US1983180A

US1983180A - Manufacture of surface coverings

Info

Publication number: US1983180A
Application number: US497313A
Authority: US
Inventors: Mccarthy J Clarence
Original assignee: Armstrong Cork Co
Current assignee: Armstrong World Industries Inc
Priority date: 1930-11-21
Filing date: 1930-11-21
Publication date: 1934-12-04
Anticipated expiration: 1951-12-04
Also published as: GB378523A

Description

Dec. 4, 1934. Q MCCARTHY 1,983,180

MANUFACTURE (5F SURFACE COVEFINGS Filed Nov. 21. 1930 2 Sheets-Sheet l Dec. 4, 1934. J Q MCCARTHY 1,983,180

MANUFACTURE OF SURF'AC E C OVER I NGS Filed Nov. 21, 1950 2 Sheets-Sheet 2 'INVENTOR Patented Dec. 4, 1934 7 1,983,180 MANUFACTURE OF summon covsamcs J. Clarence McCarthy,

Lancaster, Pa., assignor Armstrong Cork Company, Lancaster, Pa.,

a corporation of Pennsylvania Application November 21, 1930, Serial No. 497,313

23 Claims.

. This invention relates to the manufacture of surface coverings, for example, floor coverings having a paint surface and usually'referred to as-printed goods. The present invention, however, has to do with the application of the color, which may be oil paint,'-in such away as to blend the colors, and without the monotony of the repetition of pattern which is characteristic of the usual printed goods. It is particularly concerned "'10 with the production of a surface having an appearance which simulates marble or other surfaces of varying tone and color and of irregular design. I v

In the manufacture of inlaid linoleum, marbles '15 are produced by calendering diflerent colors of linoleum composition together and carefully controlling the calender-ing conditions. Printed goods, however, have been signally faulty wherever it has been attempted to simulate marbles or the like. A printing process is essentially one wherein the pattern is repeated, and when dealingwith the typeof paint employed in the floor covering industry, or, for that matter, in employing thetype of colors generally used in sur- '26 face coverings, the final result has been harsh and-mechanical in appearance, and has lacked the softness and fine blending of color characteristic of natural marbles.-

By my invention it is'possible at a low cost 180 to obtain a product which has the highly desirable qualities from the standpoint of appearance of natural marbles without any apparent repetitions of pattern and with'a soft blending of color not heretofore obtainable in painted goods.

"86 I apply a color or colors to a backing, spread the same longitudinally and laterally of the goods, and then engage the colors thus spread and further spread them. Preferably the first spreading action is such as to form sinuous streaks of color which are thereafter spread. laterally and longitudinally. A doctor. blade serves admirably for spreading the color. Inpractice- Ihave applied color in spots or-blobs on a painted backing, have spread the same into sinuous streaks of color by means" of a doctor blade, and have then engaged the streaks withv a second doctor blade for the purpose of furtherspreading and blending the same. The doctor blades are reciprocated as the material moves .thereunder, and the reciprocation may be effected by handv or mechanically. Preferably the blades are reciprocated in anirregular fashion and this may be done by acam.- Provision is further made for adjusting the angularity of the'blades to the path of travel of the material. -An adjustment of the angularity of a blade has a marked effect on the appearance of the goods.

The color may be applied by means of paint guns of the usual character, such guns being electrically controlled and the paint being fed'under 0 low air pressure so that the guns control the flow of paint and cause it to spatter to form spots or blobs of color on the goods as the same moves thereunder.

In the accompanying drawings illustrating a present preferred embodiment of the invention,

Figure 1 is a diagrammatic view illustrating successive steps in the manufacture of a floor covering according to my invention;

Figure 2 is a view to full size of a piece of material in process of manuacture and showing the manner of applying the paint;

Figure 3 is a plan view more or less diagrammatic, illustrating the manner of applying and spreading the color; and

Figure 4 is a side elevation thereof.

The material illustrated in Figures 1 and 2 comprise a base material 2, such as the felt base ordinarily employed in the floor covering industry, having a uniform paint coating 3 thereon. This 30 coating may be applied in any desired fashion, as by a coating blade or a roll. If it is of a quickdrying character, a solvent which will prevent its drying until after the marble en'ect has been obtained may be included in the coating Prefer- B5 ably, however, an oil paint is used. In any event, it has proven to be the best practise to apply the spattered color spots immediately after the coating operation. Thus, as illustrated in Fig. 2 of the drawings, the several colors which have been selected to make up the marble, are applied to the wet or tacky backing in spots or blobs 4. I have illustrated in Figure 1 the approximate amount of color which is required on the backing to form a marble and have shown spots to full size in Figure 2. It will be understood that different colors are employed in this particular material as is indicated by the different hatchings oi the drawings.

The spots of color are first spread into sinuous streaks, as indicated by the portion M of Figure 1. As hereinafter described this is best done by a reciprocating doctor blade. In Figure 1 the path of movement of the material is indicated by an arrow B, and the line of reciprocation of the doctor blade is indicated by the line DD,- and the blade is moved back and forth in varying amounts so as to give the sinuous streaking on the portion M of the drawings. By this operation there is some blending of the spots of color into the. coating 3, which is still wet or tacky. Moreover. the spots of color are spread out and the diil'erent colors are blended somewhat, although they retain their individual character to some extent. For example, if a spot of green paint is followed at some distance by a spot of brown paint, there will be a sinuous streak of green which will fade out into the background or fade into the brown color, depending upon the spacing of the spots, and then there will be a sinuous streak of the brown color, both of the streaks varying in width and intensity of color from point to point. When spots of color lie alongside one another orare closely spaced. they blend somewhat as the color is distributed :ide wise by the doctor blade, but the several colors and the streaks attributable to different spots are readily distinguished when the material is in the condition indicated by the section M of Figure 1.

The sinuous streaks are subsequently further blended, thus giving an appearance represented by the section N of Figure 1. As above stated and as hereinafter more fully described, this is preferably accomplished by another reciprocating doctor blade. The second blade effectually removes any sharpness or harshness which may remain from the action of the first doctor blade and further blends and spreads the colors so as to destroy practically every vestige of mechanical action. Moreover, the mobility or plasticity of the coating 3 is of material assistance in blending the whole color scheme so as to obtain the desired appearance of marble. Thus the streaks and tinges of color are worked into the coating 3 in a very natural appearing manner. In the case of a lacquer, there is a tendency for the lacquer to become tacky; and a very desirable marble effect is produced, the tackiness causing the material to be pulled out when it passes under the doctor blades, producing a very characteristic marble. The second doctor blade may be actuated at a different angle from the first, or at a different rate or amplitude. By varying these several factors the first formed sinuous streaks are so modified and obliterated that the resulting material has an appearance characteristic of natural marbles and entirely free from any mechanical appearance.

If desired, the material may be overprinted. I have illustrated this in section P of Figure 1, where black squares have been printed over the material so as to produce a pattern consisting of alternate black tiles and marble tiles.

Figures 3 and 4 illustrate an apparatus which maybe employed. The material is advanced in any convenient manner, as by pin bands 10, the material being carried over the base or table indicated at 11. The coating 3 is applied to the material at the forward end of the machine (not shown), and the material is then passed beneath a series of paint guns 12 there being several rows of guns connected with paint tanks 13 containing difierent colors. The guns are operated without sufilcient pressure to atomize the paint, and preferably under a pressure of from 5 to 10 pounds. This pressure may be merely the head of pressure which results from placing the paint tanks 13 at an elevation above the guns. The

, operation of the guns may be more readily adjusted if pressure, as for instance air pressure, is applied to the surface of the paint in the tanks 13. Where the color is such that but small spots or blobs are desired, a relatively light pressure is desirable, and where the color is a more predominating one, a relatively higher pressure is desirable. In any case, the paint is fed to the guns with sufiicient pressure to spatter rather than drip, this spattering taking place at predetermined intervals. I have shown electromagnets 14 adapted to be energized by means of a control drum 15, whereby the supply of paint to the material may be controlled. The control drum 15 will be provided with a row of contact points 16 for each paint gun 12, and by varying the circumferential length and the number and spacing of such contact points the guns may be controlled as desired. For example, small spots of color, such as illustrated at 4a. in Figure 2, may be applied, or long streaks, such as illustrated at 41), may be obtained.

The doctor blade for forming the first series of sinuous streaks of color is illustrated at 17 in Figure 3. It consists of a square metalbar 18 having a thin flexible steel blade 19 secured thereto. This blade is pressed down on the material and its edge portion lies substantially flat thereover. The bar 18 has extensions 20 working in bearings 21. The doctor blade is reciprocated by hand or by any convenient mechanism. I have illustrated in Figure 3 a cam 22 bearing against a follower roller 23 on-one of the extensions 20, the cam being carried on a shaft 24 which is rotated by a drive mechanism, not shown. A spring 25 serves to return the doctor blade after each movement imparted to it by the cam. The shape of the cam may be varied so as to make the streaks irregular, as indicated in Figure l.

The doctor blade and its associated mechanism is mounted on a base plate 26 which is pivoted at 2'7. The entire base plate may be swung around the pivot 27 being held in position by bolts 28. In this manner the direction of movement of the doctor blade relative to the path of travel of the material may be varied.

The final spreading of the color is effected by a second doctor blade indicated at 30 in Figure 3. This doctor blade is shown as extending at right angles to the path of travel of the goods but it is mounted and controlled in the same manner as the doctor blade 17, so that its inclination to the path of travel and its amplitude may be varied at will.

Preferably the cams for actuating the doctor blades will be driven by electric motors having a speed control, whereby the number of reciprocations per unit of time may be varied as desired.

It will be seen that with these adjustments, coupled with the use of cams of different shapes, an infinite variety of effects may be obtained. Even with a fixed setting there is no discernible repeat in the pattern because the action of the paint guns is to some degree haphazard and the colors are so spread and blended that it is 'impossible for the eye to find any repeat in the goods.

I have illustrated and described a present preferred embodiment of the invention. It will be understood, however, that the invention is not thus limited but may be otherwise embodied or practiced within the scope of the following claims.

I claim:

1. In the manufacture of surface coverings, the steps consisting in applying color to a backing, passing the same under a doctor blade while effecting relative lateral movement between the material and the doctor blade, thereby spreading the color, and then passing the material under a second doctor blade and eifecting relative lateral movement whereby the color is further spread.

2. In the manufacture of surface coverings, the steps consisting in applying color to a backing, passing the same under a doctor blade and effectmam-so ing relative lateral movement of the doctor blade and the'material so as to spread the 6010:- into sinuous streaks, passing the same under a second doctor blade and effecting relative lateral movement'so as to further spread the colon-and varying the angularity of'at least'o'ne doctor blade relative to the path of movement 'ofthe-materi l '1 1 3. In the manufacture of surface coverings, the

steps consisting 'inapplyin'g color to a backing? passing the'same under a doctor blade and effect-j ing relative lateral movement of the doctor blade and the material so as to spread-thecolor i'ntd sinuous streaks, passing the same under a second doctor blade and effecting relative lateral movement so as to further spread the color, and varying the amplitude of said relative lateral movement for at least one of the doctor blades.

4. In the manufacture of surface coverings, the steps consisting in applying color to a backing, passing the same under a doctor blade and effecting relative lateral movement of the doctor blade and the material so as to spread the color into sinuous streaks, passing the same under a second doctor blade and effecting relative lateral movement so as to further spread the color, said relative movement of the doctor blades and the material being in a reciprocable manner, and varying the number of reciprocations of at least one of the doctor blades in a unit of time.

5. In the manufacture of surface coverings, the steps consisting in coating a backing, applying color to the coating before the latter is hard or firm, passing the same under a doctor blade while effecting relative lateral movement between the material and the doctor blade, thereby spreading the color, and then passing the material under a second doctor blade and eifective relative lateral movement whereby the color is further spread.

6. In the manufacture of surface coverings, the steps consisting in coating a backing, applying color in spots to the coating while the latter is still plastic, spreading the color into sinuous streaks, and then further spreading the streaked color by a doctor blade.

7. In the manufacture of surface coverings, the steps consisting in coating a backing, applying color to the coating while the latter is still plastic, spreading the color into sinuous streaks by means of a reciprocating doctor blade, and then further spreading the streaked color.

8. In the manufacture of surface coverings, the steps consisting in coating a backing, applying color to the coating while the latter is still plas- 1' tie, passing the same under a doctor blade and effecting relative lateral movement of the doctor blade and the material so as to spread the color into sinuous streaks, passing the same under a second doctor blade and effecting relative lateral movement so as to further spread the color, and varying the angularity of at least one doctor blade relative to the path of movement of the material.

9. In the manufacture of surface coverings, the steps consisting in coating a backing, applying color to the coating while the latter is still plastic, passing the same under a doctor blade and effecting relative lateral movement of the doctor blade and the material so as to spread the color into sinuous streaks, passing the same under a second doctor blade and effecting relative lateral movement so as to furtherspread the color, and varying the amplitude of said relative lateral movement for at least one of the doctor blades.

10. In the manufacture of surface coverings,

i the steps consisting in coating a backing, applying color to the coatingwhile'the latter-is still plastic, passing the same under a doctorbl'ade and"eifectingrelativc lateral movement of the doctor blade and. the material so as to spread the color into sinuous streaks, passing the same under a second doctor blade and effecting relative lateral movement so as to further spread thecolor, said relative movement of .the doctor blades and the material being in 'a reciprocable manner, and varying the number ofreciprocations of at least one of the doctor blades in a unit of time.

11. Apparatus :for the manufacture of patter'ned surface coverings comprising a doctor blade adaptedto'engage material moving thereunder, means-for reciprocating the doctor blade, and means for varying the direction of movement of the doctor blade relative to the direction of movement of the material.

' 12. Apparatus for the manufacture of. patterned surface coverings comprising means for advancing material, a doctor blade lying over the moving material, means for causing relative lateral movement between the doctor blade and' the material, and means for varying the speed of such movement.

13. Apparatus for the manufacture of patterned surface coverings comprising means for advancing material, a doctor blade lying over the moving material, means for causing relative lateral movement between the doctor blade and the material, and means for varying the angularity of the doctor blade relative to the direction of movement of the material.

14. Apparatus for the manufacture of patterned surface coverings comprising means for advancing material, a doctor blade lying over the moving material, and means for causing relative lateral movement between the doctor blade and the material, said means being effective for causing lateral movement in varying amounts.

15. Apparatus for the manufacture of surface coverings comprising means for moving the surface covering material, and a plurality of reciprocable doctor blades engaging said material.

16. Apparatus for the manufacture of surface coverings comprising means for moving the surface covering material, and a plurality of reciprocable doctor blades engaging said material, said blades being individually adjustable as to direction relative to the path of movement of the material.

17. Apparatus for the manufacture of surface coverings comprising means for moving the surface covering material, and a plurality of reciprocable doctor blades engaging said material, said blades being individually driven for reciprocation.

18. Apparatus for the manufacture of surface coverings comprising means for applying spots of color to the material, and a plurality of doctor blades for successively engaging the same, at least one of the doctor blades being reciprocable.

19. Apparatus for the manufacture of surface coverings comprising means for advancing a backing, means for applying wet color composition to the backing, means for applying wet color composition to the previously applied composition, a doctor blade for engaging the same as the backing is advanced, and means for reciprocating the doctor blade.

20. Apparatus for the manufacture of surface coverings comprising means for advancing a backing, means for coating the backing, means for spraying color in spots onto the coating, a doctor blade for engaging the, same as the backing is advanced, and means for reciprocating the doctor blade.

21. In the manufacture or surface coverings, the steps consisting in applying wet color to a backing, engaging the wet color with a doctor blade and eilecting relative lateral and longitudinal movement between the backing and the doctor blade so as to spread the color and, whfle the spread color is still wet, again mechanically engaging the same and further spreading it.

22. In the manufacture of surface coverings, the steps consisting in applying wet color to a backing, mechanically engaging the wet color so as to spread the same laterally and longitudinally and, while the spread color is still wet,

engaging it with a doctor blade and effecting relative lateral and longitudinal movement between the doctor blade and the backing so as to further spread the color.

diilerent portions oi the backing, engaging the wet'colorwith a doctor blade arranged at an angle to the longitudinal direction of the goods, moving the goods longitudinally under the doctor blade and laterally moving the doctor blade so as to spread the wet color.

J. CLARENCE MCCARTHY.