US2098015A - Method of making inlaid linoleum - Google Patents

Description

Nov`2, 1937. w. RowEETAL 2,098,015

METHOD oF MAKING INLAIDLINOLEUM Filed May 22, 1935 W/LL/AM ROWE. ABRAHAM BEC/f M/LLER. INVENTOR,

ATTORNE YS,

Patented Nov. 2, 1937 UNITED STATES METHOD OF MAKING INLAID LINOLEUM William Rowe, Oakland, and Abraham Beck Miller, Berkeley, Calif., assignors to The Parafne Companies, Inc., San Francisco, Calif., a corporation of Delaware Application May 22, 1935, Serial No.` 22,734

5 Claims.

exible covering materials such as linoleum, lincrusta, and the like, and particularly to the manufacture of so-called straight-line inlaid mate- 5 rials of this class. Y I

Among the lobjects of this ,invention are: To provide a method of applying tesserae of straightline material `to a backing which axes them immediately and permanently in place without the necessity of utilizing temporary holding means for this. purpose; to Vprovide a method of afxing pattern elements of straight-line material, which Iare smallA in dimension and therefore peculiarly subject toV deformatiom which does not subject 15 `Said elements to such distortions; to provide a method Ofattaching to a backing continuous, grid-like `pattern elements in the form of a matrix which will serve to position and hold in place v later applied tesserae'; and to provide a method of 20 making straight-line inlaid linoleums of intricate patterns at a relatively low cost. s

Ourinvention possesses numerous other objects and features of advantage, some of which, together with the foregoing, will beset forth in the 25 following, description of specific apparatus embodying and utilizing our novel method. It is therefore to be understood that our method is Yapplicable to other apparatus, and that we do not limit ourselves,.in yany way, to the apparatus of 30 the present application, as we may adopt various other apparatus embodiments, utilizing the method, within thescope of the appended claims. .Referring to the drawing: i Figure 1 is an isometric View showing aportion of a die of the type used for applyingnarrow pattern `elements in. accordance with this invention,ftogether.with a section of the covering material in course of manufacture. Figure 2is-a similar isometric view, partly in 40 section, `showing a form of die used in Yapplying larger pattern ,elements inf accordance with this process. Y p

Figure3 is a schematic ,diagram-'illustrating the process as used to apply a reticulated pattern or matrix to a backing, whereon the larger tesserae are laterapplied in the interstices of said matrix by hand.

Figure 4 is a similar `schematicdiagram illustrating the application ofan entire inlaid patter to a covering material by this process.

Throughout. this-specification the termV linoleum is used as a generic rather than a specific term. A s here used it applies to any ofthe flexible covering materials of the linoleum class, wherein a plastic or semi-plastic coating is ap- This invention relates to the Vmanufacture of plied to a web or backing, Whether said backing be of the conventional treated burlap or of cheese cloth, paper, impregnated felt, or any other suitable material. In like manner, the term straight-line material includes any plastic sur- 5 face coating which may be rolled into sheets from which tesserae may be cut and applied to the backing. In other words, the terms are used as 'defining the physical properties of the materials rather than their chemical composition.

Although the process of this. invention was primarily devised for use inIl connection with the processes describedin our copending applications, Serial Nos. 22,732 and 22,733, led simultaneouslywwith this application, in manufacturing embossedA inlaid linoleum of the straight-line class, such, Afor example, -as those representing ceramic tilespthe process is by no means limited to such use, but is equally vadapted to the application of patterns of anyform and to the formation of level as well as embossed surface linoleums.

Considered broadly, the process of our invention comprises overlaying ya suitable backing with a sheet or layer of straight-line linoleum material.. lCertain, portions of the overlying sheet, corresponding to the pattern elements which are to be formed therefrom, are then pressed against the backing with sufficient force to cause them to adhere thereto, the pressure at the edges of the pattern elements vin particular being sufiiciently great to cut or score the outline of the pattern elements nearly, if not quite, through its entire thickness. The interstitial portions between the pattern elements thus applied remain loose and non-adherent, and are readily stripped away from the backing veither mechanically or by hand. Tesserae corresponding to other pattern elements are then applied interstitial portions of the pattern, either by a repetition of the same processorin any otherdesirable manner, and the entire covering is then subjected to a suicient pressure to cause a slight plastic flow of the tesserae whichconsolidates them with the backing and with the edges of the contiguous tesserae, whereafter the entire material is subjected to the requisite curing process.

One of the most useful applications of this process is in the manufacture of linoleum in tile patterns. In the process described in our copending applications above referred to, the gridi like network vof narrow interconnected lines representing the lmortar between the tiles is first applied toi the backing as., a matrix, and the tesserae representing the tiles themselves are later laid in the interstices of the matrix, the

tesserae being positioned by the matrix and held in place by gravity and edge friction. The process to which this application refers is especially adapted to the application of the matrix to the backing, and is illustrated schematically in Figure 3.

In this figure the backing I is supplied from a roll 2, and on top of it is laid the sheet 3 of straight-line material, preferably directlyvfrom a pair of calendar or feed rolls 4. The straightline material 3 may be the usual linoleum composition compounded principally of blown linseed oil, rosin and cork, or it may be of any other suitable compound which may be handled in the same manner, such as the composition described in the companion case, Serial No. 22,733 above referred to.

The bacle'ng with its loosely overlying sheet of straight-line material is next passed under a press 5 which carries the cutting and afx'ing die l. In the schematic diagram, this press is shown of the roller type, which form of press lends itself particularly to a continuous process, but it is specically to be understood that the form of press which is used for applying the linoleum material to the fabric is immaterial, and may be any standard press such as is used for either cutting or printing. v f

Where the patterns to be applied constitute a matrix of the type described above, the die may conveniently be of the form shown in Figure l. The cutting element in this case is preferably a strip of steel 8 whose lower or active surface is channeled by groove 9, leaving the sharp peripheral cutting edges I0. The. groove 3 has Va depth which is equal to or slightly lessthan thel thickness of the linoleum material 3 when compacted, and the press is` adjusted so that the cutting edges lil do not penetrate the layer of fabric l. It is immaterial Whether they touch the fabric or clear it slightly, since when the. press operates the action of the die is to force the material embraced by the groove simultaneously against the fabric backing and toward the center of the pattern element, and when the die is withdrawn it leaves the material of the layer 3 deeply scored by the grooves I2 and strongly adherent to the backing in those portions lying between these two grooves. The linoleum material, whether cut completely through or not, has nonethe-less been subjected to so strong a shearing action immediately beneath the cutting edges IU as practically to leave those portions of the sheet which were not subject to the action of the die completely free, so that they may be stripped off readily by hand or machine.

It is to be noted that a die of this characterV applies the greatest pressure to the figure elements thus punched out immediately adjacent their edges. This assures that the edges will be strongly adherent to the backing, evenfthough the Vcentral portions of the figure may not be, and it follows that it is thus possible to supply suicient pressure to attach the particular pattern elements even though they may be so large that the press would not have sufficient capacity to apply the requisite pressure throughout the entire area of the figure.

it is also to be noted that this type of die, although preferable for the particular use speciiied, is not an essential to the process. Where the iigure elements are large or curvilinear in outline, dies formed as shown in Figure 2 are equally applicable, and frequently preferable. Such dies are formed by inserting sharp-edged steelor brass strength in shear, and is somewhat resilient. In

this case, the die may be in the form of a simple punch having a at surface and a substantially vrectangular cutting edge around its periphery.

The overlying linoleum material is usually so weak in shear that the yielding of the layer 3 and the backing under the application of the pressure are v sufficient to sever the pattern from the remainder of the sheet. We prefer, however, to utilize the projecting cutting edges as described.

The interstitial portions of the sheet 3 which are non-adherent to= the backing, having been stripped away, their places may be illed by tesserae 2G, previously cut to fit the interstices of the matrix, whereafter the entire covering is subjected to pressure in a suitable press, typied in the diagram by a roller 22, against which the linoleum is held by means of a pressure belt 23. Again, any form of press suitable tothe manufacture of linoleum materials of this class may be used. Suflicient pressure is applied in the press to cause a slight flow of the linoleum material comprising the various pattern elements, consolidating the contiguous edges of the various tesserae and also the tesserae against the backing. No change in the conventional curing processes is made. The process is not limited to the application of any single group of gure elements, but, after one color of tesserae has been applied, the process may be repeated with another color as is shown in Figure 4. This merely requires a duplication of certain of the parts, such as the feed rolls 4 which feed the sheet 3 of straight-line materialN to be afxed by the press roller 5 which carries the cutting and ailxing die 1.

The remaining portions of the diagram are identical with those of Figure 3, `and these elements may be duplicated as often as is neces,- sary to apply the requisite number of color elements to the pattern. Ihe dies 1, 1', etc., are of course, complementary, so that the portions aixed in one operation coincide with those which are stripped away in the preceding and succeeding ones. We claim: l

l. The method of making covering materials of the linoleum class which includes the steps of overlaying loosely a sheet of uncured straight line linoleum material upon a backing, pressing limited sharply defined portions of said sheet corresponding to the pattern elements of the completed covering against said backing to cause adherence thereto by said portions and to cause shearing of the linoleum material at the boundaries of said adherent portions, and stripping the remaining non-adherent portions of said sheet from said backing.

2.'The method of making covering materials of the linoleum class which includes the steps of overlaying loosely a sheet of uncured straightline linoleum material upon a backing, simultaneously pressing limited portions of said sheet corresponding to pattern elements of the completed covering against said backing to cause 'adherence thereto and scoring through a major portion of the thickness of said sheet around the outline of said pattern elements, and stripping from said backing the non-adherent portions of said sheet between the adherent portions.

3. The method of making covering materials of the linoleum class which includes the steps of overlaying loosel;T a sheet of uncured straightline linoleum material upon a backing, applying pressure to limited areas of said sheet corresponding to pattern elements downwardly against said backing and inwardly toward the central portions of said pattern elements to cut through the major portion of the thickness thereof and affix said pattern elements to said backing, removing the unwanted portions of the linoleum material from the backing, positioning tesserae corresponding to the remaining pattern elements in the interstices between said rst-mentioned patten elements, and applying pressure to the entire surface to cause sufficient plastic iiow of said pattern elements to fill the cracks therebetween.

4. The method of making covering materials of the linoleum class which includes the steps of overlaying loosely a sheet of uncured straightline linoleum material upon a backing, simultaneously punching tesserae corresponding to pattern elements from said sheet and pressing said tesserae against said backing to cause adherence thereto, removing the unwanted portions of the linoleum material from the backing, tting additional tesserae between the first applied tesserae, and applying suicient pressure to all of said tesserae to cause consolidation of the adjacent edges thereof.

5. The method of making covering materials of the linoleum class which includes the steps of overlaying loosely a sheet of uncured straightline linoleum material upon a backing, simultaneously punching tesserae corresponding to pattern elements from said sheet and pressing said tesserae against said backing to cause adherence thereto, removing the unwanted portions of the linoleum material from the backing, repeating each of said steps to apply additional tesserae intermediate said rst-named tesserae, and applying pressure simultaneously to adjacent tesserae to cause a flow thereof consolidating their contiguous edges.

WILLIAM ROWE. ABRAHAM BECK MILLER.

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