Methods for encapsulating a substrate and products produced from same

Patent metadata

Field	Value
Publication number	US-9677287-B2
Application number	US-201314139498-A
Country	US
Kind code	B2
Filing date	Dec 23, 2013
Priority date	Dec 23, 2013
Publication date	Jun 13, 2017
Grant date	Jun 13, 2017

Abstract

Described herein are methods for encapsulating a fiberglass substrate using a calendered film; along with products produced from same. The methods improve the efficiency of the manufacturing process and provide a product with improved performance characteristics.

First claim

The invention claimed is:

1. A method for preparing a flooring product comprising an encapsulated substrate comprising:
providing a substrate having a first and a second major surface;
applying a first calendered film to a first major surface of the substrate to form a composite, wherein at least a portion of the second major surface of the substrate remains exposed after the first calendered film is applied to the first major surface of the substrate;
applying a foamable polymer formulation to said composite; and
applying a second calendered film to said composite,
wherein at least a portion of the first calendered film protrudes through the second major surface of the substrate.

2. The method of claim 1 , wherein the second calendered film is applied to the second major surface of the substrate.

3. The method of claim 1 wherein the first calendered film adheres to the substrate in the absence of an adhesive.

4. The method of claim 1 , wherein the second calendered film adheres to the substrate in the absence or an adhesive.

5. The method of claim 1 , wherein the first calendered film comprises a composition comprising a melt processable resin selected from: polyvinyl chloride, polyethylene, polypropylene, polystyrene, polycarbonate, polyester, rubber, polyvinyl acetate, acrylonitrile butadiene styrene, a copolymer thereof, and a combination of two or more thereof.

6. The method of claim 1 , wherein the second calendered film comprises a composition comprising a melt processable polymer selected from: polyvinyl chloride, polyethylene, polypropylene, polystyrene, polycarbonate, polyester, rubber, polyvinyl acetate, acrylonitrile butadiene styrene, a copolymer thereof, and a combination of two or more thereof.

7. The method of claim 1 , wherein the first calendered film has a thickness of from about 10 mils to about 20 mils.

8. The method of claim 1 , wherein the first calendered film has a thickness of from about 10 mils to about 30 mils.

9. The method of claim 1 , wherein at least a portion of the second calendered film is in contact with said first calendered film.

10. The method of claim 1 , wherein the first calendered film or second calendered film further comprises a filler selected from limestone, clay, talc, dolomite, and a combination of two or more thereof.

11. The method of claim 1 , wherein the first calendered film is applied to the substrate at a line speed of from about 40 to about 160 fpm.

12. The method of claim 1 , wherein the second calendered film is applied to the substrate at a line speed of from about 50 to about 100 fpm.

13. The method of claim 1 , wherein the substrate is a glass veil.

14. A method for preparing a multilayer composite comprising:
providing a substrate having a first and a second major surface:
applying a first calendered film to the first major surface of the substrate;
applying a foamable polymer formulation to said first calendered film layer;
wherein at least a portion of the substrate remains exposed after the first calendered film is applied to the first major surface of the substrate, and
wherein at least a portion of the first calendered film protrudes through the second major surface of the substrate; and
applying a second calendered film to the second major surface of the substrate.

15. The method of claim 14 , wherein the multilayer composite is suitable for use as a flooring product.

Assignees

• Armstrong World Ind Inc
• Afi Licensing Llc

Inventors

• Laukhuff Barbara L
• Neeper Lawrence C

Classifications

• B32B38/06

  Embossing · CPC title

• B32B17/04

  bonded with or embedded in a plastic substance · CPC title

• B32B2315/085

  Glass fiber cloth or fabric · CPC title

• B32B2037/243

  Coating · CPC title

• Y10T428/239

  Complete cover or casing · CPC title