U.S. patent application number 14/821281 was filed with the patent office on 2016-01-28 for perforated nonslip non-adhesive surface covering.
The applicant listed for this patent is KITTRICH CORPORATION. Invention is credited to Mark A. Calkins.
Application Number | 20160023430 14/821281 |
Document ID | / |
Family ID | 46507455 |
Filed Date | 2016-01-28 |
United States Patent
Application |
20160023430 |
Kind Code |
A1 |
Calkins; Mark A. |
January 28, 2016 |
PERFORATED NONSLIP NON-ADHESIVE SURFACE COVERING
Abstract
A surface covering that is a multilayered composite material.
The multilayer composite material includes a top facing layer of
polymeric film and a bottom layer of unsupported foam.
Inventors: |
Calkins; Mark A.; (San
Jacinto, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KITTRICH CORPORATION |
LA MIRADA |
CA |
US |
|
|
Family ID: |
46507455 |
Appl. No.: |
14/821281 |
Filed: |
August 7, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13022468 |
Feb 7, 2011 |
9132283 |
|
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14821281 |
|
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|
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61432906 |
Jan 14, 2011 |
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Current U.S.
Class: |
428/137 ;
156/220; 156/253; 428/158; 428/317.1; 428/318.4; 428/319.3;
428/319.7 |
Current CPC
Class: |
Y10T 428/24496 20150115;
Y10T 428/249953 20150401; B32B 2038/0084 20130101; Y10T 156/1041
20150115; A61B 6/032 20130101; B32B 27/065 20130101; Y10T
428/249987 20150401; Y10T 428/249993 20150401; B32B 2266/0207
20130101; Y10T 428/24995 20150401; B32B 27/304 20130101; A61B
6/4085 20130101; B32B 5/18 20130101; B32B 2266/0278 20130101; A61B
6/405 20130101; A61B 6/482 20130101; B32B 3/30 20130101; A61N 5/103
20130101; B32B 38/1875 20130101; A61B 6/481 20130101; B32B 7/12
20130101; Y10T 428/15 20150115; A61B 6/507 20130101; A61B 6/541
20130101; B32B 37/06 20130101; Y10T 428/249982 20150401; B32B
29/007 20130101; B32B 2262/02 20130101; Y10T 428/24851 20150115;
B32B 27/12 20130101; B32B 2266/0221 20130101; Y10T 156/1057
20150115; A61B 6/4275 20130101; B32B 2266/0214 20130101; A61N
5/1037 20130101; B32B 38/06 20130101; Y10T 428/249985 20150401;
B32B 2305/022 20130101; B32B 3/266 20130101; B32B 2307/744
20130101; Y10T 428/249992 20150401; B32B 37/12 20130101; A61N
5/1039 20130101; B32B 2266/0235 20130101; B32B 2266/02 20130101;
Y10T 428/24322 20150115; A61B 6/0487 20200801; B32B 38/04 20130101;
B32B 2038/045 20130101; Y10T 428/24504 20150115; A61B 6/04
20130101; B32B 7/14 20130101; B32B 2479/00 20130101; Y10T
428/249991 20150401; B32B 2038/047 20130101; A61M 5/007
20130101 |
International
Class: |
B32B 5/18 20060101
B32B005/18; B32B 3/30 20060101 B32B003/30; B32B 27/06 20060101
B32B027/06; B32B 7/12 20060101 B32B007/12; B32B 38/06 20060101
B32B038/06; B32B 29/00 20060101 B32B029/00; B32B 37/06 20060101
B32B037/06; B32B 37/12 20060101 B32B037/12; B32B 38/04 20060101
B32B038/04; B32B 3/26 20060101 B32B003/26; B32B 27/30 20060101
B32B027/30 |
Claims
1. A surface covering comprising: a multilayered composite
material, wherein, the multilayer composite material further
comprises (1) a top facing layer of polymeric film and (2) a bottom
layer of unsupported foam.
2. The surface covering according to claim 1, wherein the
multilayered composite material further includes a plurality of
vertical perforated lines and a plurality of horizontal perforated
lines, the vertical and horizontal perforated lines forming a
grid.
3. The surface covering according to claim 1, wherein the top
facing layer comprises single or multiple layers of a thermoplastic
film.
4. The surface covering according to claim 3, wherein the top
facing layer comprises a single layer of polyvinyl chloride
film.
5. The surface covering according to claim 4, wherein the single
layer of polyvinyl chloride film has a thickness of about 0.075 mm
to 0.1775 mm.
6. The surface covering according to claim 1, wherein the top
facing layer comprises a paper stock.
7. The surface covering according to claim 1, wherein the top
facing layer of polymeric film is thermally fused to the bottom
layer of unsupported foam.
8. The surface covering according to claim 1, further comprising an
adhesive layer in-between the top facing layer of polymeric film
and the bottom layer of unsupported foam.
9. The surface covering according to claim 1, further comprising an
embossed pattern on the top facing layer of polymeric film.
10. The surface covering according to claim 1, wherein the bottom
layer of unsupported foam comprises a polymeric compound having a
diffusion of minuscule gas bubbles.
11. The surface covering according to claim 10, wherein the
polymeric compound is selected from a group consisting of latex,
polyvinyl chloride, polyurethane and ethylene vinyl acetate.
12. The surface covering according to claim 1, wherein the bottom
layer of unsupported foam has a thickness of about 1.275 mm to
1.675 mm.
13. The surface covering according to claim 10, wherein the bottom
layer of unsupported foam is configured with a fine pattern of
micro-embossed indentations.
14. The surface covering according to claim 10, wherein the bottom
layer of unsupported foam has a smooth continuous surface.
15. The surface covering according to claim 1, wherein the surface
covering is a shelf liner, a drawer liner and/or a storage
container liner.
16. A method of manufacturing a surface covering comprising the
steps of: supplying a sheet of polymeric film as a top sheet and a
sheet of polymeric foam as a bottom sheet; simultaneously
transporting the sheet of polymeric film and the sheet of polymeric
foam under a laminating unit; thermally combining the sheet of
polymeric film to the sheet of polymeric foam to form therein, the
thermal combining step resulting in a composite material; cooling
the composite material; and cutting a grid of perforations into the
composite material, wherein, the composite material comprises an
upper layer sheet of polymeric film and a bottom layer of polymeric
foam.
17. The method of manufacturing the surface covering according to
claim 16, further comprising the step of embossing an upper surface
of the sheet of polymeric film.
18. The method of manufacturing the surface covering according to
claim 16, further comprising the step of applying an adhesive to an
underside of the polymeric film and contacting the underside of
polymeric film to the polymeric foam before simultaneously
transporting the sheet of polymeric film and the sheet of polymeric
foam under the laminating unit.
Description
RELATED APPLICATION DATA
[0001] The present application claims priority to provisional
application 61/432,906 filed in the United States Patent Office on
Jan. 14, 2011, the entirety of which is hereby incorporated by
reference herein to the extent permitted by law.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed to removable, nonslip,
non-adhesive coverings which are used as shelf, drawer or storage
liners. In particular, the covering sheet features an improved
composite material having a top decorative layer of polymeric film
combined to a continuous bottom layer of unsupported foam. The
structure of the multilayered composite material facilitates the
convenient hand tearing of the sheet to size through a grid of
perforations oriented along the vertical and horizontal axes of the
covering.
[0004] 2. Description of the Prior Art
[0005] Shelf, drawer or storage liners have been extensively sold
at retail venues and are available in a selection of self-adhesive
or non-adhesive coverings. Printed wall coverings or papers were
once used to protect the wooden interiors of cabinets or drawers
from exposure to moisture. These permeable materials were
eventually replaced with the application of decorative
self-adhesive plastic sheets, which provide a greater degree of
water resistance to the unfinished or varnished surfaces of
cupboards. Self-adhesive shelf liners primarily consist of a facing
layer of transparent, opaque or printed polymeric film coated with
an underlying layer of pressure sensitive adhesive. The pressure
sensitive adhesive may be combined with a siliconized release
liner, which is removed prior to the application of the decorative
plastic laminate. To assist the consumer in the installation of the
product, the release liner typically features an imprinted grid of
guide lines following the vertical and horizontal axes of the
covering. The interior dimensions of cabinets or drawers are then
transferred to the printed release liner prior to cutting the shelf
liner to size.
[0006] Another provision known in the art includes a decorative
laminate having a releasable first face with an adhesive coated
reverse face, thereby permitting the sheet to be rolled upon itself
and readily unrolled without the need for a separable siliconized
liner. In one variation, the covering may consist of a
polypropylene film having a fine pattern of micro-embossed
indentations formed into the exterior facing of the sheet. The
micro-embossed pattern reduces the surface area of the laminate and
limits the corresponding degree of contact with the adhesive layer
when wound into rolls for retail distribution. Alternatively,
transparent varnishes containing an admixture of polymerized
siloxanes, which are more commonly referred to as polysiloxanes,
have been applied to create a releasable decorative layer for
self-adhesive shelf liners made from paper or polymeric materials.
Although the use of silicone coatings or micro-embossed
indentations enhance the smooth separation of pressure sensitive
laminates, the installation of such self-wound materials can be
very troublesome in poorly accessed locations. The omission of a
printed release liner eliminates the efficient means for preparing
the self-adhesive covering to fit within the confined interiors of
cabinets or drawers. Instead, it is necessary to first adhere the
self-wound sheeting to an uncovered surface, while folding any
remaining edge portions up along the adjacent walls of a cupboard,
then subsequently trimming away the excess material with a razor
blade.
[0007] In the prior art, the application of self-adhesive coverings
are known to become frequently unmanageable. It is difficult to
accurately achieve consistent straight cuts along the length and
width of the material, even with the added convenience of an
imprinted release liner, and especially when the shelf liner is
self-wound. Irregular, oversized or non-conforming laminates that
will not precisely adhere to their intended surfaces may result in
the formation of entrapped air pockets beneath these impermeable
coverings. Such air pockets eventually collapse under load,
permanently causing unsightly creases and wrinkles Moreover, a
further problem emerges when the exposed adherent layer
inadvertently folds upon itself, as the separation of these
mutually bonded surfaces results in the irreparable deformation of
the polymeric film.
[0008] Previous attempts have been made in the prior art to
simplify the alteration of self-adhesive shelf liners so that they
may correspond to the dimensions of cabinets and drawers. For
example, earlier methods include the provision of forming lines of
weakness into a laminate sheet to facilitate the hand-tearing of
the covering to fit a surface of predetermined size.
[0009] U.S. Pat. No. 6,238,762, issued on May 29, 2001 to R.
Friedland et al., discloses a self-adhesive decorative covering
adapted with through-cut microperforations and embossed prescores,
which are oriented at right angles, to provide rectilinear yield
lines enabling the manual hand sizing of a sheet. Lines of weakness
may also run diagonally between the grid of microperforations to
facilitate changes in the direction of tearing. The disclosure
further includes a provision for extending the embossed prescores
partially through the profile of the laminate. The arrangement of
through-cut microperforations and embossed prescores may be used in
combination with a self-adhesive covering having a separable
release liner that includes a corresponding pattern of perforations
or, alternatively, with a self wound sheet having a releasable
polysiloxane facing.
[0010] U.S. Pat. Nos. 4,380,564 and 4,465,729, issued on Apr. 19,
1983 and Aug. 14, 1984, respectively, to Cancio et al., disclose a
plastic laminate having an intersecting grid of tear lines formed
into the surface of the sheet material whereby the film may be torn
by hand in more than one direction. In a preferred embodiment
presented in both patents, the plastic sheet materials are composed
of a polymeric component consisting of a low density polyethylene
having a disperse phase of calcium carbonate, with the preferred
ratio of the foregoing ingredients contingent upon the dimension of
the grid pattern embossed into the film. The inventors claim that
the selected admixtures of polyethylene and calcium carbonate
enhance the tear assisting provision of their polymeric sheet while
maintaining the overall tensile strength characteristics of the
material. In each disclosure, a layer of adhesive may be disposed
on one side of the plastic covering, which is protected by a
release liner that does not have any cross-tearable lines.
Accordingly, installation of the materials taught in both patents
first requires the removal of the release liner prior to hand
tearing the laminate to size.
[0011] The primary disadvantage of the prior art, inherent within
self-adhesive coverings which integrate perforated or
cross-tearable features, concerns the inadvertent separation of the
shelf liner along unselected lines of weakness, especially when
attempting to pull apart mutually adhering surface portions that
have accidentally folded upon themselves. The strong reciprocal
bond created through such mishaps may surpass the tensile strength
property of the yield lines, causing the unintended fragmentation
of the plastic sheet, thereby rendering the covering unsuitable for
installation. Moreover, another difficulty relates to the
replacement of perforated or cross-tearable laminates after
long-term use, as the molecular structure of the polymeric film
degrades with age, while the self-adhesive coating becomes fully
cured to the interior surfaces of cabinets or drawers.
Consequently, the increased bond strength of the adhesive, combined
with the embrittlement of the plastic, will result in the adverse
disintegration of the material into miniscule pieces upon
removal.
[0012] Although the use of self-adhesive coverings in the prior art
have long provided consumers with the means to both decorate and
protect shelving and drawers, the thin layer of polymeric film
often fails to conceal uneven surface flaws or irregularities. More
recently, the renovation or construction of kitchens and bathrooms
now feature cabinets with water-resistant interior laminates, sold
commercially under the Wilsonart.RTM. or Formica.RTM. brands, which
are primarily manufactured from thermosetting plastic resins. Since
the latest cabinet fabrications also use composite particle board
materials, the application of such laminates inhibits moisture from
coming into contact with the bonded wooden fibers and produces a
smooth consistent surface that can be easily cleaned. Where
functionality and durability is therefore enhanced, the thermoset
resin permanently hardens under heat and pressure during the
formation of these laminates, thereby increasing the rigidity while
diminishing the impact resistance of the material. Without the
benefit of a suitable protective covering, the striking force of
ordinary household articles can cause pieces of the thermoset
plastic sheet to break away from shelving or drawers. In view of
the fact that self-adhesive coverings offer superficial protection
against impact resistance, and their subsequent removal often
leaves behind a viscous residue, non-adhesive shelf liners have
gained widespread acceptance.
[0013] One type of non-adhesive shelf liner in the prior art
consists of a knitted polyester scrim with a coating of thermally
foamed polyvinyl chloride (PVC) resin. The knitted construction of
the scrim provides an arrangement of woven yarns defining a pattern
of apertures that correspond to a configuration of openings
extending through the thickness of the cured PVC material.
Alternatively, the PVC resin may be knife coated to both sides of a
knitted scrim devoid of openings, or to a non-woven fabric of
autogenously bonded polyester fibers, producing a solid continuous
layer of supported foam. The PVC compound also includes a
plasticizer that imparts a removable nonslip mechanical bond
between the shelf liner and an applied surface. Such coverings
provide a degree of protective cushioning and are often laminated
or fused with a top decorative layer of plastic film. The basic
deficiency of foamed non-adhesive liners is that they do not
incorporate any provision for the consumer to conveniently alter
the product to match the interior dimensions of cabinets or
drawers. Moreover, the overall thickness of the shelf liner, along
with the variable density of the knitted scrim and thermally cured
foam, makes it difficult to maintain the uniform alignment of cuts
along the length and width of the material.
[0014] Further, prior art methods--which are used to configure
cross-tearable features within self-adhesive shelf liners--cannot
be successfully applied to form lines of weakness in removable,
nonslip, non-adhesive versions that are supported with a knitted
scrim or non-woven fabric. The embossment of an intersecting grid
of tear lines will not adequately diminish the tensile strength
property of the woven yarns or bonded polyester fibers, where the
perforation of a linear series of discontinuous holes will not
effectively weaken adjacent segments of imperforated substrate. The
adaptation of these coverings for hand tearing becomes even less
viable with the added combination of a laminated or fused layer of
decorative plastic film.
[0015] U.S. Pat. No. 5,707,903, issued on Jan. 13, 1998 to H.
Schottenfeld, discloses a nonslip laminated liner comprising a
foamed PVC coated scrim with a vinyl sheet covering. The scrim
increases the tensile strength properties of the foamed nonslip
pad, which includes a plurality of open cells extending through the
thickness of the cured PVC material. Additionally, the vinyl sheet
covering is permanently bonded to the top plane of the nonslip
pad.
[0016] U.S. Pat. No. 5,854,144, issued on Dec. 29, 1998 to J.
Hawley, describes a nonslip multilayer sheet material for covering
household surfaces. The cushioned shelf liner is made by laminating
a layer of thin plastic film to the top surface of a spunbonded
non-woven polyester fabric. The bottom surface of the non-woven
fabric is coated with a continuous layer of polyurethane foam.
[0017] U.S. Pat. Nos. 5,863,845 and 5,874,371, which respectively
issued on Jan. 26, 1999 and Feb. 23, 1999 to T. Owen, similarly
disclose a removable non-skid, non-adhesive surface covering
comprising a woven substrate having a plurality of apertures,
wherein at least a portion of the bottom surface of the substrate
is coated with a PVC resin. Alternatively, a non-woven substrate
may also be used. The application of the polymeric compound
prevents the covering from skidding tangentially or laterally in a
plane parallel to an applied surface. A decorative sheet is adhered
to the top surface of the non-skid covering.
[0018] U.S. Pat. No. 6,022,617, issued on Feb. 8, 2000 to M.
Calkins, discloses a laminated nonslip liner or mat having an
intermediate layer of non-woven material printed on one side with a
pattern of relatively high friction material. The imprinted pattern
consists of a high density matrix of latex or PVC projections. A
decorative vinyl sheet is laminated to the obverse side of the
non-woven material. Similarly, U.S. Pat. No. 6,159,583, issued on
Dec. 12, 2000 to the same inventor, discloses a laminated nonslip
liner or mat comprising an interposing layer of non-woven material
printed with a high density matrix of polyethylene projections. The
imprinted thermoplastic resin provides non-adhering, non-marring
contact with an underlying surface.
[0019] U.S. Pat. No. 6,221,796, issued on Apr. 24, 2001 to J.
Hawley et al., describes a laminated shelf lining material having
nonslip characteristics. The covering is produced by bonding a
smooth continuous layer of vinyl film to a layer of scrim
comprising woven threads surrounded by a foamed PVC plastic.
Comparatively, U.S. Pat. No. 6,130,174, issued on Oct. 10, 2000 to
the same inventor, discloses a smooth surfaced foam laminate and a
method for making the material similar to the Hawley '796
patent.
[0020] U.S. Pat. No. 7,253,126, issued on Aug. 7, 2007 to W.
Browne, discloses a decorative nonslip shelf liner that comprises a
multi-layered thermoplastic composite sheet. A decorative top layer
of a thin polyvinyl chloride film is laminated or fused to a
non-slip bottom layer via a disposed interlayer of polyvinyl
chloride plastisol. The non-slip bottom layer consists of a
supporting non-woven fabric coated on both sides with a foamed
plasticized polyvinyl chloride resin.
[0021] U.S. Patent Application Publication US 2003/0036323 A1 by R.
Aliabadi, published on Feb. 20, 2003, discloses a multilayered
nonslip plastic shelf liner comprising an intermediate layer of
fibrous polyester fabric enveloped by two thermally bonded layers
of polyvinyl chloride. A thin coating of polyurethane is applied to
the obverse side of the covering to provide a smooth frictionless
surface, where the reverse side remains uncoated to impart nonslip
properties to the laminated material.
[0022] None of the above inventions and patents, taken either
individually or in combination, is seen to have solved the
aforementioned problems associated with resizing removable,
nonslip, non-adhesive surface coverings.
[0023] Accordingly, it is an object of the present invention to
provide a removable, nonslip, non-adhesive covering sheet with an
improved composite material having a grid of perforations to
facilitate the convenient hand tearing of shelf, drawer or storage
liners to size.
[0024] It is a further object of the invention to provide a
removable, nonslip, non-adhesive covering sheet with a multilayered
composite material having a top layer of polymeric film combined to
a continuous bottom layer of unsupported calendered foam.
[0025] It is yet another object of the invention to provide a
removable, nonslip, non-adhesive covering sheet having a top layer
of polymeric film that reinforces the dimensional stability of the
underling layer of unsupported calendered foam.
[0026] Finally, an object of the invention is to provide a
removable, nonslip, non-adhesive covering sheet having an underling
layer of unsupported calendered foam configured with a fine pattern
of micro-embossed indentations to assist in the hand tearing of the
material.
[0027] These and other objects of the invention will be apparent to
those skilled in the art from the following detailed description of
the preferred embodiments of the instant invention.
SUMMARY OF THE INVENTION
[0028] The disadvantages and limitations of the background art
discussed above are overcome by the present invention. With this
invention, a removable, nonslip, non-adhesive covering is provided,
wherein an improved multilayered composite material having a top
decorative layer of polymeric film is combined to a continuous
bottom layer of unsupported foam. The structure of the multilayered
composite material facilitates the convenient hand tearing of the
shelf, drawer or storage liner to size through a grid of
perforations oriented along the vertical and horizontal axes of the
covering.
[0029] In accordance with the present invention, the composite
material includes a top facing layer of polymeric film that
reinforces the dimensional stability of the underling layer of
unsupported foam. The polymeric film may be combined to the
unsupported foam by means of thermal fusion or, alternatively,
through the application of an intermediate layer of adhesive. In a
specific embodiment, the facing layer may be a polyvinyl chloride
sheet, although other synthetic films may be used. The polymeric
sheet has sufficient tensile and tear strength properties along the
machine and transverse directions of the film to inhibit failure of
the multilayered composite material during perforation. The top
facing surface of the polyvinyl chloride sheet may be smooth or,
more preferably, thermally embossed with a decorative pattern
during fusion of the polymeric film to the layer of unsupported
foam. By this means, the thermal embossment of the composite
material obscures the grid of perforations that penetrate the
obverse layer of the shelf, drawer or storage liner.
[0030] The underlying layer of unsupported foam consists of a
polymeric compound having a diffusion of minuscule gas bubbles. In
a preferred embodiment, the polymeric admixture is a polyvinyl
chloride resin that includes a chemical foaming agent. The chemical
foaming agent is selected from the group of hydrazine derivatives,
and is more particularly an Azodicarbonamide powder that is
suspended in the resin formulation. Under thermal decomposition,
Azodicarbonamide releases nitrogen when exposed to temperatures in
the range of 200.degree. to 215.degree. C., thereby causing the
expansion of the polymeric composition. The polyvinyl chloride
compound is cured by means of a thermal calendering process,
wherein the polymeric admixture is uniformly coated on a releasable
belt or casting paper which is compressed against a heated roller.
In the absence of a knitted scrim or non-woven fabric substrate,
the releasable belt or casting paper provides support and
dimensional stability to the unsupported polymeric compound while
maintaining the uniform thickness of the nonslip material during
solidification. The heated roller, releasable belt or casting paper
may be configured to impart a fine pattern of micro-embossed
indentations on the bottom surface of the unsupported calendered
foam. The micro-embossed indentations essentially weaken the tear
strength properties of the nonslip layer and enhance the hand
alteration of the perforated covering.
[0031] The present invention advantageously includes a grid of
perforations that are oriented along the vertical and horizontal
axes of the multilayered covering. The perforations extend through
the profile of the composite material, and are produced with a
rotary or flat bed die assembly having a series of perforating
rules. The perforating rules consist of a sequence of projecting
teeth which are separated at regular intervals by an arrangement of
indented gaps. The sequence of projecting teeth incise a linear
succession of perforations into the composite material, where the
indented gaps form an alternating pattern of uncut tie portions
which run adjacent to the incised perforations. The length of the
projecting teeth or indented gaps may be of equivalent dimension
along the vertical or horizontal axes of the surface covering or,
alternatively, may be adapted to compensate for perpendicular
variations in the tensile and tear strength properties inherent
within the machine and transverse directions of the composite
material.
[0032] Further objects and advantages of the present invention will
be apparent from the following description of the preferred
embodiments when considered in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is an enlarged perspective view of a removable,
nonslip, non-adhesive covering according to the present invention,
showing a perforated multilayered composite material with torn edge
portions;
[0034] FIG. 2A is a cross-sectional view drawn from lines 2A-2A of
FIG. 1, showing the layered construction of a removable, nonslip,
non-adhesive covering according to the present invention;
[0035] FIG. 2B is a cross-sectional view similar to FIG. 2A showing
the layered construction of a first alternate embodiment of a
removable, nonslip, non-adhesive covering according to the present
invention;
[0036] FIG. 2C is a cross-sectional view similar to FIG. 2A showing
the layered construction of a second alternate embodiment of a
removable, nonslip, non-adhesive covering according to the present
invention;
[0037] FIG. 2D is a cross-sectional view similar to FIG. 2A showing
a perforated bevel configuration of a third alternate embodiment of
a removable, nonslip, non-adhesive covering according to the
present invention;
[0038] FIG. 3 is a plan view showing micro-embossed indentations
formed into the bottom unsupported foamed layer of a removable,
nonslip, non-adhesive covering according to the present
invention;
[0039] FIG. 4 is a schematic diagram of an apparatus for making a
calendered unsupported foamed layer of a removable, nonslip,
non-adhesive covering according to the present invention;
[0040] FIG. 5 is a plan view of a perforating rule segment showing
a sequence of projecting teeth and indented gaps for perforating a
removable, nonslip, non-adhesive covering according to the present
invention; and
[0041] FIG. 6 is a schematic diagram of an apparatus for making a
removable, nonslip, non-adhesive covering according to the present
invention.
[0042] Similar reference characters denote corresponding features
consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] The present invention is a removable, nonslip, non-adhesive
surface covering suitable for use as a shelf, drawer or storage
liner, and designated generally as 10 in the drawings. With
reference to FIG. 1, the surface covering 10 is a multilayered
composite material 12 having a top facing layer of polymeric film
14 combined to a continuous bottom layer of unsupported foam 15.
The structure of the multilayered composite material 12 facilitates
the convenient hand tearing of the shelf, drawer or storage liner
through a grid of perforations 19a and 19b, which are respectively
located along the vertical and horizontal axes of the surface
covering 10.
[0044] The top facing layer of polymeric film 14 reinforces the
dimensional stability of the underling layer of unsupported foam
15. The facing layer 14 may consist of single or multiple layers of
thermoplastic film which may be extruded, calendered or cast from
the group of polymers that include Polyvinyl Chloride (PVC);
Polypropylene (PP); Polyethylene (PE); Polyester (PET); Ethylene
Vinyl Acetate (EVA); or other appropriate polymeric formulations.
Alternatively, the facing layer 14 may consist of a paper stock
having a water resistant coating.
[0045] In a preferred embodiment, and as shown in FIG. 2A, the
facing layer 14 is composed of a single layer of polyvinyl chloride
film that is in the range of 0.075 mm to 0.1775 mm in thickness.
The polyvinyl chloride sheet 14 has sufficient tensile and tear
strength properties along the machine and transverse directions of
the film to inhibit failure of the multilayered composite material
12 during perforation. The preferred tensile strength of the
polyvinyl chloride layer 14, when measured according to the
standard testing method for tensile properties of thin plastic
sheeting under ASTM D-822, is in the range of 175-290 kg/cm.sup.2
in the machine direction and 140-270 kg/cm.sup.2 in the transverse
direction of the polymeric film. Additionally, the tensile modulus
of the plastic layer 14, when measured under the same ASTM
protocol, is in the preferred range of 130-225 kg/cm.sup.2 in the
machine direction and 115-200 kg/cm.sup.2 in the transverse
direction of the film. The preferred tear resistance of the
polyvinyl chloride layer 14, when measured according to the
standard testing method for tear resistance (Graves Tear) of
plastic film and sheeting under ASTM D-1004, is in the range of
50-90 kg/cm for both the machine and transverse directions of the
polymeric sheet. The tensile and tear strength properties of the
top facing layer 14 may be enhanced by increasing the thickness of
the material or, alternatively, by using thermoplastic sheets that
are composed of multiple layers of polymeric film 140 and 141, as
illustrated in FIG. 2B.
[0046] As further shown in FIGS. 2A-2D, the facing layer of
polymeric film 14 may be combined to the unsupported foam 15 by
means of thermal fusion or, alternatively, through the application
of an intermediate layer of adhesive 17. In a preferred embodiment,
the facing layer 14 is a single layer of polyvinyl chloride film
that is thermally fused to the layer of unsupported foam 15. The
thermal fusion of the polyvinyl chloride film 14 and the
unsupported foam 15 creates a cohesive bond 16 between the layers
of polymeric material, rather than through the lamination of such
materials through the application of an intermediate layer of
adhesive. In an alternate embodiment, and as disclosed in FIG. 2C,
the facing layer 14 and unsupported foam 15 may be laminated
through the application of an intermediate layer of adhesive 17.
The bonding agent 17 may be selected from the group of synthetic
resins that includes Acrylic Polymers, Polyamides, Polyolefins,
Polyurethanes, or other suitable adhesive systems. The layer of
adhesive 17 may be solidified through the application of heat,
ultraviolet light or electron beam curing methods. As an
alternative, the adhesive layer 17 may be compounded to be a
moisture curable formulation that may reactivate with the
application of heat and pressure. Although the facing layer of
polymeric film 14 may be a smooth continuous sheet, in a specific
embodiment, the top layer is preferably a polyvinyl chloride film
that is embossed with a decorative pattern 18. The embossed
decorative pattern 18 may be formed under heat and pressure with
engraved cylinders or casting papers during the thermal fusion of
the top facing layer 14 to the underling layer of unsupported foam
15. The embossed pattern 18 may also be simulated through the
application of a rotary screen printed thixotropic resin
formulation to the surface of the polymeric film 14. The
thixotropic resin may be hardened with ultraviolet light or
electron beam curing. The embossment of the composite material 12
obscures the grid of perforations 19a and 19b that penetrate the
obverse layer 14 of the shelf, drawer or storage liner 10.
[0047] As detailed in FIGS. 2A-2D, and FIG. 3, the underlying layer
of unsupported foam 15 consists of a polymeric compound having a
diffusion of miniscule gas bubbles 42. The underlying layer of
unsupported foam 15 may consist of natural or synthetic resins that
include Latex; Polyvinyl Chloride (PVC); Polyurethane (PUR);
Ethylene Vinyl Acetate (EVA); or other appropriate compounds. It
can be appreciated that the polymeric compound may also contain
additives that are standard in the art, including fillers,
pigments, matting agents, UV inhibitors, flame-retardants,
biocides, fungicides, and other ingredients. In a preferred
embodiment, the polymeric compound is a polyvinyl chloride resin
that includes a chemical foaming agent. The chemical foaming agent
is selected from the group of hydrazine derivatives, and is more
particularly an Azodicarbonamide powder that is suspended in the
resin formulation. Under thermal decomposition, Azodicarbonamide
releases nitrogen when exposed to temperatures in the range of
200.degree. to 215.degree. C., thereby causing the expansion of the
polymeric composition.
[0048] The underlying layer of unsupported foam 15 can be made
according to the process that is schematically depicted in FIG. 4.
The polyvinyl chloride compound 41 is cured by means of a thermal
calendering process 40, wherein the polymeric admixture is supplied
by metering vat 49 and uniformly coated on a releasable belt 43.
The polyvinyl chloride compound 41 and releasable belt 43 are then
compressed under tension against a heated roller 44. As an
alternative, a releasable casting paper (not shown) may also be
used. In the absence of a knitted scrim or non-woven fabric, the
releasable belt 43 or casting paper functions as a carrier for the
uncured polymeric compound 41. The carrier maintains the uniform
thickness of the foam material 15 during thermal solidification. In
a preferred embodiment, the layer of unsupported polyvinyl chloride
foam 15 is in the range of 1.275 mm to 1.675 mm in thickness. The
layer of the polyvinyl chloride foam 15 may be partially solidified
as the material exits the heated roller 44, and may be further
cured through the use of heated ovens 45. The solidified layer of
polyvinyl chloride foam 15 is then cooled through contact with
cooling rollers 46, and collected on a take-up roll 47. The uniform
layer of cured polyvinyl chloride foam may be smooth on both sides.
In a preferred embodiment, the heated roller 44, releasable belt 43
or casting paper is configured to impart a fine pattern of
micro-embossed indentations 48. The pattern of micro-embossed
indentations 48 are alternately spaced at 0.889 mm intervals,
although other micro-embossed configurations may also be used. The
micro-embossed indentations 48 essentially weaken the tear strength
properties of the unsupported foam 15 and enhance the hand
alteration of the perforated surface covering 10.
[0049] With further reference to FIGS. 1, 2A-2D, and FIG. 3, the
present invention includes a grid of perforations 19a and 19b that
are oriented at right angles along the vertical and horizontal axes
of the surface covering 10. The perforations 19a and 19b extend
through the profile of the composite material 12, and penetrate the
obverse layer 14 of the shelf, drawer or storage liner 10. The
perforations 19a or 19b may extend at perpendicular angles x
through the profile of the composite material 12 or, as illustrated
in FIG. 2D, the perforations 19a or 19b may extend through the
composite material at beveled angles x'. In a preferred embodiment,
to reduce the visible appearance of perforations scored into the
surface of the shelf, drawer or storage liner 10, the perforations
19a and 19b are incised from the bottom of the unsupported foam
layer 15 through the obverse layer 14 of the composite material 12.
Alternatively, the perforations 19a and 19b may be incised from the
obverse layer 14 through the unsupported foam layer 15. In a
specific embodiment, the perforations 19a run linearly along the
machine direction of the surface covering 10, and are spaced in
parallel along the transverse direction of the material in 6.35 mm
increments. Conversely, the perforations 19b run linearly along the
transverse direction of the surface covering 10, and are spaced in
parallel along the machine direction of the material in 6.35 mm
increments. Accordingly, the corresponding series of perforations
19a and 19b produce a pattern of interconnecting square portions
100 having all four sides that are approximately 6.35 mm in length.
In an alternate embodiment, the parallel arrangement of linear
perforations 19a or 19b may not be equidistantly spaced along the
machine or transverse directions of the surface covering 10.
Moreover, the horizontal or perpendicular arrangement of linear
perforations, 19a or 19b, may not be necessarily arranged at
corresponding parallel intervals to form a uniform grid along the
machine or transverse directions of the shelf, drawer or storage
liner 10.
[0050] The perforations 19a and 19b are produced with a rotary or
flat bed die assembly having a series of perforating rules that are
oriented at right angles. As disclosed in FIG. 5, the perforating
rules 190 consist of a sequence of projecting teeth 51, which are
separated at regular intervals by an arrangement of indented gaps
52. The sequence of projecting teeth 51 incise a linear succession
of perforations 19a and 19b into the composite material 12, where
the indented gaps 52 form an alternating pattern of uncut tie
portions 20 which run adjacent to the incised perforations. In a
preferred embodiment, the projecting teeth 51 are each 2.38 mm in
length, where the indented gaps 52 span a distance of 0.8128 mm
each. In an alternate embodiment, the length of projecting teeth
51, or indented gaps 52, which are machined into the series of
perforating rules 190, may be adapted to compensate for
perpendicular variations in the tensile and tear strength
properties inherent within the machine and transverse directions of
the composite material 12. For example, if the tensile and tear
strength properties of the composite material 12 are greater in the
machine direction, than the tensile and tear strength properties
oriented along the transverse direction, the perforating rules
190--which in this instance form the series of linear perforations
19a--would be altered to lengthen the dimension of each projecting
tooth 51, while the span of each indented gap 52 would be similarly
decreased. Accordingly, modification in the dimensioning of the
projecting teeth or indented gaps equalizes the tear resistance of
the perforated grid along the vertical and horizontal axes of the
surface covering 10.
[0051] A method for manufacturing the surface covering 10 is
schematically illustrated in FIG. 6. The top sheet of polymeric
film 14 and bottom layer of unsupported polymeric foam 15 are
respectively supplied in roll form 64 and 65. The top sheet of
polymeric film and bottom layer of polymeric foam are
simultaneously transported under controlled tension to a laminating
unit 60 where they are thermally combined. An optional intermediary
coating of adhesive 17 may be applied to the underside of the
polymeric film 14, or the contacting surface of polymeric foam 15,
before the two materials are joined. The adhesive may be applied by
way of an anilox roller 61 supplied from an adhesive reservoir 67
or, alternatively, may be spray coated. The facing layer of
polymeric film 14 and bottom layer of polymeric foam 15 are then
brought together and mutually conveyed under tension around a large
heated cylinder 62. The heating process causes the polymeric film
14 and unsupported polymeric foam 15 to become fused together
forming a cohesive bond 16. Since the layers are not nipped
together during the fusion process, the expanded cellular structure
of the polymeric foam 15 does not become permanently compressed,
thereby preserving the thickness of the material from thermal
deformation.
[0052] During the fusion of the composite laminate 12, a decorative
pattern 18 may be optionally embossed into the facing layer of the
polymeric film 14 by way of an engraved sleeve 63 that is removably
secured to the heated cylinder 62. Alternatively, the embossed
pattern 18 may be formed into the facing layer of the polymeric
film 14 through the use of a casting paper (not shown). The casting
paper is supplied in rolled form and wrapped under tension and in
direct contact around the heated cylinder 62. Under heat and
tension, the composite material 12 assumes the embossed pattern 18
that is engraved into the removable sleeve 63 or contoured into the
casting paper. The combined layers of the composite laminate 12 are
then passed through a series of cooling rollers 66 to set the
cohesive bond 16 and embossed pattern 18.
[0053] After fusing, embossment and cooling of the composite
material 12, the laminated web is die cut with a grid of
perforations 19a and 19b which are oriented at right angles along
the vertical and horizontal axes of the surface covering 10. To
ensure the perpendicular accuracy of the incised perforations 19a
and 19b, the laminated material 12 is preferably passed between a
two-stage rotary die assembly 70, which is comprised of two rotary
die cutters 71a and 71b. Each rotary die cutter includes a
rotatable knife cylinder 72a or 72b having perforating rules 190a
or 190b that are fixed on each circumference thereof. The
respective die cutters 71a and 71b also include an anvil cylinder
73a or 73b, made rotatable in a face-to-face relation to and in
synchronism with the knife cylinders 72a or 72b. The two rotary die
cutters 71a and 71b subject the laminated material 12 to a
predetermined cutting treatment by feeding the web through the
central converging portions of cylinders 72a and 73a, and then
again through cylinders 72b and 73b. To inhibit failure of the
multilayered composite material 12 during perforation, the linear
succession of perforations 19a, which run along the machine
direction of the web, are incised first with rotary die cutter 71a.
The complementary arrangement of linear perforations 19b, which run
along the transverse direction of the web, are then incised with
rotary die cutter 71b. The shelf, drawer or storage liner 10 is
then collected on take-up roll 74. It can be appreciated by those
skilled in the art that the grid of perforations 19a and 19b may be
concurrently incised into the composite material 12 with a rotary
die cutter having a grid of perforating rules machined on a single
rotatable knife cylinder.
[0054] Even though numerous characteristics and advantages of the
present invention have been set forth in the foregoing description,
together with details of the structure and function of the
preferred embodiments, the above disclosure is illustrative only.
Changes may be made in detail, especially in matters of shape, size
and arrangement of parts within the principles of the invention to
the full extent indicated by the broad general meaning of the terms
in which the appended claims are expressed.
* * * * *