalate, diazoaminobenzene, N,N'- dinitrosopentamethylenetetramine, aminoquanidine bicarbonate, p,p'-thiobis-(benzene sulfonyl hydrazide), p,p'- diphenylmethane disulfonyl hydrazide, benzene m-disulfonyl hydrazide, benzene sulfonyl hydrazide, terephthalazide, benzazide, p-t-butyl benzazide, phthalazide, isophthalazide, 1,3-diphenyltriazene, azohexahydrobenzonitrile, azodicarboxylic acid diethylester, naphthalene-1,5-disulfonyl hydrazide and biuret; b. a binder component comprising about 3% to about 70% by weight of the printable composition and further comprising a polymer resin binder; c. optionally an aqueous or non-aqueous solvent component comprising about 0 to about 65% by weight of the printable composition; and d. optionally, an accelerator component comprising an effective amount of an accelerator for the blowing agent selected from the group comprising dioctyl phthalate, dioctyl adipate, paraffin oil, calcium sulfate, magnesium sulfate, carbon black, stearic acid, barium sterate, stannous stearate, titanium oxide, citric acid, triethanol amine, dibutyl tin laurate, dibutyl tin bis isooctyl, thio glycolate, dibasic lead phosphite, dibasic lead stearate, dibasic lead phthalate, zinc laurate, zinc oxide, zinc stearate, zinc carbonate, zinc octoate, zinc naphtholate, zinc dust and zinc mercaptoben- zothiazote.

Claim 22

A printable composition according to claim 16, which comprises: a. a blowing agent component comprising p-toluene sulfonyl semicarbazide in the amount of about 17% by weight of the printable composition; b. a binder component comprising about 6% by weight of a copolymer of vinyl chloride and vinyl acetate in the amount of the printable composition; c. a solvent component comprising methyl ethyl ketone in the amount of about 60% by weight of the printable composition; and d. an accelerator component comprising zinc octoate in a 39% mineral spirits and alcohol mixture in the amount of about 17% by weight of the printable composition.

Claim 23

A printable composition according to claim 16, which comprises: a. a blowing agent component comprising azodicarbonamide in the amount of about 17.6% by weight of the printable composition; b. an accelerator component comprising zinc oxide in the amount of about 6.6% by weight of the printable composition; c. titanium dioxide in the amount of about 11.4% by weight of the printable composition; d. a wetting agent about 0.4% by weight of the printable composition; e. a solvent component comprising methyl ethyl ketone in an amount of about 45% by weight of the printable composition; and f. a binder component comprising a copolymer of vinyl chloride and vinyl acetate in a ratio of about 86:14 by weight in an amount of about 5% by weight of the printable composition.

Claim 24

A printable composition according to claim 16, which comprises: a. 16% by weight of p-toluene sulfonyl semicarbazide; b. 30% by weight of an acrylic thermoplastic resin; c. 33% by weight of water; d. 16% by weight of zinc stearate; and e. 5% by weight of a wetting agent all based on the total weight of the printable composition.