US1249734A

US1249734A - Rug and the process of making same.

Info

Publication number: US1249734A
Authority: US
Inventors: Frank B Foster
Original assignee: Congoleum Co
Current assignee: Congoleum Industries Inc
Priority date: 1916-02-18
Filing date: 1916-02-18
Publication date: 1917-12-11
Anticipated expiration: 1934-12-11

Description

F. B. FOSTER.

RUG AND THE PROCESS OF MAKING SAME. APPLICATION mm FEB. 1a. 1916.

Patented Dec; 11, 1912'.

2 SHEETS-SHEET 1.

' F. B. FOSTER.

RUG AND THE PROCESS OF MAKING SAME.

APPLICATION FILED FEB 18. I916.

Patented Dec. 11, 1917.

2 SHEETS-SHEET 2- BLBE R2 YELEVY w r r \F I 1 I I l I I l l 11 I l l l l I L c R L c: R L. c R

IINIHHIIHIWIWWIWI 1. EMMA] I lilil'i Illlllllllllllllllllllfl Nllilllllllllllllllllll mmm N TED STATES PATENT orrIoE.

FRANK FOSTER, OF HAVERFOBD, PENNSYLVANIA, ASSIGNOl-b TO THE CONGOLEUM COMPANY, OF PHILADELPHIA, PENNSYLVANIA, A CORPORATION OF PENNSYL- VANIA.

Specification of Letters Patent. Patented Dec, 11, 1917,

Application filed February 18, 1916. Serial No. 79,167.

To all whom it may concern:

Be it knownthat I, FRANK B. Fos'rER, a' citizen of the United States, and a resident of Haverford, county of Montgomery, State of Pennsylvania, have invented certain Improvements in Bugs and the Processes of "Making Same, of which the following is a specification.

One object of my invention is to manufacture a fioor'covering that can be used as 'a rug which will lie flat upon the floor withall out the use of fastenin devices.

' A further object of the invention is to make the rugs from a long strip of material which is printed and cut into sections, each section forming a complete rug.

A still further object of the invention is to lessen the cost of manufacturing rugs of this type without reducing the quality.

In the accompanying drawings:

Figure 1 is a plan view of a rug made in accordance with my invention;

Fig. 2 is a view of a strip of material showing a series of rugs rinted thereon;

Fig. 3 is a perspective view showing the layers cut away and exaggerated to 1llustrate different steps in the process of manu-* facturing the rug; and

Fig. 4 is a diagrammatic view illustrating one method .of printing the rugs.

A typical example of carrying out my im proved process of manufacturing the floor covering is as follows:

Referring to Fig. 3, I first make a body 5. of dry felt from cotton rags, or equivalent material. The felt, when formed, is of such a consistency that it can be readily,

saturated. This felt is then saturated with a substance, as at 6, which will thoroughly impregnate it, making it proof against moisture and pliable so that the base of the finished product will expand and contract with the surface coating and, consequently, will lie flat upon the floor.

The substance I prefer to use is a semisolid bituminous material, preferably con- "sisting of fpetroleum flux oil and a residual pitch, pre rably derived from asphaltic or semi-asphaltic base oils, which is brought to a temperature of about 500 degrees F. The material is then placed in. a saturating kettle of such a size as to allow the felt to be passed through it, the material in the kettle being heated to about 325 degrees F.

during the saturating process. The dry felt in passing through the liquid will becomethoroughly impregnated, making it pliable so that when the rug is finished and placed upon a floor it will lie flat.

While I have described the felt as preferably made from cotton rags, it will be understood that it may be made of cotton waste or other materials having sufiicient strength and the capacity for taking up a given amount of the semi-solid bituminous material.

'After the saturation the material is allowed to cool to a certain degree but while still warm the surface of the felt, which is to form the back of the rug, is coated with a composition, as at 7, preferably consisting of alcohol, shellac, or any other gum soluble in alcohol, and a pi ent. The alcohol is allowed to vaporize rom the coated surface which is subjected to an air blast, which sets and dries the coating and seasons the felt. .As' soon as the back coating is dry and the felt is seasoned, then the face of which provides a suitable surface to receive the printed design 11. After this last coating the material is allowed to dry, it being then in condition for printing.

The strips of material may vary in length depending considerably upon the length 0 the drying chamber into which the material is carried after being printed. The material is then passed through a block printing machine of the character described and shown in Letters Patent No. 1,145,821, granted to William I. Waldron on the \sixth day of July, 1915, in which there is a series of printing blocks mounted on carriers having an intermittent reciprocating motion to and from the material, and the material is intermittently moved through the machine,'the design being in the form of an appropriate rug pattern consisting of a central body portion and a border. The rug is printed in twoor more sections and may be of as many colors as desired, depending considerably upon the particular design.

I The material is fed through the printing machine in a long strip'and the various portions of the rug pattern are successively printed upon it in appr priate pglors. When 110 30 stance, the blocks are intermittently oper- 50 tion of the material. Then

sections

1 and 3 individual rug patterns are being printed,

the patterns are printed both successively "and simultaneously, since, while one set of blocks is printing the border, or other por- 5 tions of the pattern, other sets of blocks are rug patterns are produced on the strip of material in plurality form, as shown in Fig. 2., Rugs so printed may be of any form and color desired and the colors may be multiplied, depending considerably upon the particular design to be printed.

After the printing operation is completed, the material is transferred to a suitable drier and after being dried it is cut into rugs, which are ready for the market. surface coating and'the body portion of the felt have the same coeflicient of expansion, the rug will lie flat upon the floor under all conditions and is not affected by atmospheric changes.

' In Fig. 4, I have illustrated in diagram one method of printing the rug design in colors on a strip of material, such as described above. In the diagram three colors are represented-blue, red and yellow, and there are three printing blocksL. C. and R.for each color. As the material is intermittently fed through a machine, for inated, but the movement of the blocks is controlled. so that certain blocks are held out of action while others are printing. In the present instance, the block L is the left hand border block which makes the impression on the section 1 of the strip of material. The block 0 is the center block arranged to make an impression on the

sections

2 and 3, and R is the right hand border block arranged to make an impression on the section 4. As the material progresses through the machine, when a'machine i used, the

sections

1 and 3 are printed, strip 0;; then 2 and 3 are printed, stripb; completing the blue color printing of that particular portion of the material. Then

sections

1 and 3 of the preceding portion are printed in red, strip a; then 2 and 4 are printed, strip (1; completing the red color printing on this porof the portion preceding the last mentioned portion are printed in yellow, strip 6; and then

sections

2 and 4 are printed in yellow, str p f; completing the design in three colors on that particular portion of the material two rugs in advance of the portion receiving the first printing, strip a; and as the mat-erlal 1s intermittently moved after each impression the portion first mentioned rece1 ves the red colors when it reaches the 'po nt indicated in strips 9 and h, the blocks belng held out of action until the left hand section 1 is in line with the left hand block L, printing the red color. After the red As the color is printed, these blocks are held out of action while the material is being intermittently moved forward, strips '5, j, k and l; and when the section 1 is in line with the left hand yellow block L, then the

sections

1 and 3 are printed in yellow, strip m, then on the next movement the

sections

2 and 4 are printed in yellow, strip a.

While I have shown a given arrangement of the Col rs and the blocks, this arrangement may be varied without departing from the essential features of the invention.

Producing rugs in plurality form is of great advantage, since 1t enables them to be manufactured-in large numbers at a very low cost. It also enables the felt to be run through the various steps employed without loss of time and to be handled with a minimum of labor and with much greater precision than in the case where separate sheets are used for each rug.

A rug made in accordance with this invention is moisture-proof and can be used in damp places without disintegrating, as the bodyof the rug is water-proof and the different. layers of surfacing materials resist the deleterious action of moisture.

Furthermore, a rug of this character can be made of lighter material than heretofore, the body being substantial and the surface retaining the printed coatings for a greater length of time than oilcloth, having a pattern printed thereon. It is much cheaper than oilcloth in which a woven burlap is used as a base.

. I have not claimed the particular method of preparing the material for printing, nor have I claimed any ofthe ingredients, nor the specific manner of printing the design, as the first mentioned details are fully set forth and claimed in an application for patent filed by George Prifold on February 18, 1916, under Serial No. 79,168. The specific manner of printing designs is set forth and claimed in an application for patent filed by me on the twelfth day of April, 1917, under Serial No. 161,524.

I claim:

1. As a new article of-manufacture, a material of the class described comprising a continuous strip of felt saturated with a substance whichwill make the felt waterproof and pliable, said strip being coated on its under side with a pa1nt com osition which is partially absorbed by the elt and on the opposite side with a paint composition forming a wearing surface and having on said wearing surface a design formed by depositing paint thereon, said surface being divided into a plurality of patterns, each having a complete border and each comprising a complete rug design, the felt body portion and the upper surface having the same coeflicient of expansion so that the material will lie flat upon the floor.

till

llllll 2. A material of the character described, comprising a continuous strip of dry felt having cotton fibers therein' saturated with a semi-solid bituminous material and having a thin coat of paint on its under side, which is partially absorbed by the felt and having on the opposite side a paint composition forming a wearing surface, said paint composition being much heavier than the coat at the back and having on said wearing surface a design formed by depositing paint thereon, said surface being divided into a plurality of patterns, each having a complete border and each comprising a complete rug design, the felt body portion and the upper surface coating having the same coefiicient of expansion so that the material will lie flat upon the floor.

3. As a new article of manufacture, arug having a felt base saturated with a material that will make the base impervious to moisture and will allow it to retain its flexibility and having on its under side a thin paint composition, which. is partially absorbed by the felt, and having on its upper surface a much heavier paint composition forming a wearing surface with a border design on. said wearing surface formed by depositing. paint thereon, the felt base and the wearing surface having the same coefficient of expansion so that when the rug is placed on a floor it will die flat thereon.

4t. The process herein described of manufacturing a waterproof floor covering, said process consisting in making a dry felt body, saturating the felt wlth a semi-solid bituminous material, then, while the material is still warm, coating the back of the felt with a paint composition, which will be partially absorbed by the felt, then applying a pai t coating to the upper surface of the felt to? provide a printing surface, then allowing this surface to dry and printing a bordered design on said surface, the felt base and the upper wearing surface havmg the same c0- efficient of expansion so that the rug, when placed upon a floor, will lie flat thereon.

5. The process herein described of manufacturing a waterproof floor covering, said process consisting in making a dry felt having cotton fibers therein, saturating the felt with a semi-solid bituminous material, which will make the felt waterproof and will allow it to'retain its flexibility, allowing the saturated felt to cool to a certain degree and, while still warm, applying a paint coating to the back thereof, said coating beingpartially absorbed by the felt, then applying two coats to the upper surface of the felt to provide a wearing surface, then printing a design on said upper surface, the felt base and the upper wearing surface having the same coefficient of expansion so that when the material is placed upon a floor it will lie flat thereon.

6. The process herein described of making a floor covering in the form of a rugwhich will lie flat on the floor, said process consisting in taking a dry felt of cotton rags,

saturating the felt with a hot semi-solid bituminous material consisting of petroleum flux oil and residual pitch derived from asphaltic or semi-asphaltic base oils, then, while the material is still hot, applying a thin paint coating to the under side of the felt, the felt absorbing a portion vof the paint coating, allowing the coating to dry, then applying to the upper face of the felt body a paint coating, applying a second paint coating to provlde a suitable Wearing surface to receive the printed design, then allowing the material'to dry, and then printing a rug design thereon, and finally drying the material, the felt base and the upper wearing surface having the same coefiicient of'expansion so that the rugwill lie fiat upon a. floor under different atmospheric changes.

FRANK 1B. FOSTER.