UNDERPRINTED INLAID ^" SHEET MATERIALS HAVING

UNIQUE DECORATIVE DESIGN EFFECTS AND METHODS FOR THEIR

PRODUCTION F--i.el,d. of _< . t _« h.e I _τ nvent1on

The present invention relates to decorative sheet material and the like. More particularly- the invention is concerned wi the decorative effects obtained by using a combination of clea and variously colored decorative particles applied over a substrate printed with similar and analogous colors to produce realistic, attractive inlaid patterns for floor and wall covering products.

Background of the Invention

Sheet materials, in particular, sheet vinyl flooring products, made with chips or other particulate material, are commonly referred to as inlaids. Inlaid floorcoverings are normally characterized as those which maintain their decorativ appearance as the surface is worn or abraded away. This characteristic makes such products particularly suitable for u in commercial areas where significant wear is encountered. The products and processes for their manufacture are well known in the floorcovering business and originate back to the early linoleum times where through—patterned floor coverings, based linseed oil, cork dust and resins were developed by the industry. The process was later modified for vinyl.

Vinyl inlaid floorcovering consists of coarse, colored particles, such as chips or dry blends, which are "laid on" a substrate and then sintered by heat, or "laid in" a transparen or transluscent liquid or solid matrix and fused by heat and/o pressure. The chips are produced from pre—gelled or fused, spread, calendered or extruded compounds cut into geometricall

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regular profiles or ground into randomly shaped particles.

The dry blends a.rs made by mixing fine PVC powder with plasticizer, filler and color pigments and heating above the compound's softening temperature. The small original particle "grow" and form a loose, porous, coarse, fluffy mass.

Currently, to produce registered inlaid patterns for shee vinyl, conventional manufacturing procedures distribute the coarse particles on the substrate in different steps with the help of area—complementary stencils, followed by topcoating w a clear wearlayer. This method is complicated and can only be used to produce large geometric patterns.

Modern inlaids generally fall into two classi ications: resilients and non—resilients. Resilients include a substantially continuous layer of foam and are usually made b incorporating solid particulate material into a plastisol coating, followed by gelling and fusing. Non—resilients do no contain a foam layer and usually are made by sintering and/or calendering, or otherwise compacting, particulate material.

The non—resilient products commercially offered are those containing large (about 1/8 inch) square chips in a clear mat and those containing small (about 0.004 inch) dry blend resin particles made by sintering and/or compacting normal dry blen resins.

While construction of inlaid products by compaction from discreet chips or particles (normally of different colors) offers distinct styling opportunities, a significant premium paid in terms of expensive, cumbersome equipment. Furthermore, the nature of the process restricts the range of designs available. For example, in order to effect specific registere pattern definition, it is necessary to deposit chips of different colors in preselected areas on the sheet. This is difficult mechanically, and results in a slow cumbersome proc which does not produce finely defined designs.

Some of the inherent difficulties in current production

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techniques for non-resilient inlaids have been minimized by u of increasingly sophisticated materials and design techniques such as using fine particle size, dry blend resins, printing over the surface of the resulting inlaid product and, optionally, embossing, with and without application of a wearlayer. Unfortunately, whereas the use of the finer partic size preserves the specific characteristic of an inlaid produ ie. the pattern does not change as the product wears through, overprinting the product, whether or not a wear layer is applied, essentially negates this characteristic because wear through the print layer essentially destroys the pattern. Thi eliminates the product from commercial, high-use environments and limits its utility principally to styling effects in residential and related applications.

Resilient inlaids are usually made by embedding ground plastic particulate material in a plastisol coating. United States Patent 4,212,691 exemplifies such products and methods for their manufacture. One of the limitations of such technology, as taught, for example, in United States Patent 4,126,727, is the substantially uniform appearance of relativ small decorative particles, chips or flakes produced by simpl dispersing them uniformly in the wear layer.

It is, therefore, a principal purpose and object of this invention to provide real through—patterned inlaids and, in particular, inlaids with registered patterns, having heretofo unobtainable decorative effects. It is also an important purp and object of this invention to provide a novel process for producing such inlaids which is believed to be simpler than current inlaid production technology. Other purposes and obje of the invention will be apparent from the following discussi

Summary of the Invention The foregoing and other purposes and objects of this invention are accomplished by providing a resinous polymer sh

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material having selective, decorative effects in selected portions thereof which comprises: a) a substrate, b) a first layer of a resinous polymer composition, c_), a pattern or design, printed on the surface of first layer and having two or more differentiab or distinguishable, colored, printed portions a d) a second layer of a resinous polymer compositio overlying the surface of the printed first laye in contact therewith, and containing a pluralit of transparent, translucent and/or opaque, variously colored particles, substantially, uniformly dispersed throughout said second laye the colors of which are chosen to produce uniqu visual effects, more fully described hereinafte The colors of the particles are similar to, analogous to or i contrast with the colors of the printed pattern or design so that, when the finished product is viewed, the colors of the underprinted pattern or design show through the transparent o translucent areas of the second layer and combine with the co of the particles to produce varying shades of colorations whi differ from one area to another and are different from the colors of the underprint. Additionally, the transparent or translucent particles and the transparent or translucent, preferably clear, void spaces therebetween, provide a unique three—dimensional optical effect of visual depth. This effect, in most cases, is further enhanced by the above described col variation effect.

The result is a registered, inlaid appearance, obtained using a uniform blend of particulates. Thus, the compositions this invention and the processes for their manufacture overco the previously discussed limitation of prior art technology, that only a substantially uniform appearance has, to date, be

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obtainable, when such uniform particle blends are employed to produce inlaids.

As discussed more fully hereinafter, additional wearlayer of both PVC and/or polyurethane polymers), registered reliefs backcoatings and other finishing embodiments conventionally employed in the production of floor or wall covering products can be- tilized, provided that such embodiments do not interf with or- significantly detract from the visual effects and registered, inlaid patterns produced in accordance with this invention.

Description of the Drawings

Figure 1 is a fragmentary, cross sectional view of a typi final product of the present invention. Figure 1 is not drawn scale and, therefor, is not intended to represent precise dimensional relationships. As shown, Figure 1 is drawn to clearly illustrate the structure of the product layers as the appear in a typical final product of this invention. In this view it is not intended that the thickness of the various lay be precisely represented. Rather, the various layers are represented on a scale which is intended to more clearly illustrate the details of smaller portions and to accentuate some of the more important features of the present invention.

Detailed Description of the Invention

Substrate

In the ensuing discussion, numerical designations of the individual compositions and components of the products of thi invention refer to corresponding numerical designations in Figure 1.

The substrate 1 is a relatively flat fibrous or non—fibro backing sheet material, such as a fibrous, felted or matted,

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relatively flat sheet of overlapping, intersecting fibers, usually of non— sbestos origin. The substrate can, if desire be asbestos or non-asbestos felts or papers, woven or non-wo knitted or otherwise fabricated textile material or fabrics comprised of- cellulose, glass, natural or synthetic organic fibers,, or~ natural or synthetic inorganic fibers, or support or non—supported webs or sheets made therefrom or filled or unfilled, thermoplastic or thermoset polymeric materials. The and other substrate or base materials which can be employed this invention are well known in the art and need not be furt detailed here.

Substrate Coating

Although the use of a sealing or priming coat is not considered essential, it is preferred, especially where a gl fiber mat or certain felt bases materials are used.

Thus, the substrate or base material, optionally, can be coated to improve the print quality of the substrate. Such coatings can be plastisols, organosols, lacquers, filled or unfilled latex coatings, or other coatings conventionally employed as preprint sealants in the manufacture of floor or wall covering products.

As used herein, the term "plastisol" is intended to cove relatively high molecular weight polyvinyl chloride resin dispersed in one or more plasticizers. The plastisol upon heating or curing forms a tough plasticized solid. For purpo of the present invention, plastisol compositions are intended include organosols, which are similar dispersed polyvinyl chloride resin materials that, in addition, contain one or m volatile liquids that are driven off upon heating.

Those skilled in the art will appreciate that, in additi to the basic resin constituents, other commonly employed constituents can be present in the plastisol compositions in minor proportions. Such other constituents commonly include h

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and light stabilizers, viscosity depressants, and/or pigments dyes, the latter in order to contribute color to the polyvinyl chloride resin.

Typically the substrate coating employed in the products o this invention is a resinous polymer composition, preferably, polyvinyl chloride plastisol which is substantially uniformly applied to the substrate surface, for example by means of a conventional reverse roll coater or wire wound bar, eg. a Meye Rod Coater, wherein the grooves provided by the wires assist i metering the flow of the plastisol. The particular means for applying the substrate coating to the surface of the substrate is not critical to practice of the invention and any suitable coating means can be employed. Exemplary of other coating mean are a knife—over roll coater, a rotary screen, a direct roll coater and the like.

The thickness of the resinous polymer composition or plastisol, as it is applied to the surface of the substrate, i substantially uniform, and is in the range of about 3 mils to about 30 mils, S mils to about 10 mils being especially preferred. The substrate can be thinner or thicker as may be required by the particular product application.

Although the preferred and typical substrate coating is a polyvinyl chloride homopolymer resin, other vinyl chloride resins can be employed. Exemplary are a vinyl chloride—vinyl acetate copolymer, a vinyl chloride—vinylidene chloride copolymer, and copolymers of vinyl chloride with other vinyl esters, such as, vinyl butyrate, vinyl propionate, and alkyl substituted vinyl esters, wherein the alkyl moiety preferably lower alkyl containing between about 1—4 carbons. Other suita synethetic resins such as polystyrene, substituted polystyren preferably wherein the substituents are selected from the gro consisting of alkyl CJ-CJ , preferably C _j -C^. , aryl (preferably, C^-C-^^, , polyolefins such as polyethylene and polypropylene, acrylates and methacryl tes, polyamides,

polyesters, polyurethanes and any other natural or synetheti resin capable of being applied to the substrate or base coat of this invention to provide a smooth and uniform surface an to improve the print quality of the substrate or base coatin surface, are also applicable; provided such resin is otherwi compatible with the overall product composition and, therefo withiτ-ϊ the principles of this invention. Thus, it is not essent ial. that a plastisol always be used. Organosols and aqueous, latices (aquasols and hydrosols) are also of use, employing as the dispersing or suspending media, organic solvents and water, respectively, rather than plasticizers, in the case of a plastisol.

Where the preferred plastisol is employed, typical of th the plasticizers which can be used are dibutyl sebacate, but benzyl sebacate, di enzyl sebacate, dioctyl adipate, didecyl adipate, dibutyl phthlate, dioctyl phthlate, dibutoκy ethyl phthlate, butyl benzyl phthlate, dibenzyl phthlate, di(2-ethylhexyl) phthlate, alkyl or aryl modified phthalate esters, alkyl, aryl, or alkylaryl hydrocarbons, tricresyl phosphate, octyl diphenyl phosphate, dipropylene glycol dibenzoate, dibasic acid glycol esters, and the like. Other constituents of the resinous substrate coating can include a blowing or foaming agent such as azodicarbonamide (if a blow or foaming procedure is desired), conventional stabilizers/accelerators, initiators, catalysts, etc., such zinc oleate, dibasic lead phosphite, etc., conventional heat light stabilizers, such as metallic soaps, etc., UV absorber colorants, dyes or pigments, notably, titanium oxide, solven and diluents, such as methyl ethyl ketone, methyl isobutyl ketone, dodecyl benzene, etc., fillers, such as clay, limest etc, viscosity modifiers, antioxidants, bacteriostats and bacteriosides, and the like.

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Bellation Step

After the substrate coating has been applied and adhered t the substrate, it is then heated in an oven, or other suitable heating apparatus, maintained at an elevated temperature of fr about 240°F to about 450°F, and preferably from about 260°F to about 410°F, for a period of time of from about 1 minute to about 5 minutes, whereby it gels and becomes firm. T temperature and the time are interdependent; the higher the temperature, the shorter the time and vice versa. During this step the elevated temperature, however, is maintained below th point at which decomposition of any blowing or foaming agent which may have been included in the formulation of the substra coating occurs.

Printing of the Belled Substrate Coating After the substrate coating is gelled and firmed in accordance with the process of this invention, it is cooled an then printed or coated with a suitable printing ink compositio 3, Figure 1, in an appropriate pattern or design. In a preferr embodiment, a minimum of two colors and, preferably, three or more colors, which can include the substrate color, provided that it is not completely and opaquely overprinted, are used i such pattern or design to achieve an exceptionally realistic inlaid look. This is illustrated in Figure 1 wherein the four colors 3a, 3b, 3c and 3d are shown printed in a typical patter As shown in Figure 1, the left hand portion of the pattern contains colors 3a, 3b and 3c only; the center portion C contains color 3c only, and the right hand portion R contains colors 3b, 3c and 3d only.

Suitable inks include those normally used in the manufacture of floor covering, preferably resilient floor covering. These include plastisol, solvent based systems and water based systems. Such systems can include a chemical suppressant in those cases where the substrate to which the in

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is to be applied is a foa able plastisol or organosol. Such suppressants are well known in the art (eg. see U.S. Patent 3,293,094).

Printing onto the substrate can be effected by rotogravur flexigraphic, screen printing, or other printing techniques conventionally employed in making floor or wall covering products. Normally printing is effected by means of one or mo suitably engraved printing rolls and associated back-up rolls Compositions, thicknesses and methods used in applying these optional components may be as conventionally known in the art including, for instance, but not limited to, those described United States Patent 3,458,337.

Application of the Adhesive Layer and Decorative Particles

The printed, gelled, coated substrate is then coated with suitable wet PVC plastisol or organosol. The particular means used for applying the adhesive is not critical and any suitab device may be used. Exemplary are reverse roll coaters, knife—over—roll coaters or other similar devices. The thickne of the ungelled adhesive layer prior to application, or deposition, of the decorative resinous particles of this invention is between about 3 and about 40 mils, preferably, between about 5 and about 20 mils.

The adhesive layer is normally a PVC plastisol or organos containing a plasticizer system, associated diluents, viscosi control aids and stabilizers. Those discussed above are exemplary. The adhesive can contain colors in the form of dye or pigments, provided that such colors do not render the adhesive layer opaque, ie. the underprinting of this inventio is discernible therethrough.

Other homopolymers and copolymers of vinyl chloride, (ie. vinyl resins other than a plastisol or organosol) such as tho discussed above, can also be employed, and, therefore, the discussion herein and the examples setting forth the use of P

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plastisols is intended to be exemplary and non—limiting. It only because of current economics and availability that the examples set forth herein have used polyvinyl chloride plastisols.

Decora ive Particles

The decorative resinous particles of this invention are deposited onto the gelled and printed substrate with the ungelled adhesive top coating. The method of application is critical and can be by any suitable means which essentially uniformly deposits the particles onto the surface of the ungelled adhesive coating in an essentially single layer. Th can be conveniently accomplished using a vibrating pan feede device, such as the SYNTRON vibratory feeder made by FMC Corporation.

To obtain the desired inlaid appearance of the products this invention, the resinous particles must adequately cover surface of the adhesive coated substrate. In general between about 40% and about 80% surface coverage is required. For a single layer of uniformly sized spherical particles, the max coverage obtainable can be shown mathematically to be 78.5%. the case of other particle shapes, there may be some overlap and, consequently, maximum coverage cannot be determined mathematically, weight and/or visual examination being used control coverage within the ranges specified.

The resinous decorative particles of this invention can of a variety of materials, PVC, PVC plastisols and organosol and the like being preferred. These particles can be of vari sizes and geometric shapes, spherical and essentially spheri (sometimes referred to herein as "spheroidal"), being one especially preferred shape. The thickness of the particles m be substantially the same as the thickness of the combined adhesive and decorative particle layer which is normally fro about IO and about 6 mils and, preferably, from about 30 to

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about 50 mils. The ratio of the thickness of the particles t the thickness of the adhesive matrix typically falls within range of between about 50% and 100% and preferably between a 70% and about 95%.

The decorative particles of this invention are employed blend made up of transparent, translucent and/or opaque particles comprising a plurality of colors, plus, optionally, clear particles. At least some of the particles, or the matr must be sufficiently transparent or sufficiently translucent, permit the underprin ing described herein to show through so that the underprinting is discernible by visual observation the naked eye, preferably, from at least an arms-length distance, eg. between about 1 to about 5 feet.

A substantial portion of the colors of the colored particles are similar to or analogous to (as these terms are conventionally used in color physics, and as more particular defined herein) the colors of the underprinting described herein, so as to provide the illusion of depth characteristi real inlaid products. Typically, the color difference betwee the color of the particles and the similar color of the underprint is between about 0 and about 10 CIE units, prefer between about 2 and about 5 CIE units. For production of exceptionally realistic inlaid products, one particle color closely match the color of that portion of the underprint wh particles of such color overlie, eg. within about 0 to about CIE units, and at least one other particle color must be "analogous" (as that term is defined herein) to the color of that portion of the underprint which particles of such color overlie, eg. within about 10 to about 20 CIE units. (The CIE cylindrical coordinate system for describing color space is described more fully hereinafter.)

Discreet spheroidal particles provide enhanced visual ef of depth and improved wear characteristics. Illustrative of those spheroidal particles which are especially preferred ar

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the particles and the methods for their manufacture taught United States Patent 3,856,900. This procedure is particula convenient for the production of relatively small plastisol beads or "pearls" having a particle size of generally about 0.030 inch or smaller.

For smaller particles and those ranging up to about 0.4 inch, these can be obtained by screening the oversized part from normal suspension grade resin production or by making special particle sizes, for example, in accordance with U.S Patent 3,856,900. Particles in this size range are particul useful for achieving certain desireable design effects. Suc procedures are also capable of making smaller particle size for example, ranging from about 0.015 inch to about 0.125 i (eg. see U.S. Patent 3,345,235), but in the case of spheroi particles, the procedure of U.S. 3,856,900 is preferred.

Another particularly desirable particle shape is chips flakes, characterized by one dimension being significantly smaller than the other two. For example, such shapes may ra from 30 to 250 mils in the two larger dimensions, provided the area of each individual particle does not exceed 15,000 mils^, and from about 7 to about 15 mils in thickness. Such chips or flakes also offer specific design effects. Those approaching 250 mils in both larger dimensions are too larg give the desired through—patterned inlaid appearance, resul instead in a "sprinkled on" impression.

The chips or flakes utilized in this invention are conveniently prepared from gelled plastisol sheets by grind or chopping. These sheets are normally prepared by coating a release paper and gelling at conditions previously descri and then stripping from the release paper. The plastisol st can contain a conventional blowing or foaming agent, in whi case the temperature of the gellation step is restricted, a previously described, to prevent activation or decompositio the blowing agent.

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Two typical and preferred chip formulations are:

Solid Chip Stock

Parts By Wei .g

PVC Homopolymer Dispersion Resin, RV=3. 55

PVC Homopolymer Dispersion Resin, RV=1.90 45

Barium/Zinc Stabilizer 4. 6

Epoxy Sccyst Oil 7

Mineral Spirits 3

Tex nol Isobutyrate 1. 7

Glycol Butyrate Benzoate 32

Foamable Chip Stock

Parts By Weig

PVC Homopolymer Dispersion Resin, RV=3.O 56

PVC Homopolymer Dispersion Resin, RV=1.90 44

Glycol Butyrate Benzoate 44

Mineral Spirits 5

Zinc Oxide/Cadmium Oxide Stabilizer Catalyst O. 5

Azodicarbonamide 2. 5

Titanium Dioxide 7. 5

Epoxy Soya Oil 6. 0

In general the particles employed in this invention can ha a wide variety of geometric shapes. Exemplary of other geometr shapes are squares, triangles, circles, annuli, other polygons etc., or irregular sizes and shapes, or a mixture of any or al of such shapes, including spheroidal. The method of preparatio of the decorative resinous particles or the specific formulati thereof is not critical to the practice of this invention. Any particles, falling within the parameters discussed herein, and conventionally employed in making inlaid floor and wall coveri products can be used.

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Colors and Pattern Detail Through the proper combination of particle geometry, particle colors, underprinting colors and appropriate positioning thereof into patterns or designs, which are in register with and permit the colored underprinting to show through, this invention creates unique optical effects, visua discernible by the naked eye, and provides realistic and true inlaid products. A typical and representative example of such combination is shown diagrammatically in Fi ure 1.

Referring to Figure 1, it can be seen that there is inclu in the underprinting at least one color, ink 3b, which will provide an underlying tone value by virtue of its presence in essentially all areas of the pattern (grout or other feature lines, optionally, excluded) and which, when viewed around overlying particles Sa, 5b, 5c and 5d, provides an illusion o depth, ie. a three—dimensional, optical effect. At least two other underprint colors, represented by inks 3a and 3d, are necessary to provide the desired contrast between adjacent pattern areas (which may, optionally, be further separated by grout or other feature or detail line). In a preferred embodiment these colored printed patterns or designs are not continuous prints within the respective pattern or design are but, rather, are broken and random and of a size where the narrowest dimension of any localized area of print does not exceed approximately 4 times the diameter of the largest spherical particle or the largest visible dimension of other shapes. Thus, when the underprinting is viewed through transparent or translucent particles or through the transpare or translucent adhesive matrix the observer is given the impression of a cluster of similar sized particles. In Figure this phenomenon is exemplified by viewing positions 10a, 10b, 10c and lOd. At least one particle color and, preferably, two more, therein exemplified by particle 5a, must be similar to, analogous to, one of the underprint colors, therein exemplifi

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by color 3a, and analogous to the other underprint colors providing the desired contrast between adjacent pattern areas, therein exemplified by color 3d. The colors of the other particles overlying, but not necessarily in register with, the inks used in the underprint pattern or design 3 are not critical. Particle 5b is representative. It, of course, is preferred that the colors of such non—critical particles be artistically compatible with the colors of the overall pattern or design and that such colors provide a continuity of color an shade throughout the entire pattern or design in such a way tha the underprint will emphasize or enhance a specific or selected pattern or design area by increasing the total area of its constituent color. Furthermore, in an especially preferred embodiment of this invention, particles of at least one color, represented by particles 5d in Figure 1, which contrasts with the colors of the other particles employed, are utilized to enforce the particulate nature of the inlaid final product. Transparent or translucent particles 5e or open expanses 4a of the transparent or transluscent matrix 4, not exceeding 5 times the diameter (or largest dimension if non—spherical) of the decorative particles, are also necessary to allow the underprin to be visible to the naked eye, when viewed from the distances discussed herein.

Additionally, the ratio of transparent to colored particles affects the visibility of the printed pattern underneath the particle—containing, adhesive matrix. Generally, 50% or less, and preferably 0—30%, transparent to colored particle loading i preferred. The amount actually used depends upon the type of end—use application and design effect desired. Good results hav even been achieved in the range of 0-10% transparent to colored particle loading.

The CIE (Commision Internationale de l'Eclairage) Cylindrical Coordinate System (CIE System) for describing color space is well known and conventionally employed in color

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technology. (See, for example, "Principles of Color Technol F. . Billmeyer and M. Saltzman, Second Edition, John Wiley Sons, New York, New York. ) The CIE System is based upon a mathematical treatment wherein color differences are expres in CIE units and is employed herein to simplify the definiti of terms and the specification of limits of the invention.

The term "similar" colors in color technology and as u herein means monochromatic or the same hue, differing only i shade (lightness). According to the CIE System, this means t same a* value, along the red—green axis, the same b* value, along the yellow— reen axis, and varying L* values, along t lightness axis. The "same" values, for commercial purposes, usually means a color difference less than two CIE units (t eye cannot determine a difference less than one unit).

"Analogous" colors in color technology and as used herei are those adjacent in color space. For purposes of this invention, these are defined as having a total color differ up to 15 or 20 CIE units, and generally having the same sig (positive or negative) on both values of a* and on both val of L*.

"Contrasting" colors have a greater difference than tho set forth above and "complementary" colors generally have c differences falling within the above ranges, but opposite si for each a* value and b* value, which is to say, they are o opposite sides of color space in the CIE System.

For purposes of this invention, it is preferred to defi the "same" or "similar" colors as those having a difference hue (delta H) of less than 10 CIE units, and, preferably, l than 7 CIE units. "Analogous" colors have a total color difference (delta E) of less than 20 CIE units and, prefera less than 15 CIE units. "Contrasting" colors have a total c difference (delta E) greater than 20 CIE units and also hav same sign for each a* value and for each b* value (unless t values are close to 0.0, ie. less than an absolute value of whereupon they have opposite signs). "Contrasting" colors h

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total color difference (delta E) greater than 20 CIE units an opposite signs for each a* value and each b* value.

Wearlayer

The optional overcoat or wearlayer is preferably a plasti o the same or similar type as that discussed above in connection with the resins employed in the substrate coat and the adhesive layer or matrix. The formulations generally incl materials to enhance special specific properties, for example gloss, wear, stain resistance, and scuff resistance.

Other resins suitable for use as a top coating can be employed. Exemplary are wear resistant polyurethanes, such as those described in U.S. Patent 4,087,400.

Thus in another embodiment of this invention the decorati inlaid floor or wall coverings comprise: a) a flexible mat substrate, b) a gelled, resinous print layer, applied over sa substrate, the surface of which is printed with one or more inks suitable for use in the manufacture of floor or wall covering products, and having two or more distinguishably differen colored, printed portions, c) an adhesive matrix, overlying said print layer, containing an effective amount of a homopolymer a copolymer of vinyl chloride, in which are embedded a plurality of transparent, translucen and/or opaque, variously colored resinous particles (optionally, some of which can be clear), substantially, uniformly dispersed throughout said adhesive matrix, the colors of which are chosen to produce unique visual effec as more fully described hereinabove, at least s of which permits the underprint to show through and

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d) an optional topcoating or wearlayer or wearlayer selected from the group consisting of a plastiso a polyurethane resin or a suitable mixture of each. The following examples are intended to demonstrate preferr embodiments of this invention without limiting the scope thereof. Inr t e; following examples all parts and percentages a by weight.

Example 1

Residential Floorcovering with Registered Printed and Emboss Red Brick Pattern (Chemically Embossed)

A loorcovering substrate sheet of conventional type non—asbestos felt (Tarkett Inc., Whitehall, Pa.) approximately mils thick was coated with a foamable plastisol the compositio of which was as follows:

Parts by Weigh

PVC dispersion: k value 65 70

(Occidental FPC 605)

PVC extender resin: k value 60 30

(PLIOVIC M-50)

Di(2-ethylheκyl) phthlate 28

Butyl benzyl phthlate 15

Texanol isobutyrate (TXIB) 15

Titanium dioxide 10 Azodicarbonamide 2.5

Kerosene 4

Zinc oxide 1.5

Viscosity: 2500 cps

The coated substrate is then pregelled in a hot oven at

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275°F. for 2.5 minutes. The surface is then gravure printed on a flat bed press using SERIES 125 solvent based inks from American Inks, Inc. The inks used to cover the plate printing valley areas of the pattern (ie. the grouts) contain, additionally, 140 parts benzotriazole, a chemical suppressant, inhibit in these selected areas the expansion of the foamable plastisol. The pattern is a brick printed in predominately red coloration. The pattern is separated into 5 colors, the true m tone color values of which are:

CIE Separation L* a* b*

Salmon Background 49.79 18.08 10.89

Maroon Highlight 37.04 12.12 3.48

Orange Highlight 43.21 20.15 19.97

Brown Highlight 33.37 4.71 7.67

Gray Grout

After drying in warm air at about 140 ⁰ F, an adhesive layer about 10 mils thick is applied by drawdown bar and an excess of premixed plastisol pearls (produced by the process o Example 4 and having the composition set forth herinafter), having the following blend of specific colored and clear particles, are evenly distributed on the surface of the wet, tacky adhesive layer from a vibrating pan (SYNTRON vibrator, manufactured by FMC Corporation).

The composition of the adhesive mix is:

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Parts by Weig

PVC dispersion: relative viscosity 2.05 70

(Occidental FPC 6458) PVC extender: k value 60 30

(PLIOVIC M-50) Butyl benzyl phthlate 25

Di—isononyl phthlate 25

Stabilizer, barium—zinc type 4

(SYNPRON 1665)

The composition of the pearl particles is:

Parts by Weight Colored Transpare

Suspension grade PVC resin: k value 65 100 lOO

(PEVIKON S658 GK) Butyl benzyl phthalate 40 40 Stabilizer, barium—zinc type 4 4

(SYNPRON 1665) Titanium dioxide 5 — Color—pigment 5 5

(Purchased blend of red iron oxide, yellow iron oxide and carbon black dispersed in di (2-ethylhexyl) phthalate)

The PEVIKON S658 GK resin has an aspect ratio of about 1 (the particles are round) and the particle size, by microsco observation, averages about 600 microns (approximately 30 me Screen analysis is as follows:

Mesh % Retained

28 (589 microns) 68.0

65 (208 " ) 25.2

100 (147 " ) 1.4

Thru 100 mesh 5.4

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The blend ratio and color value of the pearl particles are: CIE Parts by Weight L* a*

Clear

White. 84. 11 -1. 68 9.

Orange. 46. 28 18. 26 25.

Brown 30.83 5. 10 4.

Almond' 53.26 6.46 12.

The excess pearls, which are not wetted by the adhesive coating and embedded therein are blown away by a gentle air stream. The resultant grainy matrix is then gelled by conta the coated side against a heated chromium drum (350°F. ) and smoothed between a rubber pressure roller and the drum surf The thickness of the matrix containing the adhesive coat (1 mils) and the embedded pearls (approximately 20 mils) is 30 mils.

The surface of the matrix is then bar coated using a drawdown bar with a transparent plastisol wearlayer having following composition:

Parts by Wei

Dispersion grade PVC, relative viscosity 2.05 lOO

(Occidental FPC 6458)

Isobutyric acid and glycol ester of benzoic acid 56

(Tenneco NU0PLAZ 1538)

Stabilizer, barium—zinc type 5

(SYNPRON 1665)

Epoκidized soybean oil 5

Kerosene 2

Brookfield Viscosity: _^ 1200 cps

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The wearlayer is fused in a hot air oven at about 380°F. for 3 minutes. The floorcovering produced exhibits a relief structure (embossing) in register with the printed areas. The decorative inlaid product thereby produced has an overall thickness of about 82 mils and exhibits excellent wear and exceptional three— imensional inlaid design characteristics, particularly with respect to visual depth.

In the foregoing example it is noteworthy that, in accordance with the principles of this invention, there is similarity in hue (ie. the CIE a* and b* values) between the orange highlight underprinting (20.15, 19.97) and the orange pearls (18.26, 25.63) and between the brown highlight underprinting (4.71, 7.67) and the brown pearls (5.10, 4.20). The almond pearls (6.46, 12.79) provide a pleasing combinatio with the salmon background underprinting (18.08, lO.89), almo being an analogous color differing from salmon only in being less "red". The white pearls add contrast and accentuate the visual granular texture of the product.

Example 2

Residential Floorcovering with Registered Printed and Emboss White Brick Pattern (Chemically Embossed)

The procedure of Example 1 is repeated in a predominately white coloration. The same pattern separations are used, with the exception that printing is carried out using an ink havin the following true mass tone color values: CIE Separation L* • a* b*

•White Background 96. 52 -1. 83 1. 6

Highlight 70. 99 O. 81 5. 1

Highlight 71. 91 -0. 75 0. 7

Highlight 54. 13 O. 94 3. 3

Grout

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After drying, an adhesive layer is applied and an excess of premixed plastisol pearls having the following blend of color is evenly distributed on the surface:

CIE Parts Bv Weight L* a* b*

Clear

White 84.11 -1.68 9.66

The excess pearls are removed and the resultant matrix gelled and then topcoated.

The resulting decorative inlaid product thereby produced exhibits pleasing appearance and visual depth.

When the decorative blend of Example 2 is applied over th print of Example 1 or vice versa, the illusion of a registere inlaid is not obtained. The resultant product appears to simp have a uniform layer of particles distributed over the surfac

Example 3

Floor Covering with Overall Pattern Suitable for Commercial U

A floor covering substrate sheet of conventional type non—asbestos felt (Tarkett Inc., Whitehall, Pa.), approximate 32 mils thick, is bar coated (wire wound bar) with approximat 3 mils of a layer of white printable plastisol, the compositi of which is as follows:

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Parts by Weig

PVC emulsion: relative viscosity 2.05 70

(Occidental FPC 605) PVC extender: k value 60 30

(PLIOVIC M-50) Di (2-ethylheκyl) phthalate 30 Butyl benzyl phthalate 30 Titanium dioxide 5 Crystalline calcium carbonate 80 Barium—zinc type stabilizer 3

(IRGASTAB BZ 530)

After gelling against a heated chromium drum at 300°F. , the resulting smooth surface is gravure printed on a flat pri press using SERIES 125 solvent based inks from American Inks, Inc. with a small tile pattern in a predominately tan coloration. The pattern is separated into five colors, the tr mass—tone color values of which are: CIE

Separation L* a* b*

Tan Background 64. 67 4. 57 25. 6 Brown Texture 36. 17 1. 30 7. 6 Burnt Orange Highlight 40. 25 12. 85 19. 7 Maroon Hi hlight 32. 02 5. 64 5. 8 Brown Grout 34. 58 3. 66 8. 1

After drying in warm air at about 140°F, an adhesive layer about lO mils thick and having the same composition as that used in Example 1 is applied by drawdown bar and an eκce of premiκed plastisol pearls of the same composition and coloration as those used in Example 1 is evenly distributed o the surface of the wet, tacky adhesive layer from a vibrating pan (SYNTRON vibrator, manufactured by FMC Corporation) and t

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eκcess removed. The resulting matriκ is gelled and then topcoated using the procedures described in Example 1. The wearlayer is fused in a hot air oven at about 380°F for 3.5 minutes and then embossed between a cooled embossing roll and rubber pressure roll.

The resultant product has 15 mils of wearlayer, gives th i_T.uusi.on of registered inlaid particles and has excellent wea characteristics similar to the product of Eκample 1.

Example 4

The plastisol spherical "pearls" used in the foregoing examples are prepared using the following formulations:

Parts by Weight Colored Transparent

Suspension grade PVC resin, coarse; k value 65 (PEVICQN S658 GK) lOO lOO Butyl benzyl phthalate 40 40 Barium—zinc stabilizer 4 4

(SYNPRON 1665) Titanium dioxide 5 — Color—pigment 5 —

In preparing the colored and transparent plastisol composition, the PVC resin (at 70°F. ) is charged to a high intensity mixer running at 3500 RPM and mixed until the batch temperature reaches 160°F. (about 10 minutes). The speed of the mixer is then reduced to 500 revolutions per minute and t pigment pastes, plasticizer and stabilizer are added slowly o a period of about 5 minutes. The speed is then increased to 2000—300O rpm and the material mixed until the batch temperat reaches 260°F (approximately 15 minutes additional). The spee is then reduced to 500 RPM and the material is mixed until th

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batch temperature cools to 70-90°F (about 30 additional minutes).

The pearls produced are essentially spherical, dry and fr running; do not exceed O.60 inch in diameter, and have a particle size distribution range of O.004 to about 0.040.

The following table summarizes the process parameters employed:

Equipment: High intensity mixer 2.6 g 1. volume

3 lbs. loading

Elapsed Time Temperature Speed

Min. Degrees F. Rev/Min

0 -v70 3SOO io 160 500 pigments, plasticiz and stabilizer adde

15 260 2000- 3000

30 500 cooling

Although the forgoing discussion describes this invention terms of floor or wall covering products, this invention is intended to encompass any covering including, but not necessarily limited to, floor or wall covering, which can be produced in accordance with the process herein described. Als while the invention has been described with respect to certai embodiments thereof, it will be apparent to those skilled in art that various changes and modifications may be made withou departing from the spirit and scope of the invention.