DEKORATIVES BAHNFOERMIGES MATERIAL UND VERFAHREN ZU DESSEN HERSTELLUNG

EMBOSSING OF FOAMED-SHEET MATERIALS-II

MULTILEVEL EMBOSSING OF FOAMED-SHEET MATERIALS

Embossed foam faced substrate - with reverse side cooled before composite has partial wrap round rollers system

A composite web, consisting of a substrate, a foam layer for embossing with a decorative pattern, and a top protective layer, is embossed by (i) heating the web to 121 degrees - 177 degrees C, (ii) moistening the bottom substrate layer so that its temp. is lowered to 55 degrees C below that of the top layer, (iii) embossing with a roller and a support roller, and (iv) cooling the embossed surface to set the pattern. The web is partly wrapped round the support roller before passing between that roller and the embossing roller, and the embossed surface is wrapped round the embossing roller so as to partly cool it. The cooling prevents formation of blisters and produces improved embossing, the wrap-round arrangement gives a good drive to the rollers and a sharp pattern.

Embossed foam faced substrate - produced by cooling reverse side of heated composite before passing to embossing roller

A web of a substrate and a foam covering has a decorative pattern impressed into its surface and the combination material is heated to 121 degrees-177 degrees C. The substrate is moistened so that the temp. of the underside drops to 100 degrees F below that of the top side, the pattern is embossed into the face of the foam covering, and the embossed surface is cooled to set its pattern. The cooling stage prevents formation of blisters which arise when using foam 0.8-1.1 mm. thick, if thicker foam is used (e.g., 2.5-3 mm.) a further roller also requires cooling.