Method for mechanically embossing an article using a recyclable solidified slurry

Abstract

Disclosed is both a method and apparatus for mechanically embossing a surface covering. The apparatus includes an embossing tool comprising a slurry. The slurry includes both a filler and binder. The method includes printing a slurry onto a surface covering and compressing the slurry onto the surface covering to create a mechanically embossed texture onto the surface covering.

1 - 17 . (Canceled).  
     
     
         18 . A method of mechanically embossing an article comprising: 
 printing a slurry in a pattern onto an article;    pressing the slurry into the article; and    removing the solidified slurry.    
     
     
         19 . The method of  claim 18 , wherein pressing the slurry onto the surface covering includes mechanically embossing the article.  
     
     
         20 . The method of  claim 19 , wherein the article is mechanically embossed in register with a printed pattern on the article.  
     
     
         21 . The method of  claim 18 , wherein the slurry is pressed into the article by an embossing roll.  
     
     
         22 . The method of  claim 21 , wherein the embossing roll has a textured surface.  
     
     
         23 . The method as claimed in  claim 18 , wherein the slurry is pressed into the article by an embossing belt or embossing plate.  
     
     
         24 . The method as claimed in  claim 18 , wherein the slurry is applied by screen printing onto the article.  
     
     
         25 . The method as claimed in  claim 18 , wherein the slurry comprises a filler and a binder.  
     
     
         26 . The method of  claim 26 , wherein the binder is biodegradable.  
     
     
         27 . The method of  claim 18 , wherein the slurry is applied in registered with a printed pattern on the article.  
     
     
         28 . The method of  claim 18 , wherein the slurry is reclaimed after being removed from the article.  
     
     
         29 . The method as claimed in  claim 18 , wherein the article is a surface covering comprising an expandable foam layer, and at least one inhibitor or activator composition disposed as a pattern proximate the foam layer, and the surface covering is expanded and chemically embossed.  
     
     
         30 . The method as claimed in  claim 29 , wherein the surface covering is chemically embossed before the slurry is applied.  
     
     
         31 - 40 . (Canceled).  
     
     
         41 . The method of  claim 18 , further including imparting a differential gloss on the article.  
     
     
         42 . The method of  claim 18 , wherein the article is a surface covering.  
     
     
         43 . The method of  claim 42 , wherein the surface covering is a floor covering.  
     
     
         44 . The method of  claim 18 , wherein the slurry is in direct contact with the article when it is pressed into the article.  
     
     
         45 . The method of  claim 18 , wherein the portion of the article into which the slurry is pressed is gelled prior to the slurry being pressed.  
     
     
         46 . The method of  claim 18 , wherein the portion of the article into which the slurry is pressed is cured prior to the slurry being pressed.