U.S. patent application number 12/668296 was filed with the patent office on 2010-12-30 for printer-compatible, pre-embossed films.
Invention is credited to William R. Guillot, Jon R. Schrader, Cornelius Joseph Toomey.
Application Number | 20100330336 12/668296 |
Document ID | / |
Family ID | 40228911 |
Filed Date | 2010-12-30 |
United States Patent
Application |
20100330336 |
Kind Code |
A1 |
Guillot; William R. ; et
al. |
December 30, 2010 |
PRINTER-COMPATIBLE, PRE-EMBOSSED FILMS
Abstract
Decorative films, useful for making a wide range of decorative
laminates, that have a relatively deep texture on one major face
and a relatively smoother, print receptive surface on the other
major face. Notwithstanding the deep texture, the films have superb
tracking characteristics and are compatible with a wide variety of
automated printing operations. This allows automated printing
equipment to print information directly onto the films.
Inventors: |
Guillot; William R.;
(Monroe, NC) ; Schrader; Jon R.; (Matthews,
NC) ; Toomey; Cornelius Joseph; (Saint Louis,
MO) |
Correspondence
Address: |
OMNOVA SOLUTIONS INC
LAW DEPT., 175 GHENT ROAD
FAIRLAWN
OH
44333-3300
US
|
Family ID: |
40228911 |
Appl. No.: |
12/668296 |
Filed: |
July 8, 2008 |
PCT Filed: |
July 8, 2008 |
PCT NO: |
PCT/US08/08376 |
371 Date: |
June 23, 2010 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60959114 |
Jul 11, 2007 |
|
|
|
Current U.S.
Class: |
428/156 ;
264/132 |
Current CPC
Class: |
B29D 7/01 20130101; B29K
2995/0024 20130101; B32B 3/10 20130101; B32B 38/145 20130101; B32B
3/263 20130101; Y10T 428/24355 20150115; B29C 48/0023 20190201;
B29C 59/04 20130101; B29C 48/002 20190201; B29C 43/222 20130101;
Y10T 428/24479 20150115 |
Class at
Publication: |
428/156 ;
264/132 |
International
Class: |
B32B 3/00 20060101
B32B003/00; B29C 59/02 20060101 B29C059/02 |
Claims
1. A method of making a textured, decorative laminate film,
comprising the steps of: a) extruding a molten film; b) while the
extruded film is at least partially molten, causing the film to
pass through a gap between and contact first and second tooling
surfaces that are maintained at one or more temperatures below the
melt temperature of the molten film in a manner effective to help
cause the molten film to set and solidify as the film passes
through the gap, said first tooling surface comprising a plurality
of irregular and random depressions on the first tooling surface
and that provide cavities that are at least partially filled by the
molten film as the film passes over the first tooling surface and
sets, and said second tooling surface being relatively smoother
than the first major surface, whereby a solidified film is formed
comprising a first, textured major face having an Ra surface
roughness of greater than about 100 microinches and a second, print
receptive major face having an Ra surface roughness of less than
100 microinches, wherein the ratio of the Ra surface roughness of
the first major face of the film to the Ra surface roughness of the
second major face of the film is in the range from about 1.1:1 to
about 500:1; and c) printing decorative information onto the second
major face of the film.
2-4. (canceled)
5. The method of claim 1, wherein the random and irregular
depressions are directional.
6. The method of claim 1, wherein the random and irregular
depressions comprise acicular, meandering depressions.
7. The method of claim 6, wherein the depressions comprise
branches.
8. The method of claim 1, wherein at least a portion of the
depressions comprises generally flat bottoms.
9. The method of claim 1, wherein the first tooling surface is a
surface of a roller rotating about an axis, and wherein the
depressions are directionally oriented circumferentially around the
roller generally perpendicular to the roller axis.
10. The method of claim 1, wherein the second tooling surface is
biased toward the first tooling surface under pressure.
11-15. (canceled)
16. A decorative laminate film, comprising: a) a first major face
comprising a random and irregular pattern of protuberances having
different shapes and sizes, said first major surface having an Ra
surface roughness of at least 100 microinches; b) a second, print
receptive major face, wherein the ratio of the Ra surface roughness
of the first major face of the film to the Ra surface roughness of
the second major face of the film is in the range from about 1.1:1
to about 500:1; and c) decorative information printed onto the
second major face.
17. The film of claim 1, wherein the film comprises polyvinyl
chloride.
18. The film of claim 16, wherein the film comprises less than 2
parts by weight of total plasticizer per 100 parts by weight of the
film.
19. The film of claim 16, wherein the film comprises less than 0.1
parts by weight of total plasticizer per 100 parts by weight of the
film.
20-22. (canceled)
23. The film of claim of claim 16, wherein the first major face has
an Ra surface roughness of at least 120 microinches.
24. The film of claim 16, wherein the first major face has an Ra
surface roughness of at least 150 microinches.
25-27. (canceled)
28. The film of any of claim 16, wherein the second major face has
an Ra surface roughness of less then 90 microinches.
29. (canceled)
30. The film of any of claim 16, wherein the ratio of the Ra
surface roughness of the first major face to the second major face
is in the range from about preferably about 3:2 to about 10:1.
31. (canceled)
32. A decorative laminate, comprising; a) a substrate; and b) a
decorative laminate film bonded directly or indirectly to the
substrate, said decorative laminate film comprising: 1) a first
major face comprising a random and irregular pattern of
protuberances having different shapes and sizes, said first major
surface having an Ra surface roughness of at least 100 microinches;
2) a second, print receptive major face, wherein the ratio of the
Ra surface roughness of the first major face of the film to the Ra
surface roughness of the second major face of the film is in the
range from about 1.1:1 to about 500:1; and 3) decorative
information printed onto the second major face.
33. A method of making a decorative laminate, comprising; a)
providing a decorative laminate film prepared according to the
method of claim 1; b) directly or indirectly bonding the film to a
substrate.
34. A method of making a decorative laminate, comprising; a)
providing a decorative laminate film according to claim 16; b)
directly or indirectly bonding the film to a substrate.
35. A method of making a decorative laminate film, comprising the
steps of: a) extruding a film having first and second major
surfaces, wherein a random, irregular, and directional texture is
formed on the first major surface while the film is at least
partially molten; and b) after forming said texture on the first
major surface, printing decorative information onto the second
major surface of the film.
36. A method of making a decorative laminate, comprising the steps
of: a) extruding a film having first and second major surfaces,
wherein a random, irregular, and directional texture is formed on
the first major surface while the film is at least partially
molten; b) after forming said texture on the first major surface,
printing decorative information onto the second major surface of
the film; and c) after printing, laminating the film directly or
indirectly onto a substrate.
Description
PRIORITY CLAIM
[0001] The present patent application claims priority to United
States Provisional Patent Application having Ser. No. 60/959,114,
filed on Jul. 11, 2007, by Guillot et al., and titled
PRINTER-COMPATIBLE, PRE-EMBOSSED FILMS, wherein said provisional
application is incorporated herein by reference in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to laminates, particularly
decorative laminates incorporating a film laminated to a substrate,
wherein the film has a first, textured face and a second,
relatively smooth face onto which decorative information may be
applied such as by printing. More particularly, the texture applied
to the first face is selected so that the film remains amenable to
printing even when the texture is relatively deep.
BACKGROUND OF THE INVENTION
[0003] Decorative laminates are widely used in the cabinet,
molding, furniture, consumer electronics, paneling, boating,
recreational vehicles, and other industries. One conventional
decorative laminate structure is formed from an at least partially
transparent decorative film that is laminated to a desired
substrate. The decorative film often includes decorative
information such as the image(s) of wood grain, stone, leather,
textile, fanciful designs, one or more colors in a pattern or
otherwise, a human, an animal, nature, architecture, and the like.
The film often is made from ingredients including one or more
polymers. The decorative information often is on the inside face of
the film while the outside face of the film bears a texture to help
provide low gloss, a matted appearance, scratch and mar resistance,
and/or anti-blocking resistance in printed roll, stack or other
form in which a film face contacts an adjacent film face of the
same or a different film. One or more additional layers may be
incorporated into such a decorative laminate, either between the
film and the substrate or otherwise, such as an additional
decorative film, an underlay, an overlay, an adhesive, protective
coating, and/or the like.
[0004] The decorative information is desirably applied onto the
film using printing techniques such as ink jet printing, laser
printing, gravure printing, offset printing, anastatic printing,
silk screen printing, transfer printing, lithographic,
flexographic, other printing methods, combinations of these, and
the like. Typically, the film is textured on one major face, while
the decorative information is printed onto the other major face. If
the film is textured prior to printing, the film is considered to
be pre-embossed. If the film is textured after printing, the film
is considered to be post-embossed.
[0005] Relatively deep textures, e.g., those textures having an Ra
surface roughness of over about 100 microinches, preferably over
120 microinches, and even over 150 microinches, are desirable in
many applications as these tend to provide much better blocking
resistance and scratch and mar resistance than lighter textures.
Also, deeper textures provide very desirable visual and tactile
properties.
[0006] However, there are significant challenges involved in
preparing films having decorative, printed information on one face
and deep texture on the other face. It is quite difficult to print
decorative information onto the smoother side of a pre-embossed
film bearing a deeper texture on the other side. Due to the deeper
texture, such films tend to experience chatter or other tracking
problems when transported through a printer. Chatter generally
refers to an undesired, vibration of the moving film, especially
side-to-side, repeated movement or jitter of a film. These problems
can seriously compromise the quality of the printed information.
Quite simply, many embodiments of conventional pre-embossed films
with deep texture have not been as printer-compatible as might be
desired. There is a bias in the decorative laminate industry,
particularly under the relatively stringent commercial standards
applicable to the decor printing industry, against trying to print
onto such deeply embossed films.
[0007] The industry generally prefers to post-emboss printed films.
In this technique, the film can be relatively smooth on both sides
at the time of printing and have good tracking characteristics
through the printer. The film is then embossed after printing.
[0008] Post-embossing involves some drawbacks, though. First, it
involves an entire extra stage of manufacture that requires
expensive equipment, facility space, utilities, and other
resources, all of which add considerable expense to the
manufacturing process. Also, post-embossing can be a bottleneck in
the overall manufacturing line, adversely impacting throughput. The
printed information is also put at risk, as extra handling is
required for the film to traverse through the post-embossing stage
of manufacturing. If the printed information is damaged or
otherwise compromised during the embossing stage, scrap is produced
and yields go down. Additionally, post-embossed texture is less
permanent than pre-embossed texture. Under pressure and heat, which
are typically used to form decorative laminates, a significant
portion of post-embossed texture can be lost. Thus, a post-embossed
film may have to be over-textured to meet a texture specification
applicable to the laminated product. It is hard to control the
uniformity of the embossing on the final product in this kind of
scenario. There can be considerable variation, and specifications
have to be less stringent to accommodate this.
[0009] Another technical solution is to use pre-embossed films that
have a very limited degree of texture, e.g., an Ra surface
roughness of under 90 microinches, even under 80 microinches, or
even under 70 microinches. By limiting the texture on the
"embossed" surface of a film, the pre-embossed film may exhibit
acceptable tracking properties during printing. However, such light
texture does not provide acceptable scratch and mar resistance
and/or anti-blocking protection in many applications. Films bearing
such light texture may also exhibit gloss levels that are higher
than desired. Additionally, the visual and tactile sensations
offered by these films may tend to be unappealing to consumers,
particularly when the decorative information corresponds to natural
surfaces such as wood grain, stone, leather, fabrics, and the
like.
[0010] Another technical solution is to print the decorative
information onto a separate film that is sufficiently smooth on
both sides to be both printer compatible and ink receptive and then
to incorporate this printed film into a decorative laminate that
includes a separate, more deeply textured film as an overlay. This
involves adding a whole extra component in the product and is
accompanied by the associated extra stages of manufacture and
resources to handle.
[0011] The industry could benefit significantly from a
printer-compatible, pre-embossed film having a deeper texture.
SUMMARY OF THE INVENTION
[0012] The present invention provides decorative laminate films
that have a relatively deep texture on one major face and a
relatively smoother, print receptive surface on the other major
face. The films are useful for making a wide range of decorative
laminate products. Notwithstanding the deep texture, the films have
superb tracking characteristics and are compatible with a wide
variety of automated printing operations. This allows automated
printing equipment to print information directly onto the films
rather than onto separate sheets which then are laminated to a
deeply textured sheet as has been practiced conventionally in the
past. (Certain embodiments may incorporate separately printed
layers where a combination of overlapping printed layers helps to
achieve one or more kinds of desired visual effects.) The ability
to print onto an already deeply textured sheet completely
eliminates any need to post-emboss the film after printing, saving
considerable time, expense, and facility resources.
[0013] As used herein, a deep texture is a texture having an Ra
surface roughness of at least 100 micrometers, preferably over 120
micrometers, and more preferably over 150 micrometers. A procedure
for determining Ra surface roughness is provided in the Detailed
Description, below.
[0014] Advantageously, the film can be textured with an embossing
tool (which in some modes of practice is a textured roller) having
a unique texture which, in the present context, is able to perform
many different functions. The texture can be relatively deep and
yet the texture has a configuration such that the film nonetheless
has good tracking characteristics to be printed at the resolutions
demanded in the decorative laminate industry. The texture on the
tool has contours that allow the texture to be formed repeatedly
and consistently on moving films at high speed with exceptional
uniformity along the length of a film. This extremely uniform
quality is a significant quality control asset. The texture also
provides excellent scratch and mar resistance and anti-blocking
protection. The texture is also extremely stable under heat and
pressure so that there is much less need, and even no need in some
embodiments, to overtexture the films to achieve a desired degree
of final texture remaining after lamination. The ability to use a
more targeted degree of texture with less overtexturing further
contributes to enhanced printer compatibility, inasmuch as
overtexturing conventionally would be expected to contribute to
tracking problems and poor or unacceptable print quality.
[0015] In one aspect, the present invention relates to a method of
making a textured, decorative laminate film. A molten film is
extruded. While the extruded film is at least partially molten, the
film passes through a gap between first and second tooling surfaces
and contacts said first and second tooling surfaces that are
maintained at one or more temperatures below the melt temperature
of the molten film in a manner effective to help cause the molten
film to set and solidify as the film passes through the gap. The
first tooling surface includes a plurality of irregular and random
depressions that provide cavities that are at least partially
filled by the molten film as the film passes over the first tooling
surface and sets. The second tooling surface is relatively smoother
than the first major surface. A solidified film is formed that
includes a first, textured major face having an Ra surface
roughness of greater than about 100 microinches and a second, print
receptive major face having an Ra surface roughness of less than
100 microinches, wherein the ratio of the Ra surface roughness of
the first major face of the film to the Ra surface roughness of the
second major face of the film is in the range from about 1.1:1 to
about 500:1. Decorative information is printed onto the second
major face of the film.
[0016] In another aspect, the present invention relates to a
decorative laminate film. The film includes a first major face
having a random and irregular pattern of protuberances having
different shapes and sizes, said first major surface having an Ra
surface roughness of at least 100 microinches. The film also
includes a second, print receptive major face, wherein the ratio of
the Ra surface roughness of the first major face of the film to the
Ra surface roughness of the second major face of the film is in the
range from about 1.1:1 to about 500:1. The film also includes
decorative information printed onto the second major face.
[0017] In another aspect, the present invention relates to a
decorative laminate that includes a substrate and a decorative
laminate film bonded directly or indirectly to the substrate. The
decorative laminate film includes a first major face and a second,
print receptive major face. The first major face includes a random
and irregular pattern of protuberances having different shapes and
sizes, said first major surface having an Ra surface roughness of
at least 100 microinches. The ratio of the Ra surface roughness of
the first major face of the film to the Ra surface roughness of the
second major face of the film is in the range from about 1.1:1 to
about 500:1. Decorative information is printed onto the second
major face.
[0018] In another aspect, the present invention relates to a method
of making a decorative laminate film that includes the steps of
extruding a film having first and second major surfaces. A random,
irregular, and directional texture is formed on the first major
surface while the film is at least partially molten. After forming
said texture on the first major surface, printing decorative
information onto the second major surface of the film. Optionally,
after printing, the film is laminated directly or indirectly onto a
substrate.
[0019] In another aspect, the present invention relates to a method
of making a decorative laminate. A decorative laminate film is
prepared according to any method described herein. The film is then
directly or indirectly bonded the film to a substrate.
[0020] In another aspect, the present invention relates to a method
of making a decorative laminate. Any decorative laminate film as
described herein is provided. This film is then directly or
indirectly to a substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 schematically illustrates one system in which a
printable, textured film may be prepared using extrusion
techniques.
[0022] FIG. 2 schematically illustrates a portion of the system of
FIG. 1, showing the path of the extruded film through a set of
rollers in which one side of the film is textured and the film is
set.
[0023] FIG. 3 is a copy of a pair of photographs showing the
texture on the pre-embossed side of the film and the print side of
the film, respectively, taken at a magnification of 700%.
DETAILED DESCRIPTION
[0024] The embodiments of the present invention described below are
not intended to be exhaustive or to limit the invention to the
precise forms disclosed in the following detailed description.
Rather the embodiments are chosen and described so that others
skilled in the art may appreciate and understand the principles and
practices of the present invention.
[0025] FIGS. 1 and 2 schematically illustrate one way in which a
printable, textured film 12 may be prepared. As seen best in FIG. 1
and as an overview, system 10 includes as main components extruder
14, heat exchanger 34, texturing station 36, viewing station 44,
automatic profile controller 46, slitter 54, and winder 56. The
path of film 12 through system 10 from the extruder 14 to the
winder 56 is shown schematically by the dotted line representing
film 12. Various rollers 58 help guide and tension the film 12
during transport through the system 10. Decorative information may
be printed onto the film to form decorative sheets, and these
decorative sheets may then be incorporated into decorative laminate
structures.
[0026] In more detail, extruder 14 includes hopper 16 into which
one or more supplies of feed material(s) schematically shown as 18,
are loaded into extruder 14 to form the film 12. The principles of
the present invention are extremely versatile and can be
beneficially used with a wide range of extrudable compositions.
That the present invention is so flexible in terms of material
choices provides a significant commercial advantage. In
representative embodiments, the feed material includes one or more
thermoplastic polymers selected from free radically polymerized
polymers (such as poly(meth)acrylates, polystyrenic polymers,
polyolefins, and/or others derived from ingredients comprising free
radically polymerized monomers having carbon-carbon double bonds),
polyester, polyurethane, polycarbonate, polyacetal, polyether,
polyamide, polyimide, polyurea, combinations of these, and the
like. Polyvinyl chloride (PVC) is a specific example of one
suitable polymer for forming very durable decorative laminate
sheets and corresponding decorative laminates of the present
invention.
[0027] In some modes of practice, thermosetting polymer(s) may be
used if the thermosetting reaction can be delayed until after the
texture is formed in the film 12, as desired texture
characteristics could be compromised if thermosetting were to
proceed too far before texturizing occurs. For instance, if a
polymer having radiation curable functionality (e.g., functionality
curable upon exposure to a suitable energy source such as
ultraviolet energy or electron beam energy) were to have a suitable
melt temperature so that extrusion could occur with undue risk of
triggering too much crosslinking prior to texturizing,
thermosetting polymer(s) may be used as at least a portion of the
feed 18 supplied to hopper 16. A suitable curing station (not
shown) could then be incorporated into system 10 to cure film 12
downstream from the texturing station 36.
[0028] In addition to one or more polymers, the feed 18 introduced
into hopper 16 may optionally include one or more other, optional
ingredients such as one or more plasticizers, ultraviolet
stabilizers, antioxidants, flatting agents; waxes; dispersants;
inorganic particles; pigments; fungicides, bactericides, antistatic
agents, fire retardants, combinations of these, and the like. In
preferred embodiments, particularly those including PVC, the feed
18 includes less than 5 parts by weight, preferably less than 2
parts by weight, more preferably less than 0.5 parts by weight, and
even less than 0.1 parts by weight of plasticizer per 100 parts by
weight of the feed. It has been found that restricting, and more
desirably avoiding, plasticizer provides rigid film
characteristics, improved embossing retention, enhanced wear
characteristics, reduced plasticizer or other component migration,
enhanced flame retardance, superior film lay flat, and/or improved
stain resistance. A particularly preferred feed 18 includes no
plasticizer.
[0029] From hopper 16, the feed 18 is fed into the barrel (not
shown) of the extruder, which is housed in barrel section 20.
Housing shrouds 22 enclose the barrel to help isolate the barrel
from the ambient surrounding the extruder. The barrel section 20
and hopper 16 are mounted on support structures 24 and 26.
[0030] Extruder die station 28 includes the die through which the
molten feed is extruded as film 12. Extruder die station 28 is
supported upon dolly 30 for mobility. The die is heated to help
ensure that the exudate leaves die station 28 in a fully molten
state at an appropriate temperature. Adapter 32 couples the
extruder barrel to the die station 28.
[0031] In representative embodiments, film 12 extruded from the die
may have a width in the range from a few inches to many tens of
inches. A convenient film width suitable for commercial scale
production would be in the range from about 8 inches to 120 inches.
For film this wide, the thermal mass of the die is rather large.
Accordingly, it is desirable if heat energy can be added at
multiple locations throughout the die to facilitate temperature
control. By way of example, one die configured to extrude film
having a width in the range from about 60 inches to about 70 inches
has seven heat input locations spaced generally equally across the
face of the die. Electric heating is convenient for this
purpose.
[0032] The temperature of the extruder 14 and die can depend upon
factors including the nature of the feed 18. Generally, it is
desirable to heat the feed 18 sufficiently so that it is fully
molten when it leaves the extruder 14 as an exudate. However, the
temperature should not be so high that there is an undue risk of
thermally damaging the feed 18. It also is convenient to use a
temperature gradient in which the temperature is ramped up to the
final desired temperature. By way of illustration, when extruding a
PVC polymer having a melt temperature of about 380.degree. F.
through extruder 14 having five heating zones and a heated die, the
first (closest to the hopper 16) through fifth (closest to the die
station 28) extruder zones may be set at 312.degree. F.,
320.degree. F., 330.degree. F., 340.degree. F., and 350.degree. F.,
respectively, while the die conveniently has a temperature set
point of 355 F, although the die temperature may independently vary
across the various die heating locations to help control the film
thickness as described further below. Even though these set
temperatures are below the melt temperature of the PVC polymer, the
significant shear energy from the extruder screw adds enough heat
energy to melt the polymer.
[0033] The molten film 12 is then processed in the texturing
station 36 to set the film, forming the textured and printable
surfaces. To ensure good transfer of the molten feed 18 from the
die to the texturing station 36, it is desirable to place the
texturing station 36 as close as is practically feasible to the
die. A distance of about 2 inches to about 12 inches between the
die outlet to the gap 45 (see FIG. 2) between the top roller 38 and
the middle roller 40 has been found to be suitable.
[0034] The texturing station 36 generally includes a tool having a
surface used for imparting the desired texture onto the film 12 and
optionally one or more other components to help with film
formation, transport, or the like. For purposes of illustration,
station 36 includes top roller 38, middle roller 40, and bottom
roller 42 mounted within a supporting structure schematically
designated by the enclosure 47. The top roller 38 and middle roller
40 contribute to forming the textured and printable faces of film
12, while bottom roller 42 helps to avoid chatter and provide a
smooth release as film 12 leaves texturing station 36. Line
operators or other observers may view the activities within
texturing station 36 from the viewing station 44, which
conveniently may be in the form of a catwalk.
[0035] The middle roller 40 is textured for embossing the film 12
and includes at least one primary and at least one additional
secondary texture. In one embodiment, the surface of the middle
roller 40 is chrome. The at least one primary texture generally
includes a plurality of depressions formed in the roller surface.
When the molten film material flows over the surface of middle
roller 40, the molten material fills and/or partially fills these
depressions and sets. In essence then, these depressions act like
female molds for forming corresponding protuberances on the
adjacent (proximal) major surface of the film 12.
[0036] The depressions formed in middle roller 40 generally are
irregular and random. Irregular refers to the shape and dimensions
of the depressions, while random refers to the arrangement of the
depressions on the roller surface. Using a population of irregular
depressions randomly formed on the surface of middle roller 40
contributes to the advantages described herein, especially tracking
performance, scratch and mar resistance, and blocking resistance
and still maintain an acceptable print quality or graphic
reproduction.
[0037] Irregular means that the depressions include a population of
depressions including a plurality of shapes and a plurality of
sizes. Viewed from the top, representative embodiments of the
depressions can be circular in a range of sizes and/or oblong in a
range of sizes and acicularity (ranging from close to circular to
string-like). The acicular depressions preferably meander in a
nonlinear fashion and/or may include one or more branches. Branches
may extend outward from one portion of a depression and rejoin the
depression at another portion. The depressions preferably have
rounded contours to facilitate smooth, easy release of the set film
12 from middle roller 40, although the bottoms of the depressions
may be flat for machining convenience.
[0038] The depressions will also vary in terms of their lengths,
widths, and depths both among features and optionally intrafeature
as well. The dimensions of these depression features can vary over
a wide range depending upon factors including the film thickness,
the desired end use, the nature of the printing equipment to be
used, and the like. Generally, if the depressions are too small,
the resulting texture on film 12 may be too fine to provide the
desired scratch and mar resistance and/or blocking resistance. A
texture that is too fine may impair visual and texture effects
desired in the resultant decorative laminate product. On the other
hand, if the texture is too much, more texture telegraphing from
one side of the film to the other than is desired may occur,
mechanical properties of the film may be reduced too much, tracking
through printing devices may suffer, and/or unacceptable print
quality may be incurred.
[0039] Balancing such concerns, one representative but non-limiting
set of roller depressions may have dimensions effective to provide
an embossed film surface having an Ra surface texture as specified
herein. This may correspond to depressions having a range of depths
up to about 5 thousandths to 6 thousandths of an inch, which in
turn may be plated with a surface covering, e.g., chrome having a
thickness of 2 mils or less, even 1 mil or less. Suitable widths
and lengths of the depressions may vary over a very wide range,
particularly given that preferred roller textures include a
population of depressions having string-like contours of varying
lengths and widths. FIG. 3 and the corresponding discussion below
shows preferred embodiments of representative film textures that
would result from correspondingly textured middle roller 40. For
instance, the protuberances formed on the pre-embossed side 105 of
the film 100 shown in FIG. 3 would be formed by a roller having
corresponding depressions in its surface that contacted and
embossed the film 100.
[0040] Random means that the depressions formed on the roller
surface are not arranged in regular columns or rows. So long as the
features are staggered so as not to be arranged in regular columns
or rows, the texture can be directional, e.g., uni-directional,
bi-directional, multi-directional, or the like. For instance, the
textures shown in FIG. 3 are directional and yet staggered so as to
be random. On the corresponding roller used to form such
protuberances in the film 12, the roller depressions would be
directionally oriented generally circumferentially around the
roller surface, generally perpendicular to the roller axis, so that
the resultant protuberances formed on film 12 are generally
directionally aligned with the direction of the moving film 12 as
the film 12 moves over the roller surface.
[0041] The density of the depression features on the surface of
middle roller 40 may vary over a wide range. For instance,
depressions may be formed so that individual depressions generally
are isolated from other depressions by intervening land areas,
analogous to the dimpled surface of a golf ball. Alternatively,
depressions may be formed so that the population of depressions may
include two or more depressions that overlap at least partially in
a depression cluster with an intervening land area between this
cluster and another cluster and/or depression. In still other
embodiments, depressions may be formed in such a density such that
substantially the entire surface of the middle roller 40 is covered
by overlapping depressions with very little unsurfaced land area
remaining. The texture desirably covers at least 50% of the roller
surface, preferably at least 80% of the surface, more preferably at
least 98% or more of the surface.
[0042] The texture on middle roller 40 can be formed in a variety
of ways, including via acid-etching, electromechanical milling,
laser engraving, die milling, peening, and/or other suitable
methods. In one circumstance, such as when a tool according to a
die mill method is used to form the texture on middle roller 40,
the tool may have to be repeatedly run back and forth over the
surface in order to complete the texture. In this sense, each pass
could be said to repeat the pattern on the tool. Yet, if the
pattern on the tool is irregular or random and/or if the tool is
run over the roller in different directions and/or configurations,
or in a spiraling or other nonparallel path, the texture on the
roller will be deemed to be random and irregular in the practice of
the present invention.
[0043] Advantageously, the primary texture used on middle roller 40
simultaneously serves multiple functions in the context of the
present invention. First, the texture on middle roller 40 allows a
corresponding, relatively deep texture to be formed on the proximal
major face of film 12 with minimal telegraphing of this texture
onto the other, print receptive major face of film 12 even when
film 12 is moving over middle roller 40 at relatively high line
speeds suitable for commercial scale production. In short, the
roller texture is an important factor that allows one major face of
the film 12 to be textured while the other major face of film 12
remains relatively smooth and printable. Without wishing to be
bound by theory, it is believed that the use of depressions to form
a substantial portion of the primary texture features of middle
roller 40 allow this. These depressions allow the molten material
used to form film 12 to flow smoothly over and fill the depressions
as the molten material sets. The other major face of the film is
far less affected by this smooth filling action than might be
expected. In contrast, if the roller surface were to include an
undue amount of protuberances, these could cause enough turbulence
or other flow disruption such that substantial telegraphing of
texture to the other major surface of the film could occur. If this
were to happen, print receptive qualities of the other major
surface could be compromised.
[0044] Additionally, the texture characteristics of middle roller
40 yield deeply textured films 12 that nonetheless track
consistently well through printing devices at line speeds suitable
for commercial scale production. This is counter to conventional
wisdom in the industry, where deeply textured films experience
tracking and chatter problems during attempted printing operations.
Without wishing to be bound by theory, it is believed that the
resultant texture formed on film 12, which is essentially randomly
and uniformly distributed over one major surface of film 12 allows
very effective and uniform air bleed characteristics under the film
12 as it traverses through a printer. As a consequence, localized
pressure changes under the film 12 having a magnitude sufficient to
induce tracking issues are substantially avoided.
[0045] Pre-embossed texture also avoids exposing print quality and
design clarity on the printed sheets to post-emboss damage risk.
Post-embossing, even when intended to be mainly applied to one
major face of a film can nonetheless result in telegraphing of the
embossed texture to the opposite, printed face. Print quality can
be lost to some degree if this were to happen in post-embossing
processes. Thus, print quality and design clarity of as printed
decorative information tend to be retained to a higher degree on
pre-embossed films than on post-embossed films.
[0046] Further, the molten material is able to smoothly,
consistently, and substantially fully and/or partially fill the
depressions on the roller before the film 12 sets. This means that
the resultant texture is very consistent along the full length of a
roll and from roll-to-roll, day after day. This is an important
advantage in commercial scale production that greatly eases quality
control activities. This extreme consistency is much more difficult
to achieve on a roller that includes relatively greater proportions
of protuberances versus depressions, particularly when the
protuberances are closely spaced sufficiently to unduly disrupt
flow over the roller surface. Thus, although middle roller 40 may
include some amount of protuberances in addition to depressions, it
is desirable to minimize these protuberances so that they
constitute less than 20%, more preferably less than 10%, and more
preferably less than 2% of the surface area of middle roller
40.
[0047] Another advantage is that the resultant texture formed on
the decorative sheet provides the sheet and a laminate
incorporating the sheet with superb scratch and mar resistance and
anti-blocking protection. In practical effect, the texture as
formed on the embossed surface of the film includes a plurality of
protuberances projected generally upward from the film surface. For
anti-blocking protection, these act like stand-offs, reducing the
contact area with an adjacent film face when stacked, wound on a
roll, etc.
[0048] Another advantage is that embossing the extruded film 12 at
the time the film is first set after emerging from the extruder 14,
i.e., pre-embossing the film, completely eliminates any need to
post-emboss the film 12 which typically has occurred after
printing. Since an extruded film desirably is run between a pair of
rollers to set it at a uniform thickness, allowing one of these
setting rollers to be the textured middle roller 40 eliminates the
entire post-embossing manufacturing stage, leading to substantial
cost savings in manufacture. This also helps to protect the
information printed on the film 12, which is at risk of being
damaged if the film bearing the printing must be run through
post-emboss equipment. Yield losses due to emboss process issues or
to printing damage occurring during a post-emboss are entirely
avoided. Since the post-emboss stage can sometimes be a bottleneck
in the manufacture process, eliminating the post-emboss also
dramatically increases throughput. Further, the facility floor
space previously taken up by post-emboss equipment can now be used
by other productive stages, increasing throughput even more.
[0049] Still another advantage is that the pre-embossed texture of
the present invention is much more stable under heat and pressure
than a post-emboss texture. For instance, when a post-embossed
sheet is laminated onto a substrate under heat and pressure, a
significant portion of the texture is lost, e.g., 30% or even more.
This has provided a motivation to over-texture post-embossed films
to ensure that the laminated product still bears enough texture
after the lamination stage. Since over-texturing makes printing
more difficult, if not impractical, printing typically occurred
prior to post-embossing. In contrast, a pre-embossed film laminated
under otherwise identical conditions loses substantially less
texture, e.g., 11% or even less. Indeed, in PVC film embodiments
incorporating no plasticizer, the surface roughness of the films
following lamination was the same as the decorative sheet prior to
lamination within the measurement capabilities of the measurement
instrument. In other words, within the measurement capabilities of
the instrument, no loss of texture after lamination could be
identified.
[0050] Thus, pre-embossed sheets of the present invention can be
fabricated with a texture that is much closer to the final, desired
texture goal. Alternatively stated, there is much less need to
resort to significant overtexturing protection when practicing the
present invention. This more targeted texture in combination with
the right kind of texture is an important combination that allows
the film 12 to be printer compatible, as much as overtexturing
would tend to be associated with a significant risk of printer
incompatibility.
[0051] It is also believed that many advantages would be realized
in the course of laminating these films onto substrates. Because of
the stability of the texture under heat pressure, lamination would
be able to occur under a wider range of manufacturing conditions.
For instance, greater heat and/or pressure may be used in order to
laminate faster, leading to higher throughput. Due to the excellent
scratch and mar resistance and blocking resistance, the films would
be more compatible with a wider range of equipment. It is also
believed that the degree, nature, and permanence of the texture
will allow the visual impact of gel spots (which are believed to
result from higher molecular weight lumps of resin in the extruded
film) to be hidden to a greater degree and, thus, lessened.
[0052] In addition to the primary texture described above, the
middle roller 40 may also incorporate one or more additional kinds
of textures. For instance, it may be desirable to further
incorporate a gloss modifying, secondary texture onto at least the
film surface bearing the primary texture. According to one
convenient approach, this texture is obtained through appropriate
surface roughening of a plating, e.g., chrome plating, covering the
primary texture. The degree of roughness can be controlled by the
grit finish used to surface the plating. This additional gloss
modifying texture is at a much smaller scale than the texture
provided by the depressions of the middle roller 40. By way of
analogy, if the roller land surface(s) and depressions are viewed
as plateaus and valleys respectively, the secondary texture may be
viewed as shrubbery growing on the surfaces of those plateaus and
valleys. Thus, returning from the analogy to the context of the
present invention, the finer texture is provided on both the
land(s) and the depressions. The amount of this kind of texture
used can vary over a wide range and depends, to a large degree,
upon what kind of gloss characteristics are desired for the final
product.
[0053] In embodiments of the invention in which film 12 is
transparent, imparting this texture onto one major face of the film
impacts the gloss on the other major face even when that other
major face was not physically modified. For instance, film
embodiments of the invention had glosses on their embossed sides of
about 51 on average and about 23 on average on the print side after
moderate roughening of the embossed side to provide a secondary
texture. Additional but otherwise identical film samples were
roughened only on the embossed side with a greater degree of
secondary texture to provide average gloss readings on the embossed
side of about 25. The gloss on the unmodified print side of these
samples averaged about 19. Note that all gloss readings herein were
taken with the gloss meter (Byk Gardner micro-gloss 60.degree.)
parallel to the web direction and are reported as an average of
five readings for each sample tested.
[0054] Top roller 38 rides on top of film 12 under a suitable
pressure as film 12 passes between middle roller 40 and top roller
38. In one embodiment, a top roller pressure of about 700 psi was
found to be suitable. The surface of top roller 38 is desirably as
smooth as is practically feasible to help ensure that the top
surface of film 12 in contact with top roller 38 is correspondingly
smooth for promoting print receptive characteristics. Optionally,
the top roller 38 also has a resilient, rubber surface so that the
risk of roller damage is minimized if the top roller 38 and the
middle roller 40 were to come into contact. A resilient rubber with
a Durometer A hardness in the range of 60 to 80 at 25.degree. C.
would be suitable. In one embodiment, top roller 38 has a rubber
sleeve on a steel core. A rubber sleeve made from a silicon rubber
have a 70 Durometer A hardness would be suitable.
[0055] The bottom roller 42 is positioned at the bottom of the
3-roll stack. The bottom roller 42 helps to avoid chatter and
promotes a smooth release of film 12 from the texturing station 36.
In one illustrative embodiment, the bottom roller 42 has a smooth,
chrome surface.
[0056] The path of film 12 through texturing station 36 is seen
best in FIG. 2. The molten, extruded, molten film 12 extruded from
the extruder 14 is introduced to the texturing station 36 by
feeding the molten film 12 into the gap 45 between top roller 38
and middle roller 40. The top roller 38 applies pressure against
the film 12, helping to hold it against middle roller 40. The
smooth surface of top roller 38 also helps to form a smooth, print
receptive surface on the major face of the film 12 adjacent to top
roller 38. In the meantime, the middle roller 40 contacts and
texturizes the other major face of the film 12.
[0057] The three rollers 38, 40, and 42 are held at a temperature
sufficiently below the melt temperature of the film material so
that the film 12 sets when the film material contacts these
rollers. In one mode of practice for processing a PVC film feed
having a melt (exudate) temperature of about 380.degree. F., the
molten film 12 entering the texturing station 36 is at a
temperature of about 350.degree. F., the top roller is at
75.degree. F., the middle roller is at 185.degree. F., and the
bottom roller is at 175.degree. F. The top roller 38 is cooler than
the middle roller 40 so that the top surface sets a little faster,
which helps to promote formation of a smoother, print receptive
surface on the face of the film 12 adjacent to the top roller. The
middle roller 40 is warmer so that the film material sets a little
slower on the adjacent face, which helps the film material to
conform to the texture of the middle roller 40 better than if the
middle roller 40 were to be too cool. Heat exchanger 34 is coupled
to texturing station 36 in order to help control the temperatures
of the rollers 38, 40, and 42.
[0058] The speed of the film 12 through the texturing station 36
can vary over a wide range, such as from about 1 foot per minute up
to about 1000 feet per minute or even more. Advantageously, a
significant, printer-compatible texture can be formed on film 12 at
high processing speeds suitable for commercial scale manufacture.
In one mode of practice, for example, roller speeds corresponding
to a film speed of about 190 feet per minute at a tension setting
of about 48 psi to about 50 psi would be suitable.
[0059] The texture of the resultant film 12 may be characterized in
terms of the Ra surface roughness of both the embossed and print
sides of the film 12. In the practice of the present invention, Ra
surface roughness is the arithmetic mean deviation of the roughness
profile, recorded within the evaluation length. Simply put, Ra is
the average of a set of individual measurements of a surfaces peaks
and valleys and is reported in units of length, e.g., microinches
(micrometers).
[0060] To measure the Ra surface roughness of the embossed side of
the film, the film is placed print side down onto a piece of
unscratched, unmarred glass. A perthometer instrument is placed on
the film parallel to web path. The device is activated and
measurements are taken. The procedure for measuring Ra surface
roughness uses a Model M1 Mahr Perthometer instrument commercially
available from Willrich Precision Instruments Co., Inc. according
to the procedure provided in the instrument's instruction manual
titled "Operating Instructions 3755321; Perthometer M1 with PFM
Drive Unit", wherein the entirety of this instruction manual is
incorporated herein by reference in its entirety. The unit is used
in ISO mode. The automatic function is not used. The maximum trace
interval of 0.7 inches is used. Five sampling lengths (cut offs) of
0.1 inches are used, although seven such lengths are measured. The
leading and trailing measurements are discarded and the central
five retained to help eliminate startup and stand-down noise. The
NHT 6-100 stylus is used. The NHT 6-100 pick up is a single-skid
pick-up whose skid has a spherical shape with a radius in the
tracing direction of 25 mm and a radius at right angles to this of
2.9 mm and a contact point 0.8 mm in front of the stylus. The
stylus tip has a radius of 2 micrometers and a cone angle of 90
degrees per DIN EN ISO 3274. The measuring force is approximately
0.7 mN. The tracing speed is 0.5 mm/s. The recorded profile is
filtered with a phase-corrected profile filter (Gaussian filter) in
accordance with DIN EN ISO 11562. Additional parameter settings for
using the perthometer are as follows:
TABLE-US-00001 Language: English Units: Inches Timeout: On
Blocking: Off V.24 38400 N 8120 Battery: 100% Pick up type: 100
Corr. Value: 3% N 5 PFM On Lc Standard 320 ui Autoprinting Off
Profile On
[0061] After taking the first measurement, the probe, or pick up,
is moved a few inches away four more times with four more
measurements taken at each move. The readings are averaged, and the
average is taken as the Ra surface roughness for that side of the
film. To measure the Ra surface roughness of the printable side of
the film, the film is turned and placed on the same place on the
glass. Measurements are done in the exact same way with readings
averaged and recorded.
[0062] Desirably, the embossed side of the film has a deep surface
texture, yet not so deep that the film is incompatible with desired
printing operations. Thus, if the texture of the embossed side is
too deep, the film could experience chatter, poor print quality or
other tracking issues during printing. For this reason, the Ra
surface roughness of the embossed side of preferred film
embodiments is desirably at least 100 microinches, preferably at
least 120 microinches, and more preferably at least 150
microinches. Desirably, the Ra surface roughness is no more than
300 microinches, preferably no more than about 250 microinches; and
the ratio of the Ra surface roughness of the embossed side to the
printed side is in the range from about 1.2:1 to 500:1, preferably
about 3:2 to about 10:1; more preferably about 3:2 to about 3:1. In
illustrative embodiments of the invention, the embossed side of
very preferred embodiments of PVC films of the present invention
had Ra surface roughness measurements in the range from about 160
to about 190 microinches (averaging 168 microinches), while the
printed sides of these films had Ra surface roughness values in the
range from about 60 to about 90 microinches, averaging 74 to 79
microinches. Consequently, in a particularly preferred embodiment,
the Ra surface roughness of the embossed side is in the range of
from about 160 microinches to about 190 microinches, and the Ra
surface roughness of the printed side is less than about 90
microinches, preferably less than 75 microinches, more preferably
less than 60 microinches, and in some desirable embodiments is in
the range of from about 60 microinches to about 90 microinches.
[0063] FIG. 3 is a copy of a pair of photographs showing the
texture on the pre-embossed side 105 of the film and the print side
110 of the film 100, respectively, taken at a magnification of
700%. The relatively deep texture on the pre-embossed face 105 of
the film 100 can be seen as a relatively random yet directional
texture of protuberances projecting upward from the main face of
this side of the film 100. The texture is random in the sense that
the features lack uniformity in two or more of length, degree of
meandering (deviation from linearity), height, and width, and
general orientation. The texture is directional in that a
substantial portion of the protuberances generally have long axes
that generally run from the top to the bottom of the photograph,
even though the axes of features from top to bottom are not
arranged in columns but instead are irregularly staggered. Some of
the features are branched, with multiple arms. The photograph of
the print side 110 of the film 100 shows a similar texture, but on
a smaller scale.
[0064] Referring again to FIGS. 1 and 2 collectively, but mainly
FIG. 1, the next major station that the film passes through is the
automatic profile controller station 46 which includes the profile
controller 48, power source 50, and electrical wiring 52 coupling
power source 52 controller 48. According to a feedback control
loop, the controller 48 measures the thickness of the film 12
passing through controller 48. If the thickness is outside of
specifications, the controller 48 sends a signal to the die heating
source(s) causing the temperature at the die to increase or go
down. Generally, increasing the temperature at the die thins the
film 12, while lowering the temperature thickens the film 12. After
the automatic profile controller station 46, the edges of the film
12 are trimmed at slitter 54. A pull roller 59 is positioned after
slitter 54. Pull roller 59 is a driven roller that helps to pull
the film 12 through the system 10. After slitting, the film 12 may
then be transported directly to a printing station (not shown),
wound up and stored until needed, or otherwise handled. For
purposes of illustration, FIG. 1 shows that film 12 is wound and
stored for further use on a take up roll 60 in winder 56.
[0065] The thickness of film 12 can be selected within a
considerably wide range. If too thin, however, the film 12 may have
poor mechanical and durability properties. Films that are too thick
waste material and may be more difficult to run through printing
equipment, but thicker films certainly could be used where excess
material usage is not a concern and printing equipment is capable
of handling the additional thickness. Generally, it is convenient
to prepare embodiments of film 12 that have thicknesses in the
range from about 1.0 mil or less to about 20 mils, preferably about
1.5 mils to about 2.5 mils.
[0066] Decorative information may be printed onto the film 12 to
form decorative laminate films, and these printed films may then be
incorporated into decorative laminate structures using any suitable
techniques. Any kind of printed information may be printed directly
onto the print receptive side of film 12. The printed image may be,
but is not limited to an image of a wood grain, stone, marble,
leather, fabric or other textile, porcelain, a metallic surface, a
pattern, one or more colors, a graphic image, combinations of
these, and the like. Photographic images of people, animals,
nature, places, things, and/or the like also may be used. The
decorative image may be a solid color without a defined image. A
variety of printing methods may be used to apply printed
information onto the film 12, including by way of example ink jet
printing, laser printing, gravure printing, offset printing,
anastatic printing, silk screen printing, transfer printing,
combinations of these, and the like.
[0067] To accommodate the deep texture of film 12, it may be
desirable to adjust print process parameters to obtain decorative
film sheets whose printing satisfies desired quality and clarity
standards. For instance, in the case of roto gravure printing,
because of the rougher texture of the embossed side and of the
moderate texture of even the printed side of films in some
embodiments, conventional settings useful may lead to images that
are too grainy and/or have dot skipping or print omits.
Consequently, use of films 12 may require adjustments to parameters
relating to ink viscosity, nip pressure, line screen density on the
design roll, and/or blade angles. Inks with moderately lower
viscosity are desired in order to help insure that the thinner inks
can adequately flow and cover the moderately textured printable
film surface. In representative embodiments, suitable inks have a
No. 2 Zahn viscosity at ambient of about 18 seconds to 20
seconds.
[0068] Nip pressure is desirably increased moderately to help
facilitate good ink penetration into the surface topography.
Whereas conventional nip pressures might be moderately below 40
psi, it is more desirable to use nip pressures above 40 psi. In one
mode of practice, a nip pressure of 45 psi is suitable.
[0069] The line screen density of the design roller can vary over a
wide range. Often, a line screen density on the order of 150 lines
per inch or higher might be desired in a conventional printing
operation. However, when printing onto a film surface with a
moderate texture, using a line screen density on the order of 150
lines per inch or less, desirably even 120 lines per inch, helps to
pick up a greater volume of ink from the ink bath and leads to
better coverage over the surface to be printed.
[0070] The doctor blade angle is desirably reduced, too, in order
to spread ink better in the current context. Blade angles ranging
from 5 degrees to 25 degrees with verticals ranging from 25/8
inches to 41/4 inches have been suitable. For instance, when
printing a three color pattern corresponding to a wood grain
texture, a blade angle of 25 degrees with 25/8 vertical is used to
print a woodgrain tick; a blade angle of 15 degrees and 2% vertical
was used to print the woodgrain key, and a blade angle of 5 degrees
with a 41/4 inch vertical was used to print the solid base color.
Web tension of 8 to 15 psi would be suitable.
[0071] The resultant decorative sheet can be readily incorporated
into a wide variety of decorative laminates. Examples from among
many suitable applications include flooring, worktops, wall
coverings, desktops, furniture, electrical and appliance housings,
cabinets and cabinet doors (kitchen, bathroom, bedroom, family
room, living room, dining room, etc.), and the like.
[0072] In an exemplary decorative laminate construction, a
decorative sheet is adhered to one or more substrates to form the
desired end product or a component thereof. Any desired substrate
may be used. The substrate can be synthetic or natural. Examples
include reinforced or unreinforced polymers, particleboard, medium
density fiberboard, plywood, wood, paper, cardboard, metal,
oriented strand board, wheatboard, strawboard, reconstituted
cellulosic panels, polymeric foams, honeycomb structural panels,
mineral filled polymer, concrete or other ceramic, or an
unreinforced or reinforced polymeric layer, combinations of these
and the like.
[0073] In addition to the decorative sheet and the substrate,
decorative laminates of the present invention may include one or
more additional layers if desired. Examples include one or more
additional decorative sheets in layers to create composite visual
effects, overlays, underlays, adhesive layers as needed for
laminating, and the like. Examples of such additional layers have
been described in U.S. Patent Publication No. 2002/0168503,
incorporated herein by reference in its entirety for all
purposes.
[0074] The laminates of the invention can be formed by any desired
process. Typically, decorative laminates are formed by using
adhesives and elevated temperatures and pressures to bond layers of
the laminate together. Continuous laminating methods are preferred
for commercial scale production. Suitable manufacturing lines
should be capable of rapid throughput with controlled temperature
and pressure during laminating steps. Optionally, one or more
layers of the product may be formed via coating a fluid
composition, which may be a liquid, dispersion, or the like, which
is then cured to form a solid or gel component, as desired.
Adhesives may be used to assist with bonding where needed. Hot
melt, ultraviolet hardening, or heat hardening adhesives are just a
few examples of the many adhesives available in the industry.
[0075] Decorative laminates, layers and features useful in
decorative laminates, methods of making these layers and features,
and methods of forming the laminates are described in U.S. Pat.
Nos. 6,436,540; 4,816,314; 6,017,612; 4,076,566; 6,579,611; and
4,396,448; and in U.S. Pat. Pub. Nos. 2003/0116261; 2007/0087126;
2002/0168503; each of which is incorporated herein by reference in
its respective entirety for all purposes.
[0076] Other embodiments of this invention will be apparent to
those skilled in the art upon consideration of this specification
or from practice of the invention disclosed herein. Various
omissions, modifications, and changes to the principles and
embodiments described herein may be made by one skilled in the art
without departing from the true scope and spirit of the invention
which is indicated by the following claims.
* * * * *