US2123646A - Method of producing felt base floor coverings - Google Patents

Method of producing felt base floor coverings Download PDF

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Publication number
US2123646A
US2123646A US204445A US20444538A US2123646A US 2123646 A US2123646 A US 2123646A US 204445 A US204445 A US 204445A US 20444538 A US20444538 A US 20444538A US 2123646 A US2123646 A US 2123646A
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US
United States
Prior art keywords
sheet
strip
design
printing
coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US204445A
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English (en)
Inventor
Neil L Campbell
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mannington Mills Inc
Original Assignee
Mannington Mills Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mannington Mills Inc filed Critical Mannington Mills Inc
Priority to US204445A priority Critical patent/US2123646A/en
Application granted granted Critical
Publication of US2123646A publication Critical patent/US2123646A/en
Priority to GB22975/38A priority patent/GB517739A/en
Priority to NL89159A priority patent/NL53036C/xx
Priority to FR843782D priority patent/FR843782A/fr
Priority to BE430383D priority patent/BE430383A/xx
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0028—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by colour effects, e.g. craquelé, reducing gloss
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1059—Splitting sheet lamina in plane intermediate of faces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702—For plural parts or plural areas of single part
    • Y10T156/1705—Lamina transferred to base from adhered flexible web or sheet type carrier

Definitions

  • one face of the impregnated felt sheet is coated with a suitable paint, usually of a solid color, to form the underside of the finished floor covering.
  • a suitable paint usually of a solid color
  • the underside of the sheet is coated with rubber or a rubber compound but which, in either case, does not enter into the present invention.
  • the second face of the felt base sheet which is to form the top, wear, or exposed surface in use is usually decorated with designs of various characters, including mottled designs, floral and/or foliage designs, blocks, tiles, etc.
  • the decoration-of the top or wear surface is usually in the form of an aggregated coating of viscous pigments arranged in laterally adjacent abutting relationto each other and collectively depicting the design.
  • the aggregating of the design elements is usually accomplished on what is known as a block printing machine, i. e. the impregnated base sheet or strip is intermittently advanced in a horizontal plane beneath a series of verticallyhreciprocable printing heads which are respectively provided on their under surfaces with wood cut blocks or flat faced pins or protuberances. Each head carries but one part of the design which is tobe applied to the wear surface of the impregnated felt.
  • the number of blocks used in completing the design depends upon the number of different colors found in the completed design, as each blockis arranged to deposit but one color in proper .position on the prepared felt base sheet as the sheet is advanced s ep by step and brought to rest under the print-. ing blocks successively.
  • a paint reservoir provided with an applying roll, is traversed beneath each block, withrthe roller. incontact with the 50' wood cut or pin faces to apply a predetermined amount of the viscouspigment to the printing surface of the block, there being one reservoir for each block to apply the particular color required for the particular part of the designcarried by 55 the block.
  • REIS SUE raised and the felt advanced one step, to bring each partly completed design into registry with the next block to receive the portion of the design depicted by that particularblock.
  • the strip After a predetermined length of the strip of felt emerges from the last printing blockthe strip is cut and the finished sheet of said predetermined length, usually a strip of approximately 80 feet in length, is carried into a suitable dryer in which the pigments are permitted to set and/or harden.
  • the coating which has been applied to the first strip by the series of printing heads or blocks is split in a median plane-between the two strips and divided substantially equally between the two strips, thereby producing two identical finished products i. e. two products finished, at least insofar as the printing or formation of the design on the two strips is concerned, it being understood that after the printing and drying of the aggregated design coating of .a felt base floor covering the printed strip is sometimes given a finished coat of transparent varnish, lacquer,
  • Fig. 5 is a perspective view, partly in section, illustrating the transfer of the pattern from the originally printed sheet to the inverted second sheet and the reversing of the second. sheet to bring the design bearing face uppermost;
  • Fig. 6 is a transverse sectional elevation taken on the line 6-6, Fig. 5;
  • Fig. 7' is an enlarged longitudinal sectional elevation of one mechanism for transferring the printed design from the originally printed sheet to the second sheet;
  • Figs. 8., 9 and 10 are enlarged longitudinal sectional views of the two sheets illustrating the manner of transferring the design from the original to the second sheet by flat, pressed contact, as in Figs. 1b and 7;
  • Fig. 11 illustrates a modification of the invention wherein the transfer is made by continuous rotary contact
  • Fig. 12 is an enlarged sectional elevation showing an intermittent rotary transfer of the pattern from the originally printed sheet to the second sheet;
  • Fig. 13 is a view similar to Fig. 12 and shows a modification of the intermittent rotary transfer
  • Fig. 14 is a view similar to Fig: 5, and shows the intermittent rotary transfer of Fig. 12 and-a modified form of sheet reversing mechanism in connection therewith;
  • Fig. 15 is a sectional elevation taken on the line i5-l5, Fig. 14;
  • Fig. 16 is a view similar to a portion of Fig. 1b and illustrates a modified arrangement for handling the second sheet between the transfer and the placing of the sheet in the drying oven;
  • FIG. 17 illustrates a preliminary step in'the handling of the second sheet, as shown in Fig. 16, or a modification thereof;
  • Fig. 18 is a modification of the invention illustrating the use of an intermediate transfer'element between theoriginally printed sheet and the second sheet;
  • Fig. 19 is a detail view showing one method and means for synchronizing the movements of the mally in the printing of felt base floor coverings,-
  • the frame I supports a rigid longitudinally extending and horizontally disposed platform 4.
  • An endless belt 5 which is provided with pins 6 at relatively spaced points throughout its length.
  • the pins 6 are adapted to pierce the strip of felt x, which is disposed on the -'platform 4, adjacent the opposite marginal edges solely of the strip in.
  • the belts 5 pass around drums or sprockets l6 which are intermittently rotatedto a predetermined extent for correspondingly advancing the sheet or strip .t step by step,
  • a series of vertically reciprocable printing blocks I, I is also vertically reciprocable with the printing blocks I, I. Also vertically reciprocable with the printing blocks I, I is a press block 8 which presses the side edges of the sheet or strip :c down onto the pins 6 of the belts 5.
  • the paint pots 9 which are .provided with rollers III for making contact with the printing surfaces II of the printing blocks I, and which, for the purpose of making-such contact, to apply the pigment to the printing surfaces llof the blocks I, are reciprocated longitudinally of the machine, beneath the printing blocks I, when said printing blocks are in a raised position is effected in synchronization with the movements of the sheet, the belts 5 and the printing blocks I by mechanism standard to the machine, and which, therefore, has been eliminated from the present drawings.
  • the strip a: is received in the form of a roll :tl which, as shown in Fig. la, is mounted on a suitable rack I2.
  • the strip :c' is threaded over and under rollers 13, i4 and I5 to and around a drum I1 and from said drum over rollers l8 and I9 to and around a roller 20 disposed adjacent the feed end 2
  • the drying oven 3 is stationary, and, as shown in Figs. 2, 3 and 4, comprises a plurality of individual compartments 25a, 25b-and 25c.'
  • the machine A is bodily moved transversely, by means .of the rollers 2 and rails 3, into the desired podtionand the cutting table 23, being provided with suitable supporting rollers 26, and if desired, rigidly connected to the frame I of the printing machine as at 21, Fig. 1b, is moved with the printing machine A into line with the compartment of thedrying oven B'which is to be loaded with strips or sheets a: after the printing thereof by the block printing machine.
  • the rack I 2 on which a plurality of the rolls :rl may be mounted, is extended vertically to provide an upper deck I2a for the reception of a plurality of rolls yi to provide the second strip or sheet 1! to which the printed pattern is to be transferred from the originally printed strip or sheet 2:, after completing of the printing of the design on the sheet at.
  • The-sheet y is led from the roll yl under the rolls l4, l4 around the roll l5 and the drum II, then over the roll i8 from which the sheet 11 passes to a roll 20a which forms one of-a series of l5 and thedrum l1, said roll and drum, or one or the other being driven either intermittently at the same rate of travel as the belts 5. or continuously to draw the strips or sheets a: and 1 off of the rolls xi, yl respectively, for feeding thereof to the rolls 20 and 200. at the receiving 'end 2
  • the strip or sheet 1 passes from a roll 28, near the delivery end 22 of the table 4, under a pair of rolls 29 and 39 which extend transversely of the machine A at opposite sides of the last of the series of vertically reciprocable heads of the machine, such as the heads which respectively carry the printing block I, and which is indicated at 3
  • which for the purpose of distinguishing from-the printing blocks I, will be hereinafter referred to as the transfer head";
  • the viscous nature of the pigments. and the condition ofthe surface of the strip 3] are such that the momentary contact causes the upper surface of the ag egated coating 2 to adhere firmly to the under surface of the strip 11, to the same degree substantially as the deposited layer sis adhering to the upper surface .”of the strip iii the deposit, and which is shown at 2
  • the efiect obtained is that the design previouslypri'nted on the strip or sheet x is transferred identically to the strip or sheet 3/. y
  • the deposits of .the viscous pigments applied by the printing blocks l are preferably heavier than would'normally be applied to a single sheet, when that single sheet constitutes the sole finished product as in the normal man- '"her of producing these products prior. to the present invention.
  • the elements 4i and 42 may be in the form of rollers driven at a peripheral speed equal to or slightly greater than the normal linear speed of the strips .1: and 1 in passing through the printing machine A, as shown in Fig. 5, or the rollersmay be mere idlers. Any suitable form of .drive may be employed for rotating the rollers 4t and 42.
  • rollers 4i and 42 are rotatably mounted in bearings 44 carried by and adiustably secured to beams 42 in the present instance.
  • the elements and 42 may be in the form of rigid bars adjustably secured to the beams 42 by clamps or other securing means.
  • and 42 are mounted on the beams 42 in such a manner that they may be moved closer together or further apart, as desired.
  • the strip a: is advanced step by step by the belts 5 and pins 6 thereon.
  • the strip 1! is correspondingly advanced by said belts and pins as previously noted.
  • a slack takeup mechanism shown in Figs. 1b and 5 is provided. This mechanism comprises a roller 5
  • revolving at a constant rate-of speed, continuously pulls the strip 1! and causes the loop
  • the strip 1! as it approaches the upper drum 4! around which the belts 26 pass, is pressed down onto the driving points or pins 25 by a pair of grooved face rollers 52 rotatably mounted adjacent the drum or sprockets 4
  • Thestrip 11 is strippedfrom the pins 25 at the lower end of the bands or belts 3
  • This incline may extend completely across the table or be arranged merely at the edges of the table and form a bridge directly above the sprockets or drums l
  • the table 22 may be completely dis-'-' connected from the frame I of the printing ma-- chine and the framework 5
  • the transfer may be made by intermittently rotating the rollers 58 and, in which case the roller 58 merely'raises ,the lower strip a: slightly above the surface of the table 4' able form of transmission mechanism, for example,.with variable speed control so that the rotation of the rolls 58 and 60 may be synchronized with the'linear movement of the bands 5, accurately, to prevent differential movements therebetween, which would result in destroying the perfect transfer of the pattern from the sheet or strip a: to the sheet or strip 11.
  • the roll as may be sup- I planted by'a platen 6
  • said platen is supported by an elevator 63. which may be supported by jack screws, wedges or other adjusting mechanism, in any suitable manner, on
  • Delicate aligning of the slfifaces may be accomplished by theprovision of shims 64 inserted at desirable or necessary points between the adjusting elevator 63 and the platen plate 6
  • shims 65 may be provided between the block 3i of the transfer head shown in Fig. 7 and the vertically reciprocating frame block 3
  • Such procedure is more particularly desirable in the; making of block designs and is not par ticularly necessary in the printing of foliage or similar designs where sharp lines of demarcation are not essential.
  • a'pigment forming such lines may be deposited separately as a last step in the completion of the printed'design andwould cover the edges of the blocks previously deposited and thus provide the clean cut lines of demarcation, representing, for example, mortar lines between blocks representing tile.
  • the deposits forming the mortar lines may be deposited i'n'the spaces 23 shown in Fig. 8 to complete the entire design surface, with all parts in actual abutting relation to each other before the transfer .of Figs. 9 and 10 is begun.
  • a transfer element intermediate the strips 4: and 1; for picking up a portion of the thickness of printed coating in toto, corresponding to the portion a2, from the coating 2 applied to the printed sheet or strip a: and carrying such portion from the strip a: to'the strip y, at a point remote from the strip :2, as shown in Fig. 18,
  • the strip 11 would be mounted on a truck ll adjustable on rails 12 transversely withrespect to the machine, beyond'the delivery end 22 of the table 4.
  • the uprights 51 of the framework 56, which support the cutting table 23, would be extended to support the transfer roll 10 and the roll 60, about which the sheet or strip 11 passes, in definite relationship to each other and properly adjusted to effect the picking up of the one half of the coating 2 by-the drum Ill from the strips: and depositing the same in toto on the strip u'passing around the roll 60.
  • the cutting table 2311., for the strip-1!, would likewise be supported in this case in superposed relation to the table 23 for the strip at, directly above the table 23, the whole structure being movable transversely. with the frame I of the printing machine A on the rails disclosed in '11 the full length of the printing machine A, in
  • the truck II in this case would be mov- 1 able relative to the frame 56' in order to replen- In place of the driving belts 3i, fcr'the strip 1!, as shown in Fig. 5, the strip 11 may be advanced either intermittently or continuously by means of a vacuum or suction'roll' I5, shown in Figs. 14 and 15, said roll comprising a perforated drum around which, throughout any suitable segment of its periphery, the strip 1! passes.
  • the opposite end of the axle 'll may be closed.
  • the closed end of the hollow shaft 'I'I may be rigidly supported against rotation in suitable bearings and power applied from a suitable source to a gear wheel 8
  • each compartment may contain eighty shelves with each shelf adapted to accommodate a complete strip of finished floor covering which, as noted above, in commercial practice are each eighty feet long.
  • the dryer may include any number of compartments.
  • the printing machine is aligned first with-one compartment and the individual strips or sheets are drawn fromthe cutting table 23 and fed onto the shelves 85 of the dryer 3 until the one compartment is completely loaded, after which the whole machine is moved laterally into alignment with the next compartment for loading the same while drying is being effected in the previously loaded compartment.
  • PIhe machine is moved relative to the dryer for the loading of each of the successive compartments and after the drying is completed in the first loaded compartment 'thedried strips are removed therefrom, leaving the compartment vacant for reloading after the last of the compartments of the dryer has been filled with freshly printed strips. whereupon the machine is moved back into line with the emptied compartment for a repeat of the operations.
  • the sheetjl. as shown in Fig. 16 may be hung in festoons over poles" prior to being drawn into the dryer B, thereby eliminating the necessity for the reversing mechanisms of Figs. 5 and 14. in which case the strip 11 after receiving the transfer is drawn backwardly with its printed side upwardly across the poles 90 and hung in festoons therebetween, as shown in Fig. 16 or permitted to lie flatly over the poles or over slats extending from pole to pole as shown in Fig. 17, until the full length of a strip has been completed, whereupon the cable 82 may be connected to the one end of the strip 11 and the strip drawn in a reverse direction overthe poles 90 and directly into the drying compartment.
  • the cable 82 may be connected to the one end of the strip 11 and the strip drawn in a reverse direction overthe poles 90 and directly into the drying compartment.
  • both strips may be of lesser width, i. e. instead of being nine feet in width they may be only six feet in width.
  • the conventional machine A described above is normally adapted to accommodate strips of' varying widths, and for this purpose one or both of the drive bolts 5-, i and their drums I, are shiftable laterally with respect to the table 4, as is common in machines of this type,
  • t e strip 1!. between the drive belts 38, 36 is supported by a slatted or other platform 9
  • the shafts which support the sprockets or drums which drive and support the belts 36, 36 are of a three-part telescopic form with the two ends keyed to the drum respectively and with sleeve sections 93 splined to the two end sections so that the drums and their respective shaft sections may be moved toward and away from each other as shown in i Fig. 6.
  • said design on said seccoverings which consists in printing a design on one face-of one prepared base sheet in the form of a viscous coating of predetermined thickness, bringing one surface of a second prepared, base shejet into intimate contact with the exposed surface of the printed coating on the first said sheet, splitting the coating intermediate said sheets, and separating said sheets with the divided portions of the thickness of said coating adhering to said sheetsrespectively, whereby the design originally printed on the first sheet is transferred in toto onto the second sheet and two duplicate finished floor coverings are produced from a single print ing of the design on but one of said base sheets, said design on said second sheet being in reversed position with respect to the design on the first mentioned sheet;
  • the method of producing hard surface floor coverings which consists in printing a design on one face of one prepared'base sheet in the form of a viscous coating of predetermined thickness, subsequently transferring a portion of said thickness of said coating in toto onto one face of a second prepared base sheet, whereby said design is duplicated in toto on both base sheets as a result of asingle printing of said design on but one of said base sheets, said design on said second sheet being in reversed position with respect to the design on the first mentioned sheet, reversing the position of the second of said floor coverings relative to the' first thereof aftervsaid transfer to bring the transferred coating uppermost for drying of the same with the floor covering support-ed from below, and feeding the two finished fioor coverings simultaneously into a dryer for setting the divided portions of the coating respectively adhering to said base sheets.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Printing Methods (AREA)
US204445A 1936-04-28 1938-04-26 Method of producing felt base floor coverings Expired - Lifetime US2123646A (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US204445A US2123646A (en) 1936-04-28 1938-04-26 Method of producing felt base floor coverings
GB22975/38A GB517739A (en) 1936-04-28 1938-08-03 Process of manufacturing felt base floor coverings
NL89159A NL53036C (en:Method) 1936-04-28 1938-08-04
FR843782D FR843782A (fr) 1936-04-28 1938-09-22 Procédé de fabrication de revêtements de planchers à support en feutre
BE430383D BE430383A (en:Method) 1936-04-28 1938-09-27

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US517739XA 1936-04-28 1936-04-28
US204445A US2123646A (en) 1936-04-28 1938-04-26 Method of producing felt base floor coverings

Publications (1)

Publication Number Publication Date
US2123646A true US2123646A (en) 1938-07-12

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ID=26729814

Family Applications (1)

Application Number Title Priority Date Filing Date
US204445A Expired - Lifetime US2123646A (en) 1936-04-28 1938-04-26 Method of producing felt base floor coverings

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US (1) US2123646A (en:Method)
BE (1) BE430383A (en:Method)
FR (1) FR843782A (en:Method)
GB (1) GB517739A (en:Method)
NL (1) NL53036C (en:Method)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2827103A (en) * 1955-03-31 1958-03-18 Armstrong Cork Co Method for producing turn-block pattern floor covering
US3434862A (en) * 1966-02-11 1969-03-25 Jane Luc Decorative process

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1171391B (de) * 1958-09-20 1964-06-04 Haas Friedrich Maschf Mansarde, insbesondere zum Trocknen von einseitig bedruckten Textilbahnen
DE1117077B (de) * 1959-03-05 1961-11-16 Dornier Gmbh Lindauer Anlage zum Daempfen und Speichern von Textilgut

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2827103A (en) * 1955-03-31 1958-03-18 Armstrong Cork Co Method for producing turn-block pattern floor covering
US3434862A (en) * 1966-02-11 1969-03-25 Jane Luc Decorative process

Also Published As

Publication number Publication date
NL53036C (en:Method) 1942-09-15
FR843782A (fr) 1939-07-10
GB517739A (en) 1940-02-07
BE430383A (en:Method) 1938-10-31

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