US1608243A - Fabricated cork sheet - Google Patents

Description

A. S'CHAVOIR FABRICATED CORK SHEET Nov. 23 1926.

Filed April 1924 Patented Nov. 23, 1926.

UNITED. STATES I Peter o ert c151;

ARNOLD L. SCHAVOIR, or STAMFORD, connncricur, assrenon, BY rrnsnn ASSIGN- MENTS, TO NEW rnocnss'oonx coMranY, ENG, or nzeoerznrn", new Years, A

CORPORATION on NEW YORK.

FABRIGATED CORK SHEET.

Application filed April 8, 1924. Serial No. 704,953;

My invention relates to a fabricated cork sheet, and more particularly to an article,

ofthis character consisting mainly of finely granulated cork, so bonded together as to form a soft, highly flexible, water proof sheet which will not harden or disintegrate as a result of the action of air or water thereon.

A sheet of material forming the subject matterof my invention has a. roughened or pebbled" surface; is of substantially uniform thickness throughout, and may be readily'pro duced by means of machinery well known in the rubber working art. In fact, material embodying my invention is capable of being used in lieu (of various rubber products, and has many advantages thereov'er in that it is notsubject to deterioration, as a result of exposure to light or air; will adhere with greater tenacity to backingfabric which is preferably used possesses relatively greater tensile strength can more readily be bonded to other substances or materials, and may be much more cheaply produced both as to the value of the ingredients entering thereinto, and in the handling of the various ingredients during the fahrication of the material.

The main ingredient ofv a sheet embodying any invention is finely granulated cork which is largely a waste product resulting 'frolnthe manufacture'of other cork products, from Waste-cork bark, and while the proportion of cork entering into the mixture for forming the sheets is but approximately two parts of said cork to one of other ingredients by weight, in actualloulk the cork-will run fromforty to fifty times that of theother ingredients.

While the material contains a binder including various gums and oils including some concentrated latex, no heat vulcanizing is required to impart thedesired characteristics to the material, the curingorsetting of this binder resulting from the mere ex posure of the material to atmospheric air at normal temperatures. It- 'requires no special treatment to condition the material for the market, since the product is not tacky and the volume ,of granulated cork used is sufliciently great to avoid the presence of any of the other ingredients in the material except in the form of a thin superficial coating upon'each cork granule, each granule also being partially impregnated with these materials so that they serve i oil, an adhesive known. in the trade as: Technical Goulac, a mixture containing animal glue and dextrine; pure rubber known as smoked sheet, or in lieu thereof, a concen trated latex; an accelerator such as litharge or super-sulphur (oxidized zinc salt of di- InethyLdi-thio-carba mic acid with or without a clay base) or both, and a suitable coloring material. These ingredients are thoroughly mixed in an ordinary rubber mill and thereafter have mixed therewith insuch a mill, a filler of fine granular cork, known as No. 4t or No. 5 cork, or a mixture of these, the size of said granules being such as may be selected by a 14 to a 24tmesh screen.

Byweight, the granular cork. which may be effectively worked into the other ingredients constituting the binder, will be approximately two to one, but in bulk the ratio will be approximately fifty to one, it being possible to work a very large volume of the granular cork in a very small volume of the binder.

I have found in actual practice that the proportions of the binder for use with about thirty-three pounds of finely granulated cork should be as follows f 1 pound Vso gumlac (shellac), 4 pounds No. 1 special (rubber substitute), 8 pounds smokedsheet. (or 3 gallons latex), 24 ounces litharge, 3 ounces super-sulphur, 1 pound Technical Goulac (glue and dextrine). .To this mixture when I desire ablack finish, I add 12 ounces carbon black.

' The composition, after the granular cork has been thoroughly worked into the other ingredients, is applied to a woven fabric such as cotton duck, by an ordinary calendaring machine, the surface of the duck before having the mixture applied thereto being provided with a coating of gum, glue or rubber cement. V

Vhen applying the mixture or composition by the calendaring machine, suitable pressure is developed so as to not only force the material of the binder as well as the cork granules well within the body of the textile backing, but to materially compress the cork granules themselves, larger granules being subjected to a greater degree of compression than smaller granules. After leaving the calendaring rolls, the cork granules which have been compressed, will expand, thus giving the pebbled finish to the composition surface of the sheet. The calendaring rolls are run hot, and heat is used only in applying the composition to the fabric back.

The various ingredients used in the composition for coating the cork granules, and the proportions of such as herein described, will permit the partial hardening of the surfacing composition when exposed to air of a normal temperature, the completed fab-- ric being and remaining highly flexible, and not being subjected to cracking even when bent sharply.

Owing to the relatively small volume of the binding composition used, the resiliency of the surface finish is practically that of the cork itself, the binder possessing sufiicient elasticity, however, to prevent the separation of the cork granules when the sheet is bent.

The exposed portion of the surface coating then receives a dressing of shellac which will improve the finish of the product and also facilitate its being cemented to glass or other objects.

The dressing of shellac may be dispensed with if desired, although even when the use of the material does not require it to be cemented to any object, the dressing of shellac will improve its appearance although it is not required to enhance the weather proof quality of the product.

The binder used will ensure continued flexibility of the sheet, and exposure to light or air over long periods, will have little or no effect as to the resiliency of the sheet or its weather proof qualities.

The sheet by reason of the large volume of cork granules, and the thin layer of the composition containing same ap lied to the textile backing, is very light in weight, per square foot.

In the drawing. a represents the textile backing, b the coating of gum. glue or rubber cement thereon, and 0 the facing of cork filled composition.

It is not my intention to limit the inven tion to the precise details of the formula for the binding medium herein set forth, it being apparent that this formula has a large range of variation both as to the quantities of the different ingredients employed, as well as the ingredients themselves, although in practice I have found the formula specified to give highly satisfactory results.

Having described the invention, what I claim as new and desire to have protected sulphur, the quantity of granulated cork being substantially twice that of the other ingredients, by weight. I

3. A fabricated cork sheet embodying therein a facing comprising finely granulated cork, a binder therefor containing rubber, an accelerator, an adhesive, a mixture containing a resin and an oil, and a vegetable gum, the volume of granulated cork being relatively much greater than the volume of other ingredients, and a surface dressing of shellac.

4. A fabricate-d cork sheet embodying therein a facing comprising finely granulated cork, a binder therefor containing shellac, a rubber substitute including therein resin and rapeseed oil, a mixture of glue and dextrine, pure rubber, litharge and supersulphur, the quantity of granulated cork being substantially twice that of the other ingredients, by weight, and a surface dressing of shellac.

5. A fabricated cork sheet including therein a facing comprising a thin stratum of flexible material embodying the following ingredients in substantially the following proportions33 pounds finely granulated cork, 1 pound shellac, 4 pounds of rubber substitute including therein resin and rapeseed oil, 1 pound of a mixture of glue and dextrine. 8 pounds sheet, 24 ounces litharge and 3' ounces super-sulphur.

6. A fabricated cork sheet including therein a facing comprising a thin stratum of flexible material embodying the followingingredients in substantially the. following proportions-33 pounds finely granulated cork, 1 pound shellac, 4t pounds of rubber substituteincluding therein resin and rapeseed oil, 1 pound of a mixture of glue and dextrine, 8 pounds sheet, 24 ounces litharge granulated cork and a binder therefor containing rubber, an accelerator, an adhesive, a mixture containing a resin and an oil, and a vegetable gum, the volume of granulated cork being relatively much greater than the "olume of other ingredients.

8. A fabricated cork sheet embodying therein a textile backing having cemented thereto a facing embodying therein finely granulated cork, a binder therefor containing rubber, an accelerator, an adhesive, a mixture containing a resin and an oil, and a vegetable gum, the volume of granulated cork being relatively much greater than the volume of other ingredients, and a surface dressing of shellac.

9. A fabricated cork sheet, a textile backing having cemented thereto a facing comprising a thin stratum of flexible material embodying the following ingredients in substantially the following proportions-83 pounds finely. granulated cork, 1 pound shellac, 4 pounds of rubber substitute including therein resin and rapeseed oil, 1 pound of a mixture of glue and dcxtrine, 8 pounds sheet, 24 ounces litharge and 3 ounces super-sulphur.

10. A fabricated cork sheet, a textile backing having cemented thereto a facing comprising a thin stratum of flexible material embodying the following ingredients in substantially the following proportions33 pounds finely granulated cork, 1 pound shellac, 4 pounds of rubber substitute including therein resin and rapeseed oil, 1 pound of a mixture of glue and dextrine', 8 pounds sheet, 24: ounces litharge and 8 ounces supersulphur, and a surface dressing of shellac.

In Witness whereof I have hereunto affixed my signature this 31st day of March, 1924.

ARNODD L. SOHAVOIR.

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