US4070435A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Multilevel embossing of foamed-sheet materials-II
Assignee: Armstrong World Industries Inc
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Filing: 1977-02-09
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Granted: 1978-01-24
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Expires: 1997-02-09
Abstract
Abstract The process herein is used for achieving multilevel mechanical embossing of a fused or cured wear layer in register with a print on an expanded foam thereunder. The expansion of the decorative foam and fusion of the wear layer are carried out and then the back of the foam is cooled by wetting and liquid evaporation. The wear layer is maintained at a high temperature for embossing and is embossed with registry between the embossed pattern and the printed pattern on the foam. Just prior to embossing, the decorative foam-wear layer web is wrapped around the backup roll of the embossing apparatus, and after embossing, is wrapped partially around the embossing roll of the embossing apparatus.
Inventors
- 👤 Walter J. Lewicki, Jr.
- 👤 William M. McQuate
- 👤 Richard M. Ringer
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 03:59
CPC Classifications
B; B32; B32B; B32B38/00; B32B38/06; B29; B29C; B29C59/00; B29C59/02; B29C59/04; B29C59/046; B32B38/18; B32B38/1825; B32B38/1833; B32B5/00; B32B5/18; B41; B41M; B41M1/00; B41M1/24; B44; B44C; B44C1/00; B44C1/24; D; D06; D06N; D06N7/00; D06N7/0005; D06N7/0007; D06N7/001; B32B2309/00; B32B2309/02; B32B2471/00; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1039; Y10T156/1041
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
228 words
A process for embossing a web of material wherein said material is composed of a composite structure having at least a carrier and a thick foam layer, said foam layer on the surface thereof adjacent the surface to be embossed having a decorative pattern printed thereon, said above composite structure being in the form of a web which is heated in an oven to a temperature of about 250° F. to 350° F., the steps comprising: a. after the carrier of the web leaves the oven, wetting the carrier of the web, which is the back surface of the web, so as to lower the temperature of the back surface of the web approximately 100° below the top surface of the web, which is the surface to be embossed, b. embossing the top surface of the web with an embossing roll and backup roll, c. cooling the embossed surface of the web to set the embossed pattern in the web, and d. the improvement comprising: 1. wrapping the web of material partially around the chilled steel backup roll prior to the time that the web passes between the nip of the backup roll and the embossing roll, to cool the backside of the web and secure good frictional contact between the web and backup roll so that good frictional drive exists between the web and backup roll, 2.
Claim 2
Dependent Claim
228 words
A process for embossing a web of material wherein said material is composed of a composite structure having at least a carrier and a thick foam layer, said foam layer on the surface thereof adjacent the surface to be embossed having a decorative pattern printed thereon, said above composite structure being in the form of a web which is heated in an oven to a temperature of about 250° F. to 350° F., the steps comprising: a. after the carrier of the web leaves the oven, wetting the carrier of the web, which is the back surface of the web, so as to lower the temperature of the back surface of the web approximately 100° below the top surface of the web, which is the surface to be embossed, b. embossing the top surface of the web with an embossing roll and backup roll, c. cooling the embossed surface of the web to set the embossed pattern in the web, and d. the improvement comprising: 1. wrapping the web of material partially around the chilled steel backup roll prior to the time that the web passes between the nip of the backup roll and the embossing roll, to cool the backside of the web and secure good frictional contact between the web and backup roll so that good frictional drive exists between the web and backup roll, 2.
Claim 3
Dependent Claim
87 words
wrapping the embossed surface of the web around the embossing roll after it has passed through the nip between the embossing roll and the backup roll to partly cool the embossed surface of the web, and 3. said wetting of the carrier of the web is carried out by two back-wetting operations, one back-wetting operation wets the carrier of the web just as it leaves the oven and the second back-wetting operation wets the carrier of the web just prior to the time the web is wrapped
Claim 4
Dependent Claim
87 words
wrapping the embossed surface of the web around the embossing roll after it has passed through the nip between the embossing roll and the backup roll to partly cool the embossed surface of the web, and 3. said wetting of the carrier of the web is carried out by two back-wetting operations, one back-wetting operation wets the carrier of the web just as it leaves the oven and the second back-wetting operation wets the carrier of the web just prior to the time the web is wrapped
Claim 5
Dependent Claim
44 words
partially around the chilled steel backup roll. 2. The process of claim 1 wherein there is the further step of: a. controlling the registry of the embossed pattern with the printed pattern of the web so that the two patterns will be in registry.
Claim 6
Dependent Claim
37 words
The process of claim 1 wherein: a. the embossing step is carried out with both the land areas and valley areas of the embossing roll contacting and impressing a pattern on the top surface of the web.
Claim 7
Dependent Claim
31 words
The process of claim 1 wherein: a. a heating means applies heat to the embossable top surface of the web just prior to the time the embossing step is carried out.
Claim 8
Dependent Claim
152 words
A process for embossing a web of material wherein said material is composed of a composite structure having at least a carrier and a foam layer, said foam layer on the surface thereof adjacent the surface to be embossed having a decorative pattern printed thereon, said above composite structure being in the form of a web which is heated to a temperature of about 250° F. to 350° F., the steps comprising: a. wetting the carrier of the web, which is the back surface of the web, so as to lower the temperature of the back surface of the web approximately 100° below the top surface of the web, which is the surface to be embossed, b. embossing the top surface of the web with an embossing roll and backup roll, c. cooling the embossed surface of the web to set the embossed pattern in the web, and d. the improvement comprising:
Claim 9
Dependent Claim
152 words
A process for embossing a web of material wherein said material is composed of a composite structure having at least a carrier and a foam layer, said foam layer on the surface thereof adjacent the surface to be embossed having a decorative pattern printed thereon, said above composite structure being in the form of a web which is heated to a temperature of about 250° F. to 350° F., the steps comprising: a. wetting the carrier of the web, which is the back surface of the web, so as to lower the temperature of the back surface of the web approximately 100° below the top surface of the web, which is the surface to be embossed, b. embossing the top surface of the web with an embossing roll and backup roll, c. cooling the embossed surface of the web to set the embossed pattern in the web, and d. the improvement comprising:
Claim 10
Dependent Claim
112 words
wrapping the web of material partly around the chilled steel backup roll prior to the time that the web passes between the nip of the backup roll and embossing roll to cool the backside of the web and secure good frictional contact between the web and backup roll so that good frictional drive exists between the web and backup roll, the web drives the backup roll and the backup roll now drives the embossing roll, and 2. wrapping the embossed surface of the web around the embossing roll after it has passed through the nip between the embossing roll and the backup roll to partly cool the embossed surface of the web.
Claim 11
Dependent Claim
112 words
wrapping the web of material partly around the chilled steel backup roll prior to the time that the web passes between the nip of the backup roll and embossing roll to cool the backside of the web and secure good frictional contact between the web and backup roll so that good frictional drive exists between the web and backup roll, the web drives the backup roll and the backup roll now drives the embossing roll, and 2. wrapping the embossed surface of the web around the embossing roll after it has passed through the nip between the embossing roll and the backup roll to partly cool the embossed surface of the web.
Claim 12
Dependent Claim
36 words
The process of claim 5 wherein there is the further step of: a. controlling the registry of the embossed pattern with the printed pattern of the web so that the two patterns will be in registry.
Claim 13
Dependent Claim
37 words
The process of claim 5 wherein: a. the embossing step is carried out with both the land areas and valley areas of the embossing roll contacting and impressing a pattern on the top surface of the web.
Claim 14
Dependent Claim
31 words
The process of claim 5 wherein: a. a heating means applies heat to the embossable top surface of the web just prior to the time the embossing step is carried out.
Claim 15
Dependent Claim
266 words
In a process for embossing a web of material wherein said material is composed of a composite structure having at least a carrier and a foam layer, said foam layer on the surface thereof adjacent the surface to be embossed having a decorative pattern printed thereon, said above composite structure being in the form of a web which is heated to a temperature of about 250° F. to 350° F., the steps comprising: a. wetting the carrier of the web, which is the back surface of the web, so as to lower the temperature of the back surface of the web approximately 100° below the top surface of the web, which is the surface to be embossed, b. embossing the top surface of the web with an embossing roll and backup roll, c. cooling the embossed surface of the web to set the embossed pattern in the web, and d. the improvement comprising: 1. wrapping the web of material partly around the chilled steel backup roll prior to the time that the web passes between the nip of the backup roll and embossing roll to cool the backside of the web and secure good frictional contact between the web and backup roll so that good frictional drive exists between the web and backup roll, the web drives the backup roll and the backup roll now drives the embossing roll, 2. wrapping the embossed surface of the web around the embossing roll after it has passed through the nip between the embossing roll and the backup roll to partly cool the embossed surface of the web, and
Claim 16
Dependent Claim
266 words
In a process for embossing a web of material wherein said material is composed of a composite structure having at least a carrier and a foam layer, said foam layer on the surface thereof adjacent the surface to be embossed having a decorative pattern printed thereon, said above composite structure being in the form of a web which is heated to a temperature of about 250° F. to 350° F., the steps comprising: a. wetting the carrier of the web, which is the back surface of the web, so as to lower the temperature of the back surface of the web approximately 100° below the top surface of the web, which is the surface to be embossed, b. embossing the top surface of the web with an embossing roll and backup roll, c. cooling the embossed surface of the web to set the embossed pattern in the web, and d. the improvement comprising: 1. wrapping the web of material partly around the chilled steel backup roll prior to the time that the web passes between the nip of the backup roll and embossing roll to cool the backside of the web and secure good frictional contact between the web and backup roll so that good frictional drive exists between the web and backup roll, the web drives the backup roll and the backup roll now drives the embossing roll, 2. wrapping the embossed surface of the web around the embossing roll after it has passed through the nip between the embossing roll and the backup roll to partly cool the embossed surface of the web, and
Claim 17
Dependent Claim
24 words
again, wrapping the web of material around the steel backup roll after it leaves the embossing roll to further cool the web of material.
Claim 18
Dependent Claim
24 words
again, wrapping the web of material around the steel backup roll after it leaves the embossing roll to further cool the web of material.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-01-23 | 1981-07-25 | 1982-01-24 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-01-23 | 1985-07-25 | 1986-01-24 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-01-23 | 1989-07-25 | 1990-01-24 | $7700.00 | Window Closed / Lapsed |