Printer-compatible, pre-embossed films

Abstract

Decorative films, useful for making a wide range of decorative laminates, that have a relatively deep texture on one major face and a relatively smoother, print receptive surface on the other major face. Notwithstanding the deep texture, the films have superb tracking characteristics and are compatible with a wide variety of automated printing operations. This allows automated printing equipment to print information directly onto the films.

1 . A method of making a textured, decorative laminate film, comprising the steps of:
 a) extruding a molten film;   b) while the extruded film is at least partially molten, causing the film to pass through a gap between and contact first and second tooling surfaces that are maintained at one or more temperatures below the melt temperature of the molten film in a manner effective to help cause the molten film to set and solidify as the film passes through the gap, said first tooling surface comprising a plurality of irregular and random depressions on the first tooling surface and that provide cavities that are at least partially filled by the molten film as the film passes over the first tooling surface and sets, and said second tooling surface being relatively smoother than the first major surface, whereby a solidified film is formed comprising a first, textured major face having an Ra surface roughness of greater than about 100 microinches and a second, print receptive major face having an Ra surface roughness of less than 100 microinches, wherein the ratio of the Ra surface roughness of the first major face of the film to the Ra surface roughness of the second major face of the film is in the range from about 1.1:1 to about 500:1; and   c) printing decorative information onto the second major face of the film.   
     
     
         2 - 4 . (canceled) 
     
     
         5 . The method of  claim 1 , wherein the random and irregular depressions are directional. 
     
     
         6 . The method of  claim 1 , wherein the random and irregular depressions comprise acicular, meandering depressions. 
     
     
         7 . The method of  claim 6 , wherein the depressions comprise branches. 
     
     
         8 . The method of  claim 1 , wherein at least a portion of the depressions comprises generally flat bottoms. 
     
     
         9 . The method of  claim 1 , wherein the first tooling surface is a surface of a roller rotating about an axis, and wherein the depressions are directionally oriented circumferentially around the roller generally perpendicular to the roller axis. 
     
     
         10 . The method of  claim 1 , wherein the second tooling surface is biased toward the first tooling surface under pressure. 
     
     
         11 - 15 . (canceled) 
     
     
         16 . A decorative laminate film, comprising:
 a) a first major face comprising a random and irregular pattern of protuberances having different shapes and sizes, said first major surface having an Ra surface roughness of at least 100 microinches;   b) a second, print receptive major face, wherein the ratio of the Ra surface roughness of the first major face of the film to the Ra surface roughness of the second major face of the film is in the range from about 1.1:1 to about 500:1; and   c) decorative information printed onto the second major face.   
     
     
         17 . The film of  claim 1 , wherein the film comprises polyvinyl chloride. 
     
     
         18 . The film of  claim 16 , wherein the film comprises less than 2 parts by weight of total plasticizer per 100 parts by weight of the film. 
     
     
         19 . The film of  claim 16 , wherein the film comprises less than 0.1 parts by weight of total plasticizer per 100 parts by weight of the film. 
     
     
         20 - 22 . (canceled) 
     
     
         23 . The film of claim of  claim 16 , wherein the first major face has an Ra surface roughness of at least 120 microinches. 
     
     
         24 . The film of  claim 16 , wherein the first major face has an Ra surface roughness of at least 150 microinches. 
     
     
         25 - 27 . (canceled) 
     
     
         28 . The film of any of  claim 16 , wherein the second major face has an Ra surface roughness of less then 90 microinches. 
     
     
         29 . (canceled) 
     
     
         30 . The film of any of  claim 16 , wherein the ratio of the Ra surface roughness of the first major face to the second major face is in the range from about preferably about 3:2 to about 10:1. 
     
     
         31 . (canceled) 
     
     
         32 . A decorative laminate, comprising;
 a) a substrate; and   b) a decorative laminate film bonded directly or indirectly to the substrate, said decorative laminate film comprising:
 1) a first major face comprising a random and irregular pattern of protuberances having different shapes and sizes, said first major surface having an Ra surface roughness of at least 100 microinches; 
 2) a second, print receptive major face, wherein the ratio of the Ra surface roughness of the first major face of the film to the Ra surface roughness of the second major face of the film is in the range from about 1.1:1 to about 500:1; and 
 3) decorative information printed onto the second major face. 
   
     
     
         33 . A method of making a decorative laminate, comprising;
 a) providing a decorative laminate film prepared according to the method of  claim 1 ;   b) directly or indirectly bonding the film to a substrate.   
     
     
         34 . A method of making a decorative laminate, comprising;
 a) providing a decorative laminate film according to  claim 16 ;   b) directly or indirectly bonding the film to a substrate.   
     
     
         35 . A method of making a decorative laminate film, comprising the steps of:
 a) extruding a film having first and second major surfaces, wherein a random, irregular, and directional texture is formed on the first major surface while the film is at least partially molten; and   b) after forming said texture on the first major surface, printing decorative information onto the second major surface of the film.   
     
     
         36 . A method of making a decorative laminate, comprising the steps of:
 a) extruding a film having first and second major surfaces, wherein a random, irregular, and directional texture is formed on the first major surface while the film is at least partially molten;   b) after forming said texture on the first major surface, printing decorative information onto the second major surface of the film; and   c) after printing, laminating the film directly or indirectly onto a substrate.