US1849275A

US1849275A - Coating and printing process and apparatus therefor

Info

Publication number: US1849275A
Application number: US117059A
Authority: US
Inventors: Neil L Campbell
Original assignee: Carthage Mills Inc
Current assignee: Carthage Mills Inc
Priority date: 1926-06-19
Filing date: 1926-06-19
Publication date: 1932-03-15
Anticipated expiration: 1949-03-15

Description

March 15, 1932. N. L. CAMPBELL 1,849,275

COATING AND PRINTING PROCESS AND APPARATUS THEREFOR Filed June 19. 1926 I 2 Sheets-Sheet 1 Illlllllll llllllllll &

fislllla Illlllllll INVENTOR 4% BY mm X I V ATTORNEY 2 Sheets-Sheet 2 INVENfOR a, (.1 W MAM 5 ORNEY March 15, 93 N. 1.. CAMPBELL COATING AND PRINTING PROCESS AND APIARATUS THEREFOR Filed June 19, 1926 B product. The quality of this type Patented Mar. 15, 1932 UNITED STATES PATENT OFFICE NEIL L. CAMPBELL, OF GLENDALE, OHIO,

ASSIGNOR, BY MESNE ASSIGNMENTS, TO

CARTEAGE MILLS INCORPORATED, OF CINCINNATI, OHIO, A. CORPORATION 013 OHIO COATING AND PRINTING PROCESS AND APPARATUS THEREFOR Application filed June 19,

My present invention relates to the manufacture of floor coverings or the like, and has particular reference to the treatment of a base material of a character which is particularly adaptable to serve as a floor covering.

The treatment of a base material so as to convert it into one type of floor covering includes the application to the base of one or more coatings of a material such as paint, these coatings imparting to the base an ornamental or pattern coating. I may apply this pattern coating in different manners so as to produce at least two differing types of finished floor coverings; one wherein the top pattern or ornamental coating is applied over the full area of the base to constitute an unbroken upper surface; another wherein the top ornamental coating is applied upon a base coating along predetermined areas of the latter, so that portions of the base or'ground coating will show through and thereby constitute por-' tions of the exposed surface which has the finished pattern thereon.

Where I have attempted to produce a floor covering according tothese two methods, I have found that the former method produces a finished product of higher quality. I have generaly denoted this type of product as a grade A product, and in actual practice I have found it advisable to lay one or more ground coatings underneath this pattern coating in spite of the fact that none of the ground coating will show through when the product is complete. The second type of product, wherein portions of the ground coating show through, is generally termed by me as a grade of product has been found by me to be somewhat inferior to the grade A product, and I attribute the inferiority to various facts. Among these is the fact that where the pattern coating is applied to cover only portions of the ground coating after the latter has become dry, an upper wearing surface is produced whose wearing qualities are obviously impaired because of this fact. In the production of floor coverings of the type designated as grade A, I have found that an increased amount of coating material is necessary, because of the fact that no part of the upper- 1926. Serial No. 117,059.

most ground coating serves as the wearing surface.

' One of the objects of the present invention is to produce a floor covering which will have the advantageous characteristics, both as to wearing qualities and as to appearance, of the type heretofore known as grade by the utilization of a method substantially like that heretofore employed to produce the type known as grade B. By means of my invention, I am enabled to produce a floor covering wherein a minimum of paint materialis necessary, and wherein only portions of the ground coating are covered by the top pattern coating, the uncovered portions of the ground ornamentation; but wherein the disadvantagenus feature of the grade B product, such as decreased wearability, are eliminated, and the advantageous features of the grade A product attained.

These objects I attain, in part, by applying the pattern coating to the ground coating before the latter is completely dry. More particularly, I apply the pattern coating at a time when the ground coating is still capable of substantial permanent distortion by pressure. In this way, I am enabled to embed the pattern coating; and if my invention is efficiently carried out, it" is possible to embed the pattern coating to a sufficient degree so as to produce a resulting surface which is devoid of irregularities of the character heretofore typical of the grade B product. In this manner, I attain the further results and advantages flowing from the fact that the ground coating does not have to be dried before further treatment thereof, and that the application of the finished pattern can be made in a process which is continuous with respect to the application of the ground coat- Another feature of my inventionlies in applying the ground coating in'such a manner that its exposed surface will be just as smooth and good-looking as the surface of the product known as grade A has been. A further feature lies in applying the ground coating by a method which produces this advantageous result while at the same time elimfeature of my invention to utilize a method akin to the so-called printing or mash-block process heretofore employed in connection with the application of the pattern coating.

More particularly I apply the ground coating by means of a series of applied coatings which are laid by means of applicators, such as mash-blocks, in positions which complement each other so as to produce an unbroken finished coating of the ground material.

. This method of laying the ground coating is beset with various difficulties; accordingly, other features of my invention lie in performing certain steps in connection with the applicator depositions whereby these disadvantages and difficulties are overcome. More particularly, I have-found it difficult to utilize a minimum amount of material and thereby produce the thinnest possible ground coating, in a manner which will at the same time produce an absolutely smooth surface for the purposes hereinbefore specified. Accordingly, a feature of my invention lies in suitably treating the applied ground coating so as to smooth out its surface, place it in such condition that the pattern coating may be subsequently applied thereto while the ground coating is still in a semi-dry condition, and in general, render it suitable for the purpose of constituting a portion of the final ornamentation.

In connection with the application of the ground coating by means of mash or printing blocks, another feature of my invention lies in utilizing mash or printing blocks whose printing or applying surfaces present a material, such as steel, which is particularly adaptable for use in connection with the practice of my invention.

My present invention embodies certain other advantageous features. Where I have attempted to apply the ground coating by pouring a mass of the material upon the base in advance of two complementary rollers desi ned to spread the material over the base, I ave found that a large amount of waste occurs, and that the'applied ground coating is not suitably smooth and efliciently applied. In accordance with an object of the present invention, I have found it necessary to produce a ground coating of extremely eflicient qualities; and in accordance with my method, the disadvantages heretofore entailed by the use of the rollers referred to have been obviated. Moreover, inasmuch as the pattern coating is applied by mash-blocks or applicators which necessitate a step by step movement of the base, I have found it necessary heretofore to utilize two machines, because the roller method of applying the ground coating could'not be effected with a step by step movement of the base. The uti-- lization of two separate machines or sets of apparatus has entailedexcessive handling of the material and has necessitated the cutting of the base material into lengths which could individually be subjected to the various steps of the process. In accordance with my present invention, I am enabled to utilize only one unitary apparatus, and I am thereby enabled to eliminate many extra steps of handling, and I am enabled to utilize the felt base ma terial in a continuous manner which eliminates the necessity for cutting, and therefore effects a great saving of time, material and labor.

A still further feature of the invention lies in applying a coating to the under-side of the base in amanner which eliminates separate manipulation even for this purpose,

and which therefore enables me to complete the entire operation in a single continuous manner and by means of a unitary apparatus. The economical advantages of my invention are therefore extremely obvious.

For the attainment of the foregoing objects and suchother objects as may hereinafter appear or be pointed out, I have illus trated one embodiment of my invention in the accompanying drawings in which Figure 1 is a diagrammatic elevation view of a piece of apparatus capable of performing the various steps of my invention;

.Figure 2 is a plan view of a portion of a continuous roll of felt base material, showing the successive steps performed by correspondingiy positioned elements of the apparatus shown in Figure 1;

Figure 3 is a fragmentary perspective view of one of the printing blocks which may be utilized for the application of the ground coating;

Figure 4 is a similar View of a complementary printing block;

Figure 5 is a fragmentary longitudinal cross-section, upon a greatly enlarged scale, of a portion of the base material during certain intervals of the process showing diagrammatically the relative functions of several elements of the apparatus;

Figure 6 is a fragmentary plan view of one of the elements shown in Figure 5; and

Figure 7 is a fragmentary cross-section of a portion of a completed floor covering, showing the nature of the article which may be produced by my present invention.

Referring to the drawings, and particularly to Figure 1, I have illustratively shown a roll of felt base material 10 mounted in any suitable manner so as to permit free unwinding of the material therefrom. In the illustrated embodiment the under-side of the base strip is coated first. Accordingly, I lead the strip of base material from the roller 10 through two complementary rollers 12 and 13 of which the former is a pressure roller and the latter is a coating roller. The roller 13 may be suitably supplied with the coating material from any the reservoir 14. It will be understood that the strip of base material will have its underside 15 coated by virtue of its contact with the roller 13.

The strip is then fed over the guide rolls 16 and 17, the latter one thereof being preferably of a type which will positively engage and feed the strip. In order to reverse the position of the strip before it is led through that portion of the apparatus which is designed to apply the upper coating, the strip is passed over the roller 18 mounted upon the end of a long platform or foundation 18. It will be observed that during the passage of the strip from the roller 13 to the roller 18, the under-side 15 of the strip, i. e., that side which has just been coated, will be untouched by the rollers 16 and 17. For the purpose of insuring suificiently complete dryness of the under-side 15 by the time the strip is made to pass over the roller 18, a length 20 of the strip is permitted to hang free between the roller 17 and the roller 18. Although I have shown the portion 20 as a slack portion constituting merely a single loop, nevertheless it will be understood that any desired number of loops may be provided for. It will be further understood that this slack may be maintained by suitably corelating the speed of operation of the feeding roller 17 and the feeding roller (not shown) which draws the strip through the main portion of the apparatus.

The strip is made to pass over the bed of the apparatus in a step by step movement, and in passing through that portion of the apparatus which I have designated A, the ground coating is applied to the upper surface of the strip; during the passage through that portion of the apparatus designated by B, the various steps for applying the pattern coating are performed.

Referring now to Figures 2, 3 and 4, It will be observed that I have shown a printing block 26 which is provided with a series of parallel ridges or printing .ribs 32, these ribs being provided with an applying surface of a material such as steel, and being adapted to apply a series of parallel transverse lines upon a predetermined area of the strip. The application of these lines, as well as the application of all other portions of the coating material, takes place during an interval of time wherein the continuous strip is momentarily stationary. This will be readily appreciated, when'it is remembered that the entire strip is made to pass through the apparatus in a step by step movement. After the strip has been moved forward one step, thereby bringing the striped portion beneath the complementary printing block 27, the latsource of supply, such as ter will apply a second series of parallel transverse markings to the strip. The block 27 is provided with ribs 33 similar to the ribs 32, and the positions of the printing blocks and of the ribs are so co-related to the step by step movement of the strip, that the second set of parallel markings will be applied to the parallel spaces lying between the original markings40. In this manner, a complete un broken layer of ground coating is applied to the base material. i

I have found that by the employment of two printing blocks of the character set forth, I obtain a ground coating which is not only uniform in character and which has increased wearing qualities, but which will present portions serving as part of the finished pattern and having all the appearance of portions which have been applied by a pattern block. This satisfactory result I attribute also in part to the employment of printing blocks made of a material such as steel.

Before proceeding to describe more fully the steps which I have found necessary for finally completing the ground coating, I Shall briefly describe the steps whereby the pattern coating is "applied. As the strip passes step by step through that portion of the aparatus marked B, each printing block or mash-block of the set 50, 51, 52, 53 applies a predetermined series of markings upon the strip. These blocks are also preferably made of metal such as steel; they are substantially of the same dimensions and character as the

blocks

26 and 27, and they carry ribs or configurations upon their lower surfaces which define the different patterns to be applied by each. The mash-blocks are so positioned and designed in relation to the step by step movement of the strip that each marking will complement the mark previously applied so as to efiect a completed ornamentation in a manner illustratively shown in Figure 2. For purposes of inking these mash-blocks, as well as the blocks 26 and 27 I may employ the sliding inking members 55 which may be of the conventional character hitherto employed for this purpose, and operating in a more or less conventional manner. It will be under, stood that the pattern mash-blocks 50, 51, 52 and 53 are reciprocated in time'd relation with the reciprocation of the

blocks

26 and 27 and in fact a single means may control the timing of all the blocks as well as the step by step feed, because all the blocks will be raised and lowered synchronously and the feed will have a predetermined timal relation thereto.

In Figure 5 I have diagrammatically represented, upon a large scale, the manner in which the parallel markings 40 are, in my opinion, applied. Whereas the markings of the

blocks

26 and 27 should theoretically produce a smooth unbroken layer of coating material, nevertheless I have found that a perfect result may not always be obtainable. I

' have observed that when the block 26 is lifted from the strip, the surface tension of the coating material causesit to adhere to the printing ribs on the block as the latter is raised so that the theoretically parallel opposite v walls of each deposited mark are made to conthe strip. However, the theoretical parallel- 'sions 36 and 38. In

ism between the opposite sides of each applied marking will not be regained, and as a result a plurality of parallel markings will have been produced, having cross-sections substantially like'those illustrated in the right portion of Fi re 5. The upper'surface 36 of each marking will have a' width somewhat less than the width of the particular rib 32 or 33 which caused its deposit, and the walls 37 of each marking will be somewhat concave, and will embody a certain upward convergence.

Referring now to the adjacent portion of Figure 5, I have illustratively shown what I believe occurs when the second block 27 applies its lines of coating material. A similar' adhesion between the ap'lied markings and the printing ribs of'the lock probably occurs, but the coating material will merge with the rows of coating material which have already been deposited, and the result of all the adhesion and cohesion which occurs, and of the surface tension of the coating material, will be the final production of a. series of alternate high spots and depresorder to remedy this condition, I have found it preferable to provide a rotatable roller 39 suitably mounted to rotate in contact with the coating, but

. intermittentl in the direction indicated by the arrow, so that no relative movement will occur between the strip and the roller. In other words, the roller 39 remains stationary while the strip is stationary, but when the strip is moved, the roller is given a rotation just suflicient to cause a pure rolling movement to take place between the roller and the strip. The roller 39 is so positionedas to iron out the unevennesses of the applied ground coating.

However, I have found that the roller 39 will become covered with a layer of pigment or coating material. As a result, although the coating material is ironed out, its resultant condition will still be imperfectly smooth.

.I have represented this imperfect condition by a wavy line in Figure 5, although I have found the imperfections to exist mostly as longitudinal streaks. For the purpose of re- 7 moving this last vestige of unevenness, I provide a second roller 41 which is designed to be stationary, and which barely touches the.

upper surface of the applied coating mate-v rial. After the strip passes underneath the roller 41, all uneven conditions-are eliminated, and the surface of the applied material is entirely smooth when it passes this point. I have found that by the treatment above outlined, the upper surface 'of the ground coating is not only made adaptable to serve as part of the wearing surface, but it is given a consistency and character which adapts it for the successful application thereto of the port 44, the handle being provided with a pin 43 engageable in a selected opening. By manipulating the handle, the roller 41 may be given an angular rotation about its axis,

and by suitably positioning the pin .43 in asuitable opening 42, the roller may then be locked into this new position wherein a new contacting surface has been brought into operation. Although I do not mean to limit myself to any particular construction, I have illustratively shown and described an arrangement of this character, and I prefer to render the roller 41 rotatable only in the direction indicated by the arrow so that impurities would not be pushed back upon that portion of the strip which has not @t come into contact with the roller. 1

By means of my invention, I am enabled I to utilize a coating material having a composition which renders it capable of drying rather quickly. This is made possible because of the extremely short intervals of time between which the ground coating and the pattern coating are applied. In accordance with an object of my invention, I control and regulate the composition of the coating material, and I co-relate the period of drying-with the distances between the elements of the apparatus in a predetermined manner, so that the coating material is in a gelatinous condition when it passes through that portion of the apparatus marked B. The condition of the coating must be such that it may be distorted by pressure only to, a degree which will embed the applied pattern coating at least partially into the ground coating. In other words, if the ground coating has become too dry by the tlme the pattern coating is applied, the latter will be deposited along raised portions, much in the.

manner of the pattern coating deposit of the product heretofore attempted by me and designated as grade B. On the other hand, if the ground coating is too moist, the pressure thereon of the mash-blocks 5053 will displace portions of it to an extent which will impair the smoothness which has previously been imparted to the ground coating. If the speed of drying has been properly corelated with the time intervals of operation, the. pattern coating will be applied so as to produce a result which is illustratively shown in Figure 7.

Referring to this figure, 10 represents the base material, 45 represents the ground coating which has been applied thereto, and 46 represents the embedded applications of the pattern coating material. Inasmuch as the latter is applied to a coated surface, the difiiculties encountered in the application of the ground coating are not present, and I have found it possible to produce a very efficient and smooth surface without undertaking any additional steps.

It will thus be observed that I have produced an article having all the favorable characteristics of the product heretofore known as grade A, whereas the nature of vthe ornamentation is such as has been characteristic of the article heretofore known as grade B. Not only is a great saving effected in the amount of pattern coating material, but a great savingin the amount of ground coating material is effected because of the method of applying the ground coating. I therefore consider the utilization of printing blocks for the application 'of the ground coating of extreme importance. By their use all waste is eliminated; and the thickness of the ground coating may be accurately controlled so as to produce the thinnest possible uniform coating. A result of this character has not been possible heretofore in cases where the ground coating has been applied in quantities, and thereupon spread over the base material by means of rollers. Moreover, it will be observed that by the use of printing blocks for the application of the ground coating, I am enabled to effect a great saving in time, handling, and floor space. The possibility of completing the entire process in one unitary apparatus is of great economical importance, as will be readily understood.

Furthermore, it will be observed that I have produced an article having entirely different characteristics from either of the articles heretofore made. Reference to Figure 7 will clearly show the salient features of the present product. It will be observed that a smooth upper surface is produced, and that portions thereof are constituted by upwardly projecting portions 47 of the ground coating material. The \vearability of a material of this character will be very great, and this alone is a very important result which I bly. Furthermore, I have illustrated and I described my process as performed by an apparatus in which both the ground and the pattern coatings are applied by reciprocating applicators, such as printing blocks, because thereby certain advantages are at tained. It nevertheless will be understood that as far as my herein disclosed apparatus and process for applying the ground coat are concerned, the broader phases of my invention are attainable even though the pattern coat is applied in a different manner from that herein disclosed, as for instance by a rotary process. So also as far as the application of a pattern coat to a wet ground coat is broadly concerned, the particular method of producing the latter or of applying the former are features that appertain to the attainment of a more or less effective practice of my invention. Where, in fact, other apparatus such as a rotary printing process is employed for applying the pattern coating, this change in the character of the feed can be compensated for by festoon- While I have herein suggested the employment of a ground coat applied by mash or printing blocks in which the color of the coating material is the same so as to provide a ground coat of a uniform color throughout, it will be understood that by my process and apparatus, I can have the longitudinal stripes applied by one of the printing blocks, for instance, that numbered 26 of one color and those applied by the other rinting block, for instance that numbered '2 of another color so that this, in connection with the rest of the mechanism will produce a variegated colored ground coat. Where ordinary floor covering is produced, I can take advantage of this variegated effect to have this effect appear in the final wearing coat by properly predeterminin g the printing mash blocks 50, 51, 52 and 53 which apply the final ornamentation and where my process and apparatus are employed for the purposes of forming rugs, I can have the rug pattern so impresse upon this variegated ground coat so as to have the ground coat worked into and form part not only of the field of the rug, but also of the border.

Having thus described my invention and illustrated its use, what I claim as new and desire to secure by Letters Patent is- 1. The process of making floor covering which comprises the steps of applying a substantially parallel markings, and treating the coating to make portions thereof suitable for constituting portions of a composite pattern coating, said treatmentcomprising the step of subjecting the coating to a pure rolling pressurelto equalize the applied complementary portions.

2. The process of making floor covering which comprises the steps of applying a ground coating to a base in complementary portions, said portions comprising sets of substantially parallel markings, and treating the coating to make portions thereof suitable for constituting portions of a composite pattern coating, saltl treatment comprising the steps of subjecting the coating to a pure rolling-pressure to level the applied portions and then subjecting the coating to a sliding pressure to remove irregularities.

v 3. In an apparatus of the character described, means for applying a ground coating to a base material, a series of pattern-coat applicators, means for moving the coated material into operative subjection to the appli- I cators, and means for smoothing the ground coating during said movement.

4. In an apparatus of the character described, means for applying a ground coating to a base material, a series of pattern-coat applicators, means for moving the coated material into operative subjection to the appliound' cators, and means for treating the 1 coating during said movement, sald last named means comprising a roller adapted to apply rolling contact to the coating.

5. In an apparatus. of the character de scribed, means for applying a ground coat- 7 ing to a base material, a series ofpattern-coat applicators, means for moving the coated material into operative subjection to the applicolor, said areas in the respectiuistations being ofl'set so as to completely co er each section with solid color, and at a succeeding station smoothin the resulting solid color, said color being of relatively quick drying paint so as to be slow flowing, and in stations suc-,

ceeding to the smoothing, and while the paint is still wet impressing patterns in paint upon the solid color, with the result of impressing the pattern coat into the solid color coat, as distinguished from depositing it upon the solid color coat, for the purpose described."

9. The process of making floor covering whichcomprises subjectin a base material to successive applications 0 ground coating, each applicatlon simultaneously producing a series of closely interspaced coated areas,

the areas in successive app lcations being complementary, whereby uncoated areas left by the first application are filled in, treating the composite complete coating thus forme to render it smooth; and printing a pattern on said ground coating before said ground coating has dried.

I In witness whereof, I have hereunto signed my name.

NEIL L. CAMPBELL.

cators, and means for treating the ground coating during said movement, said last named means comprising a roller adapted to apply rolling contact to the coating, and a stationary pressure member adapted to subject the coating to sliding pressure.

- 6. In an apparatus of the character described, means for applying a ground coating to a base material, a-series of pattern-coat applicators, means for moving the coated material into operative subjection to the applicators, and means for smoothing the 7 ground coating during said movement, said last named means comprising a stationary roller positioned to apply sliding pressure to the coating.

7. In an apparatus of the character described, means for applying a ground coating to a base material, a series of pattern-coat applicators, means for moving the coated material into operative subjection to the applicators, and means for smoothing the ground coating during said movement; said last named means comprising a stationary roller positioned to apply sliding pressure to the coating, and means for rotating the roller