CA2189614C - Patterned heat welding rod for seaming resilient flooring - Google Patents
Patterned heat welding rod for seaming resilient flooring Download PDFInfo
- Publication number
- CA2189614C CA2189614C CA 2189614 CA2189614A CA2189614C CA 2189614 C CA2189614 C CA 2189614C CA 2189614 CA2189614 CA 2189614 CA 2189614 A CA2189614 A CA 2189614A CA 2189614 C CA2189614 C CA 2189614C
- Authority
- CA
- Canada
- Prior art keywords
- welding rod
- thermoplastic
- layer
- layers
- surface covering
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/20—Making multilayered or multicoloured articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0053—Moulding articles characterised by the shape of the surface, e.g. ribs, high polish
- B29C37/0057—Moulding single grooves or ribs, e.g. tear lines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
- B29C65/12—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined and welding bar
- B29C65/125—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined and welding bar characterised by the composition of the welding bar
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/45—Joining of substantially the whole surface of the articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/81266—Optical properties, e.g. transparency, reflectivity
- B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/832—Reciprocating joining or pressing tools
- B29C66/8322—Joining or pressing tools reciprocating along one axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
- B29K2027/06—PVC, i.e. polyvinylchloride
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/002—Coloured
- B29K2995/0021—Multi-coloured
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/06—Rods, e.g. connecting rods, rails, stakes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/722—Decorative or ornamental articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/732—Floor coverings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/16—Two dimensionally sectional layer
- Y10T428/162—Transparent or translucent layer or section
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/19—Sheets or webs edge spliced or joined
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
- Y10T428/24066—Wood grain
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- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24364—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.] with transparent or protective coating
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- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
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Abstract
The welding rod is a laminate structure in which a print layer is disposed between a first thermoplastic layer and a second transparent thermoplastic layer. Preferably the welding rod is in the form of an elongated element having a half-round cross-sectional shape. The welding rod is used to join two pieces of thermoplastic sheeting, particularly flooring, together. If the welding rod has a pattern similar to the printed pattern of the sheeting the resulting surface covering looks seamless.
Description
PATTERNED HEAT WELDING ROD FOR SEAMING RESILIENT FLOORING
This invention relates to a thermoplastic welding rod used to join two pieces of thermoplastic sheeting, particularly flooring, together. More specifically, a patterned welding rod is prepared in such manner that, when welded between two pieces of similarly patterned polyvinyl chloride (PVC) resilient sheet flooring, it disguises the joined area and forms a water-tight, sealed assembly. The pattern may be any multicolored design or image, including wood grain, marble or fanciful. The welding rod is preferably directed to use with resilient floor covering sheets which have a transparent wear layer of significant thickness, and more particularly to laminated floor covering sheets.
It has been very desirable to achieve new and unique visuals in floor covering products, and many end-users find it desirable to heat weld flooring seams in an effort to prevent dirt and bacteria from entering the seams. One such method has been to heat weld seams with a solid-colored welding rod. This has become a popular practice in the healthcare industry where sanitation requirements are extremely important.
Not only have flooring manufacturers provided welding rods for seam sealing, but many wall systems are also being marketed with seam welding or seam sealing materials. The end users and job specifiers also often employ seam welding rods as an option to offer a decorative styling element to is J
the specified job. They can add a solid colored welding rod that .complements the color of the patterned floor, or they can use an "accent" color that contrasts sharply with the floor to create a bold new look.
Only recently, however, has a manufacturer offered a non-solid colored heat welding rod. The welding rod is a through-colored, patterned welding rod which matches the color and design of the floor covering pattern. This heat welding rod uses methods which create a through-color visual which extends all the way from the surface down through the entire depth of the composition in an uninterrupted fashion.
The pattern is limited to a multi-colored, chip- or granule-image. Prior to the present invention, a welding rod having a distinct, repeatable pattern has not been produced.
The welding rod of the present invention can be produced by laminating a 0.15 mm printed, calendered polyvinyl chloride (PVC) or polyester film to several overlying layers of 0.51 mm clear calendered films. The print image which matches the floor covering design is printed by any conventional means and could be done in a way that v~ould create a realistic image.
Lithographic printing and rotogravure printing techniques were found to be satisfactory. In fact, some printed film from a vendor was purchased for use in a flooring structure, and then, the same film was used to make a welding rod to match the flooring structure.
The welding rod thickness is preferably 2.0 to 2.3 ~.
The final structure was a sandwich-type structure. The bottom layer was a 0.15 mm printed film. To this print image layer, four succ~.s:sive layers of 0.51 ~ clear calendered PVC films were laminated. The lamination could be done in either a hot/cold press type of operation or one could employ other methods. Multiple film laminations were produced simultaneously on an "Auma"* machine. Also, two films were laminated using a regular calender/laminator on a roll press consolidation line. In any case, once the films have been laminated, they are die-cut into pieces/sheets that could be placed into a hot/cold press and molded into the half-round configuration of the final product welding rod.
Subsequent testing revealed that the product had adequate bond strength. Naturally, the conditions and test results would vary if one opted to use different chemical compositions for the product/process structure.
The present invention provides a 'thermoplastic welding rod comprising a first thermoplastic layer, a second transparent thermoplastic layer and a print layer disposed between the first and second layers.
The present invention also provides a surface covering comprising two thermoplastic sheets welded together with a thermoplastic welding rod, the welding rod comprising a print layer disposed between a first thermoplastic layer and a second transparent thermoplastic layer, the first and second layers having been laminated and formed into an elongated element having a half-round cross-sectional shape.
The welding rod can, if desired, be formed by splicing a plurality of rods together end-to-end.
The invention is made by printing a desired image on one layer of film and laminating successive layers of clear films to create the same unique visual as the 1 surface covering. Gauge variation can be minimized by using * Trademark calendered films. The calendered films are then preferably molded into half-round cross-sectional welding rods.
In the preferred embodiment, the printed image is protected by at least 0.76 mm of clear film, i.e., PVC or otherwise. Thus, as the product surface wears away, the underlying print does not change.
In the drawings attached to this specification:
Figure 1 is a schematic representation of a method to form the welding rod of the present invention; and Figure 2 is a schematic representation of the present welding rod after being molded and prior to being separated into individual welding rods.
In an effort to create a new flooring structure via a lamination process, heat welding rods were produced having a appearance similar to the flooring sheets. Different sandwich type structures were laminated using printed and clear PVC films. Such welding rods are more cost effective and would speed up introduction of surface covering patterns for commercial introduction, because the process merely relies on photographing the image of the surface covering structure to reproduce the visual for the welding rod.
The printed films used to create the new laminated flooring structure were used to produce the patterned weld rod in a separate process. The composition of the laminates are well known in the art. This new process offers a visual that could be readily matched to any pattern and/or design with relative ease. By merely photographing and printing the design, one could laminate the printed film and create a patterned welding rod. Referring to Figure 1, the preferred method is to laminate several layers of clear film 1 on top ' of a 0.15 ~'n printed film 2 and then pressing them into a molded i/2-round weld rod shape configuration.
Alternatively, the lamination was done on a flat-bed press. All of the films were "pinned" (or perforated) to allow entrapped air to be released. A 0.15 mm printed polyvinyl chloride (PVC) base film was placed on the bottom press platen with the printed surface up and with a cork pad and three pieces of duct cloth disposed between the platen and the base film. Four 0.51 mm clear films were placed over the printed base film, followed by a top release paper or felt.
The layers were pressed for one-half minute at 0.56 kg/cm2 and then for one half minute at 5.6 kg/cm2. The temperature of the top and bottom platens was 148.9°C
(300°F). The laminate was then cooled for 3 minutes under the 5.6 kg/cmz pressure.
The laminated sheet was pressed into welding rods by placing a half-round embossing mold 3 on the bottom press platen 4, stripping the release paper/felt from the laminate and placing it onto the mold. The bottom platen was then pre-heated for 2 minutes to 162.8°C (325°F). The top press platen 5 was then lowered onto the laminate with a top release paper, release felt or ferro-chrome plate 6 disposed between the top platen and the laminate. The laminate was pressed for one and a half minutes at 0.28 kg/cm2 and cooled for 3 minutes under the 0.28 kg/cm2 pressure.
The laminates were placed onto the mold with the back-side of the printed film against the cutting edges of the mold. Thus, after pressing, the print image was facing _ upward as shown in Figure 2. The print layer 10 is disposed between the film 11 on which the print layer is adhered and the calendered clear film 12. The individual welding rods 13 are then separated. The structure of the welding rods 13 do not resemble the homogeneous, round weld rods or the uniformly distributed chip, half-round weld rods of the prior art.
The product could also be made by multiple film laminations, using a continuous process to laminate the various layers. As such, either the films could be pre-heated and laminated to a heated/warm substrate, or one could pre-heat a substrate and then wrap the films around a cold laminator roll to consolidate the two layers. The technique depends on the thickness of the films being used, as well as their chemical composition.
To minimize plasticizer migration, the welding rod formulation, especially the plasticizer system, must be balanced with the surface covering formulation. The plasticizer content and type should be similar between the welding rod and surface covering.
Flooring is typically installed at temperatures between 12.8°C (55°F) to 29.4°C (85°F). Therefore, flexibility and ease of cutting must be maintained even near the lower end of the range. This is done by the addition of a low temperature plasticizer such as dioctyl adipate. Preferably the glass transition temperature, Tg, of the plasticized chips is no greater than -1.1°C (30°F), more preferably no greater than -3.9°C (25°F), and most preferably no greater than -5.6°C (22°F).
This invention relates to a thermoplastic welding rod used to join two pieces of thermoplastic sheeting, particularly flooring, together. More specifically, a patterned welding rod is prepared in such manner that, when welded between two pieces of similarly patterned polyvinyl chloride (PVC) resilient sheet flooring, it disguises the joined area and forms a water-tight, sealed assembly. The pattern may be any multicolored design or image, including wood grain, marble or fanciful. The welding rod is preferably directed to use with resilient floor covering sheets which have a transparent wear layer of significant thickness, and more particularly to laminated floor covering sheets.
It has been very desirable to achieve new and unique visuals in floor covering products, and many end-users find it desirable to heat weld flooring seams in an effort to prevent dirt and bacteria from entering the seams. One such method has been to heat weld seams with a solid-colored welding rod. This has become a popular practice in the healthcare industry where sanitation requirements are extremely important.
Not only have flooring manufacturers provided welding rods for seam sealing, but many wall systems are also being marketed with seam welding or seam sealing materials. The end users and job specifiers also often employ seam welding rods as an option to offer a decorative styling element to is J
the specified job. They can add a solid colored welding rod that .complements the color of the patterned floor, or they can use an "accent" color that contrasts sharply with the floor to create a bold new look.
Only recently, however, has a manufacturer offered a non-solid colored heat welding rod. The welding rod is a through-colored, patterned welding rod which matches the color and design of the floor covering pattern. This heat welding rod uses methods which create a through-color visual which extends all the way from the surface down through the entire depth of the composition in an uninterrupted fashion.
The pattern is limited to a multi-colored, chip- or granule-image. Prior to the present invention, a welding rod having a distinct, repeatable pattern has not been produced.
The welding rod of the present invention can be produced by laminating a 0.15 mm printed, calendered polyvinyl chloride (PVC) or polyester film to several overlying layers of 0.51 mm clear calendered films. The print image which matches the floor covering design is printed by any conventional means and could be done in a way that v~ould create a realistic image.
Lithographic printing and rotogravure printing techniques were found to be satisfactory. In fact, some printed film from a vendor was purchased for use in a flooring structure, and then, the same film was used to make a welding rod to match the flooring structure.
The welding rod thickness is preferably 2.0 to 2.3 ~.
The final structure was a sandwich-type structure. The bottom layer was a 0.15 mm printed film. To this print image layer, four succ~.s:sive layers of 0.51 ~ clear calendered PVC films were laminated. The lamination could be done in either a hot/cold press type of operation or one could employ other methods. Multiple film laminations were produced simultaneously on an "Auma"* machine. Also, two films were laminated using a regular calender/laminator on a roll press consolidation line. In any case, once the films have been laminated, they are die-cut into pieces/sheets that could be placed into a hot/cold press and molded into the half-round configuration of the final product welding rod.
Subsequent testing revealed that the product had adequate bond strength. Naturally, the conditions and test results would vary if one opted to use different chemical compositions for the product/process structure.
The present invention provides a 'thermoplastic welding rod comprising a first thermoplastic layer, a second transparent thermoplastic layer and a print layer disposed between the first and second layers.
The present invention also provides a surface covering comprising two thermoplastic sheets welded together with a thermoplastic welding rod, the welding rod comprising a print layer disposed between a first thermoplastic layer and a second transparent thermoplastic layer, the first and second layers having been laminated and formed into an elongated element having a half-round cross-sectional shape.
The welding rod can, if desired, be formed by splicing a plurality of rods together end-to-end.
The invention is made by printing a desired image on one layer of film and laminating successive layers of clear films to create the same unique visual as the 1 surface covering. Gauge variation can be minimized by using * Trademark calendered films. The calendered films are then preferably molded into half-round cross-sectional welding rods.
In the preferred embodiment, the printed image is protected by at least 0.76 mm of clear film, i.e., PVC or otherwise. Thus, as the product surface wears away, the underlying print does not change.
In the drawings attached to this specification:
Figure 1 is a schematic representation of a method to form the welding rod of the present invention; and Figure 2 is a schematic representation of the present welding rod after being molded and prior to being separated into individual welding rods.
In an effort to create a new flooring structure via a lamination process, heat welding rods were produced having a appearance similar to the flooring sheets. Different sandwich type structures were laminated using printed and clear PVC films. Such welding rods are more cost effective and would speed up introduction of surface covering patterns for commercial introduction, because the process merely relies on photographing the image of the surface covering structure to reproduce the visual for the welding rod.
The printed films used to create the new laminated flooring structure were used to produce the patterned weld rod in a separate process. The composition of the laminates are well known in the art. This new process offers a visual that could be readily matched to any pattern and/or design with relative ease. By merely photographing and printing the design, one could laminate the printed film and create a patterned welding rod. Referring to Figure 1, the preferred method is to laminate several layers of clear film 1 on top ' of a 0.15 ~'n printed film 2 and then pressing them into a molded i/2-round weld rod shape configuration.
Alternatively, the lamination was done on a flat-bed press. All of the films were "pinned" (or perforated) to allow entrapped air to be released. A 0.15 mm printed polyvinyl chloride (PVC) base film was placed on the bottom press platen with the printed surface up and with a cork pad and three pieces of duct cloth disposed between the platen and the base film. Four 0.51 mm clear films were placed over the printed base film, followed by a top release paper or felt.
The layers were pressed for one-half minute at 0.56 kg/cm2 and then for one half minute at 5.6 kg/cm2. The temperature of the top and bottom platens was 148.9°C
(300°F). The laminate was then cooled for 3 minutes under the 5.6 kg/cmz pressure.
The laminated sheet was pressed into welding rods by placing a half-round embossing mold 3 on the bottom press platen 4, stripping the release paper/felt from the laminate and placing it onto the mold. The bottom platen was then pre-heated for 2 minutes to 162.8°C (325°F). The top press platen 5 was then lowered onto the laminate with a top release paper, release felt or ferro-chrome plate 6 disposed between the top platen and the laminate. The laminate was pressed for one and a half minutes at 0.28 kg/cm2 and cooled for 3 minutes under the 0.28 kg/cm2 pressure.
The laminates were placed onto the mold with the back-side of the printed film against the cutting edges of the mold. Thus, after pressing, the print image was facing _ upward as shown in Figure 2. The print layer 10 is disposed between the film 11 on which the print layer is adhered and the calendered clear film 12. The individual welding rods 13 are then separated. The structure of the welding rods 13 do not resemble the homogeneous, round weld rods or the uniformly distributed chip, half-round weld rods of the prior art.
The product could also be made by multiple film laminations, using a continuous process to laminate the various layers. As such, either the films could be pre-heated and laminated to a heated/warm substrate, or one could pre-heat a substrate and then wrap the films around a cold laminator roll to consolidate the two layers. The technique depends on the thickness of the films being used, as well as their chemical composition.
To minimize plasticizer migration, the welding rod formulation, especially the plasticizer system, must be balanced with the surface covering formulation. The plasticizer content and type should be similar between the welding rod and surface covering.
Flooring is typically installed at temperatures between 12.8°C (55°F) to 29.4°C (85°F). Therefore, flexibility and ease of cutting must be maintained even near the lower end of the range. This is done by the addition of a low temperature plasticizer such as dioctyl adipate. Preferably the glass transition temperature, Tg, of the plasticized chips is no greater than -1.1°C (30°F), more preferably no greater than -3.9°C (25°F), and most preferably no greater than -5.6°C (22°F).
Thermoplastic materials which can be used to make the thermoplastic welding rods include polyvinyl chloride, acrylonitrile/butadiene/styrene, polypropylene, polyethylene, polyester and thermoplastic polyurethane. Other thermoplastic resins that can be plasticized and used include polyvinyl acetate, cellulose acetate, polystyrene, ethyl cellulose, polyvinylidene chloride, polyurethane, nylon, acrylic, and polyphenylene oxide. The following thermoplastic resins have been used to make welding rods of the present invention: polyvinyl chloride homopolymers and copolymers with acetate functionality, polyesters, and mixtures thereof. Polyvinyl chloride homopolymers are preferred.
Plasticizers which can be used include butyl cyclohexyl phthalate, tri(butoxyethyl) phosphate, trioctyl phosphate, 2-ethylhexyl Biphenyl phosphate, dibutyl phthalate, diisobutyl adipate, epoxidized di(2-ethylhexyl) tetrahydrophthalate, di(2-ethylhexyl) phthalate, diisooctyl phthalate, dioctyl adipate, diisononyl phthalate, di(2-ethylhexyl) hexahydrophthalate, n-octyl,n-decyl phthalate, tricresyl phosphate, butyl benzyl phthalate, dicapryl phthalate, di(3,5,5-trimethylhexyl) phthalate, diisodecyl phthalate, di(2-ethylhexyl) adipate, butyl epoxy stearate, epoxidized Soya oil, epoxidized octyl tallate, dimethyl phthalate, hexyl epoxy stearate, cresyl Biphenyl phosphate, di(2-ethylhexyl) isophthalate, n-octyl,n-decyl adipate, di(2-ethylhexyl) azelate, epoxidized octyl oleate, di(2-ethylhexyl) sebacate, tetraethylene glycol/di(2-~ethylhexoate ) . diisodecyl adipate, and triethylene glycol/di(2-ethylhexoate). Total plasticizer concentration _ 7 _ 2is~sl4 should be between 35 and 60 parts per hundred of resin (phr), preferably between 40 and 55 phr, and most preferably between 45 and 50 phr. Combinations of plasticizers are preferred.
g
Plasticizers which can be used include butyl cyclohexyl phthalate, tri(butoxyethyl) phosphate, trioctyl phosphate, 2-ethylhexyl Biphenyl phosphate, dibutyl phthalate, diisobutyl adipate, epoxidized di(2-ethylhexyl) tetrahydrophthalate, di(2-ethylhexyl) phthalate, diisooctyl phthalate, dioctyl adipate, diisononyl phthalate, di(2-ethylhexyl) hexahydrophthalate, n-octyl,n-decyl phthalate, tricresyl phosphate, butyl benzyl phthalate, dicapryl phthalate, di(3,5,5-trimethylhexyl) phthalate, diisodecyl phthalate, di(2-ethylhexyl) adipate, butyl epoxy stearate, epoxidized Soya oil, epoxidized octyl tallate, dimethyl phthalate, hexyl epoxy stearate, cresyl Biphenyl phosphate, di(2-ethylhexyl) isophthalate, n-octyl,n-decyl adipate, di(2-ethylhexyl) azelate, epoxidized octyl oleate, di(2-ethylhexyl) sebacate, tetraethylene glycol/di(2-~ethylhexoate ) . diisodecyl adipate, and triethylene glycol/di(2-ethylhexoate). Total plasticizer concentration _ 7 _ 2is~sl4 should be between 35 and 60 parts per hundred of resin (phr), preferably between 40 and 55 phr, and most preferably between 45 and 50 phr. Combinations of plasticizers are preferred.
g
Claims (9)
1. A thermoplastic welding rod comprising a first thermoplastic layer, a second transparent thermoplastic layer and a print layer disposed between the first and second layers.
2. The welding rod of claim 1 wherein the welding rod is in the form of an elongated element having a half-round cross-sectional shape.
3. The welding rod of claim 1 wherein the second transparent layer is substantially colorless.
4. The welding rod of claim 1 wherein a plurality of transparent thermoplastic layers overlay the first printed layer.
5. The welding rod of claim 1 wherein the rod is formed by splicing a plurality of rods together end-to-end.
6. The welding rod of claim 1 wherein the first and second layers comprise a polymer selected from the group.
consisting of polyvinyl chloride and polyester.
consisting of polyvinyl chloride and polyester.
7. A surface covering comprising two elastomeric sheets welded together with the thermoplastic welding rod of claim 1.
8. A surface covering comprising two thermoplastic sheets welded together with a thermoplastic welding rod, the welding rod comprising a print layer disposed between a first thermoplastic layer and a second transparent thermoplastic layer, the first and second layers having been laminated and formed into an elongated element having a half-round cross-sectional shape.
9. The surface covering of claim 8 wherein the surface covering is a floor covering.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/561,102 US5712032A (en) | 1995-11-21 | 1995-11-21 | Patterned heat welding rod for seaming resilient flooring |
US08/561,102 | 1995-11-21 |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2189614A1 CA2189614A1 (en) | 1997-05-22 |
CA2189614C true CA2189614C (en) | 2002-01-08 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA 2189614 Expired - Fee Related CA2189614C (en) | 1995-11-21 | 1996-11-05 | Patterned heat welding rod for seaming resilient flooring |
Country Status (11)
Country | Link |
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US (2) | US5712032A (en) |
EP (1) | EP0775563B1 (en) |
JP (1) | JPH09174690A (en) |
AR (1) | AR004339A1 (en) |
AU (1) | AU694064B2 (en) |
BR (1) | BR9605660A (en) |
CA (1) | CA2189614C (en) |
DE (1) | DE69619474T2 (en) |
GB (1) | GB2307441B (en) |
MX (1) | MX9605647A (en) |
PL (1) | PL181892B1 (en) |
Families Citing this family (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5712032A (en) * | 1995-11-21 | 1998-01-27 | Armstrong World Industries, Inc. | Patterned heat welding rod for seaming resilient flooring |
EP0950501A1 (en) * | 1998-04-16 | 1999-10-20 | Sommer Revêtements France S.A. | Process for manufacturing a welding rod for floor coverings and welding rod obtained |
NL1010455C2 (en) * | 1998-11-03 | 2000-05-04 | Forbo Int Sa | A method of manufacturing a wire or cord for welding floor coverings as well as an apparatus for manufacturing such a welding wire or cord. |
US6835425B2 (en) * | 2000-12-12 | 2004-12-28 | Konica Corporation | Layer-forming method using plasma state reactive gas |
US6815041B2 (en) | 2001-10-12 | 2004-11-09 | Awi Licensing Company | Three dimensional welding rod and surface covering |
US6998170B2 (en) * | 2001-10-12 | 2006-02-14 | Awi Licensing Company | Jaspe pattern flooring |
US6818282B2 (en) * | 2002-05-14 | 2004-11-16 | Awi Licensing Company | Resilient flooring structure with encapsulated fabric |
US20040045240A1 (en) * | 2002-09-10 | 2004-03-11 | Mcilvaine Bruce L. | Laminate flooring with custom images |
EP1619009A1 (en) * | 2004-07-19 | 2006-01-25 | Tarkett SAS | Process for producing a welding cord |
DE102005034361A1 (en) * | 2005-07-22 | 2007-01-25 | Armstrong Dlw Ag | Thermoplastic welding wire |
EP2221165A1 (en) | 2009-02-20 | 2010-08-25 | Tarkett GDL | Decorative welding rod for surface coverings |
MX2015008409A (en) * | 2012-12-28 | 2016-10-26 | Aristech Surfaces Llc | Advanced solid surface acrylic and method. |
JP5823596B1 (en) * | 2014-11-07 | 2015-11-25 | 富双合成株式会社 | Floor welding equipment |
JP6181807B1 (en) | 2016-04-27 | 2017-08-16 | 日機装株式会社 | Pressurizing device and pressurizing method |
Family Cites Families (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR989058A (en) * | 1949-04-20 | 1951-09-04 | Method for uniting by tear-resistant joints objects made of thermoplastic materials | |
FR66365E (en) * | 1952-04-23 | 1957-02-11 | Const Mecaniques De Stains Soc | Thermoplastic weld seam |
US2839441A (en) * | 1955-09-08 | 1958-06-17 | Bell Telephone Labor Inc | Method of welding together two plastic objects |
US3421277A (en) * | 1965-06-03 | 1969-01-14 | Scm Corp | Pre-grouted flexible tile panel |
US3839126A (en) * | 1972-07-03 | 1974-10-01 | Dow Chemical Co | Plastic welding apparatus |
JPS5769008A (en) * | 1980-10-16 | 1982-04-27 | Lonseal Corp | Welding rod and manufacture thereof |
SE457782B (en) * | 1987-12-01 | 1989-01-30 | Tarkett Ab | SVETSTRAAD |
JPH04105928A (en) * | 1990-08-27 | 1992-04-07 | Fuso Gosei Kk | Manufacture of welding rod |
KR960006787B1 (en) * | 1991-03-28 | 1996-05-23 | 타켓트 인코포레이팃드 | Inlaid sheet materials having a selectively applied decorative adhesive matrix and method of production thereof |
US5635266A (en) * | 1992-11-16 | 1997-06-03 | Armstrong World Industries, Inc. | Patterned heat welding rod for seaming resilient flooring |
JP3159592B2 (en) * | 1993-07-23 | 2001-04-23 | ダイワ精工株式会社 | Article having a metal decoration layer |
GB9323795D0 (en) * | 1993-11-18 | 1994-01-05 | Armstrong World Ind Inc | Patterned heat welding rod for seaming resilient flooring |
US5712032A (en) * | 1995-11-21 | 1998-01-27 | Armstrong World Industries, Inc. | Patterned heat welding rod for seaming resilient flooring |
-
1995
- 1995-11-21 US US08/561,102 patent/US5712032A/en not_active Expired - Lifetime
-
1996
- 1996-11-05 CA CA 2189614 patent/CA2189614C/en not_active Expired - Fee Related
- 1996-11-13 JP JP8301392A patent/JPH09174690A/en active Pending
- 1996-11-18 MX MX9605647A patent/MX9605647A/en unknown
- 1996-11-20 PL PL96317081A patent/PL181892B1/en not_active IP Right Cessation
- 1996-11-20 DE DE1996619474 patent/DE69619474T2/en not_active Expired - Fee Related
- 1996-11-20 AU AU71874/96A patent/AU694064B2/en not_active Ceased
- 1996-11-20 EP EP19960118629 patent/EP0775563B1/en not_active Expired - Lifetime
- 1996-11-20 GB GB9624128A patent/GB2307441B/en not_active Expired - Fee Related
- 1996-11-21 BR BR9605660A patent/BR9605660A/en not_active Application Discontinuation
- 1996-11-21 AR ARP960105284 patent/AR004339A1/en unknown
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1997
- 1997-04-25 US US08/845,687 patent/US5955173A/en not_active Expired - Lifetime
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AU7187496A (en) | 1997-05-29 |
EP0775563A3 (en) | 1998-06-24 |
US5712032A (en) | 1998-01-27 |
GB2307441A (en) | 1997-05-28 |
PL181892B1 (en) | 2001-10-31 |
AU694064B2 (en) | 1998-07-09 |
GB2307441B (en) | 1999-03-31 |
DE69619474T2 (en) | 2002-10-10 |
US5955173A (en) | 1999-09-21 |
BR9605660A (en) | 1998-08-18 |
JPH09174690A (en) | 1997-07-08 |
AR004339A1 (en) | 1998-11-04 |
DE69619474D1 (en) | 2002-04-04 |
EP0775563B1 (en) | 2002-02-27 |
EP0775563A2 (en) | 1997-05-28 |
GB9624128D0 (en) | 1997-01-08 |
CA2189614A1 (en) | 1997-05-22 |
PL317081A1 (en) | 1997-05-26 |
MX9605647A (en) | 1997-08-30 |
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