US2140196A - Method of making wall tile sheets - Google Patents

Description

Dec. 13, 1938'. c. BATCHELLER Y ,1 I METHOD OF MAKING WALL TILE. SHEETS I I Filed July 6, 1935 2 Sheets-Sheet 1 Ill/11111111111111. 4

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METHOD OF MAKING WALL TILE SHEETS Filed July 6, 1935 2 Sheets-Sheet 2 //v VEN 7-02 Z'LEMENTS EA TZI'HELLER' 4 TQ/P/VE Y6 Patented Dec. 13, 1938 UNITED STATES PATIENT OF'FIC E 12 Claims.

My invention relates to wall-tile sheets and particularly to improvements in the method of scoring and pressing the same whereby certain defects which are inherent in tile sheets of this character as made by present processes are eliminated.

One of the methods employed at present in the art of producing tile outlines on the surface of a cement asbestos sheet is to take such a sheet after it has become sufficiently hydrated, place it upon a moving table under a set of evenly spaced abrasive cutting discs and grind the tile outlines therein by moving the sheet under the cutting discs. Sheets scored in this way are mually scored upon 4" centers and after the sheet is scored in one direction, it is turned and scored in the other direction so that the surface is divided into a plurality of 4" X 4" tile outlines. Such Wall-tile sheets are furnished to a standard size of 32 1:48 to match the usual. wall frame. It

will be apparent that the scoring of the surface of a sheet of this size must always be either on 4 X 4 or 8" x 8" centers to produce tile effects to these over all dimensions.

This method of producing a scored tile outline in the product, in addition to requiring much costly supplemental labor, also creates certain serious defects in the sheet. For example, all of the wall tile sheets that have been produced up to the time of the improvements in the art described in my copending application Serial No. 30,195, have been surface colored by a seriesof pyroxylin undercoats, pigmented lacquers and clear lacquer coats. When such sheets are finally wheel-cut as above described, there is a very pronounced tendency for the hardened color lacquer film to chip away at the edges of the scored groove and thus disfigure the finished product.

To eliminate defects of this character, Walltile sheets have also been produced .by impressing the tile outline in the surface of the sheet while it is in an unset plastic state and by the use of specially prepared steel press plates which carry the tile outline. After the wall-tile sheet is finally lacquer-color-decorated a pin-stripe of white lacquer is applied to the pressed grooves by means of a special air spray gun. It is obviously more expensive to produce tile outlines by this method than by the method first described, and while the tiles are clearly outlined, the method isa purely superficial painting job and the result is a poor simulation of the usual plaster or cement joint characteristic of individual tile settings.

My invention not only completely eliminates such defects as are always apparent in products made by the above methods, but, in addition, permits the making of wall-tile sheets which are decidedly better copies of individually set tile. Furthermore, by my methods, it is possible to produce wall-tile sheets having staggered joints which cannot practically be produced by any method of Wheel scoring. By my method, 4" X 4", 8" x 8", or 3" x 6".tiles withstaggered joints can be simulated.

By combining the features of the invention described in my United States Letters Patent No. 1,995,412, with the invention .described in my copending application Serial No. 30,195 and the invention. described herein, wall-tile sheets very closely simulating a section of individually set tiles of marble or other stone can be cheaply produced.

In the drawings- Fig. 1 is a plan view of a conventional wall-tile sheet 32" .X 48 (finished size) grooved to represent 4" x 4" individual tiles, and resting upon a steel pressingplate;

Fig. 2 is a sheet similar to ,Fig. 1 but drawn to a scale approximately one-half the size of Fig. 1 and showing .a sheet divided into 8" x 8" tiles with staggered joints;

Fig. 3 shows a sheet 48" X 48 scored to represent individual tiles 3" x 6" in size set with staggered joints;

Fig. 4 is a fragmentary section to an enlarged scaleof Fig. 1 in the plane 44;

Fig. '5 is a fragmentary section to an enlarged scale of Fig. 1 in the plane 55;

Fig. .6 is a fragmentary section to an enlarged scale of Fig. 1 in the plane66 Fig. 7 is a fragmentary section of a mask for 4" x 4" tiles;

Figs. 8, '9, 10, 11 and 12 are fragmentary sec- I tions to an enlarged scale of Fig. 1 in the plane 88 showing the tile sheet at various stages of its production;

Figs. 13 and 14 are fragmentary sections to an enlarged scale showing a modified procedure; and

Fig. 15 is -a fragmentary elevation view, partially in section, illustrating how my sheets are pressedin stacked form.

In scoring wall-tile-sheets according to my improved method I utilize a mask which is blank cut to cover only those zones of the sheet which are intended to separate the tile units or, in other words, the mask is cut to represent the tile outline desired in the finished product. Such a mask is preferably made from sheet steel, and due to the fact that my finished product is only about A; in thickness, the thickness of the steel mask should not exceed about While such a mask will produce, to a degree, the results which I wish to accomplish, I have found that a secondary mask of fairly heavy paper and having a rugose or pebbled surface, coated, if desired, with a soluble dye of appropriate color which is stable, in the presence of the alkali in the cement, is preferably used; the purpose of the dye being to impart a color to the simulated cement joints which outline the individual tiles. This secondary mask is of exactly the same size and outline as the steel mask and is attached thereto with any readily soluble adhesive to form that side of the mask which comes in contact with the plastic sheet. A fragmentary portion of such a composite mask is shown in plan view at I in Fig. '7 and in enlarged sectional views in Figs. 8 to- 12. In the sections, 2 represents the metal portion of the mask and 3 represents the paper portion.

In carrying out my invention a suitable plastic cement composition, preferably that disclosed in my Letters Patent No. 1,995,412 and containing asbestos fibres, calcined magnesite, and a minor portion of bentonite, and in which a portion of the calcined magnesite may be replaced by Portland cement, is rolled into base or backing sheets of the desired size. These sheets 4 are placed upon steel press plates 4', which should be about 34" x 49" in size where a finished sheet of 32" x48" is desired. Upon the surface of each plastic sheet resting upon its steel press plate is laid the composite mask above described with the paper face down, and a series of such sheets, each resting upon its steel press plate and carrying upon its face a composite mask, is built up vertically into a stack. At the proper height, the stack is placed under a hydraulic press and subjected to a moderate pressure sufficient to embed the masks in the plastic sheets beneath as shown in Fig.'l5. The stack is then withdrawnfrom the press and broken down.

Fig. 8 shows a fragmentary portion of the plastic sheet with the mask I resting thereon, and Fig. 9 shows how the mask is embedded in the sheet after it has been subjected to moderate pressure. The sheet is now ready to be surfaced.

My preferred procedure is to place a screen box, shown. in fragmentary dotted outline at 8 in Fig. 9, over the mask; it being understood that this box is an open screen conforming in plan to the mask and resting thereon to form a plurality of compartments into which the material for the surface is placed and which serves merely to prevent the surface material from. being deposited on the mask. A dry mixture of suitable materials such, for example, as disclosed in my copending application Serial No. 30,195 and comprising principally marble dust and calcined magnesite with minor portions of Portland ce ment and bentonite, and with or without a color pigment, is distributed uniformly in the compartments. The screen box is then removed leaving the surfacing material 5, as shown in Fig. 10, only on those portions of the'base sheet which are to'form the individual tiles.

' The stack of sheets is then rebuilt and placed in a hydraulic press where it is subjected to pressure of the order of about 4000 pounds .or more per square inch. This pressure will effect a concretion of the surface material with the material of the plastic sheet and the whole will be compacted into a dense mass such as shown in Fig. 11. This pressure also causes the sheet to increase somewhat in size laterally so that the sides extend out to about the position of the dotted lines 6 and 1 shown in Fig. 1. It is to be understood that .by the term concretion I mean that the surfacing material 5 is forced into and coalesces with the base material of the plastic sheet to form an integral unit.

After the sheets are removed from the press and unstacked, the steel mask sheet is carefully removed. Because of the solubility of the adhesive with which the paper portion of the mask was attached to the metal portion, the metal portion can be removed without removing the paper portion which latter is permitted to remain in the grooves for a very definite purpose and is not finally removed until the sheet is completely finished.

After removing the metal portion of the mask the sheets are subjected to a curing treatment in the usual moist room, and, when thoroughly hardened by the curing treatment, may be surface polished by roller bufiing, wheel polishing, sanding, etc. They may likewise be surface treated, impregnated or further colored by any means as outlined in my Patent No. 1,995,412 or in my copending application Serial No. 30,195.

By reason of the fact that the paper mask is allowed to remain in the pressed sheet until after the final finishing operation, it serves to protect the white tile outline which has been pressed into the sheet surface from discoloration or other damage. After the wall-tile sheet has been otherwise completely finished, it is a simple matter to remove the paper mask and a clear-cut white tile outline will be found beneath.

I prefer that the paper used in the mask shall have a rugose or pebbled surface for the purpose of imparting a roughened surface to the tile outline so that a more natural simulation of the usual white plaster joint is attained. This effect is entirely lacking where the tile is scored by an abrasive wheel.

After the sheets are finished the overlapping portion 9, included between the solid line I!) and the dotted line H, is cut off by sawing or otherwise, and at the other lateral edge of the sheet, the portion I2, included between the solid line I3 and the dotted line I4, is also removed.

This leaves along the left hand side edge of the sheet as shown in Fig. 1 a depressed ledge I5 of the same width and depth as the grooves 16 (see Fig. 4), so that a uniform tile effect may be attained by abutting two or more sheets together laterally. It is understood, of course, that the tops and bottoms of the sheets are also cut to the proper size. 7

While, as stated above, I prefer to apply the top mixture in dry form, it will be apparent that this is not absolutely necessary. Instead, I may proceed as follows:

After, or simultaneously with the formation of the base sheets, I may form thin plastic sheets I6 of the mixture intended to form the tile faces or surfaces and of a size coextensive with the base sheets. These face sheets are then placed upon the base sheets as'shown in Fig. 13, and a composite mask is placed on top of each face sheet; it being understood, of course, that .the base sheets are resting on steel press plates. p

A stack of these sheets, each resting upon its steel plate, is then made up and subjected to pressure of the order of about 4000 pounds per square inch which will effect a concretion of the face and base sheets into an integral unit-and embed the mask therein. After the stack is broken down the steel portion of the mask is carefully removed and the sheets are cured and surface finished before removing the paper portion of the mask.

When this procedure is followed it will be apparent that the paper portion of the mask should always bear on its outside face a soluble dye l! of appropriate color to set-off the simulated joints between the tiles in contrast to the color of the tile units. Due to the highly absorptive character of the material forming the face or surface of my sheet this soluble dye will .penetrate it to an appreciable extent and will not be merely transferred to the surface thereof.

While I have described my invention in its preferred embodiments, it is to be understood that the words which I have used are words of description rather than of limitation. Hence, changes within the purview of the appended claims may be made without departing from the true scope and spirit of my invention in its broader aspects.

What I claim is;

1. Those steps in the method of making a wall-tile sheet which comprise forming a backing for said sheet from a suitable plastic composition, covering the zones separating the tile units to be formed on said :sheet with a mask comprising two separable layers of material, forcing said mask into said plastic backing by the application of moderate pressure until the surface thereof is substantially flush with the surface of said plastic backing, applying to said masked backing, while plastic, the material constituting the face of said tile and concreting it with said backing by the application of substantial pressure, removing one of the layers of said mask and subjecting the sheet to a curing treatment, and thereafter subjecting the sheet to a surface finishing treatment before removing the balance of the mask.

2. Those steps in the method of making a Wall-tile sheet formed of a plastic cement composition to define separate tile units therein which comprise embedding in said sheet while plastic by the application of pressure and in the zones intended to separate said tile units, a mask comprising separable layers of sheet-material, removing the upper layer of said mask material, subjecting the sheet with the lower layer of mask material therein to a curing treatment to effect a hardening thereof, subjecting the sheet to a surface finishing treatment and thereafter removing the balance of the mask.

3. Those steps in the method of making a wall-tile sheet formed of a plastic cement composition to define separate tile units therein which comprise embedding in and substantially flush with the surface of said sheet while plastic by the application of pressure and in the zones intended to separate said tile units, a mask comprising an upper layer of sheet metal and a lower layer of paper, removing the metal portion of the mask from said sheet while plastic while allowing the paper portion to remain, subjecting the sheet to a curing treatment, subjecting it to a surface finishing treatment and thereafter removing the paper portion of the mask.

l. The method of making a wall-tile sheet which comprises forming the body of said sheet from a plastic composition containing principally asbestos fibres and calcined magnesite with smaller portions of Portland cement and bentonite, covering the zones of said body intended to simulate the joints between the tile units to be formed thereon with amask comprising two separable layers, forcing said .mask into said body while plastic 'by the application of moderate pressure thereto until the surface thereof is substantially flush with the surface of said plastic body, applying a layer of a dry mixture containing principally :comminutedmarble and calcined magnesite with smaller portions of white Portland cement .and .bentonite, over said body with the mask-therein and concreting said mixture and said plastic body together by the application of substantial pressure to form a hard compact unit, then removing the top layer of said mask and subjecting the sheet to a curing treatment with the lower layer of said mask therein, .and thereafter surface treating said sheet and removing said lower mask layer.

5. Those steps in the method of making a wall-tile sheet which compriseforming the sheet of a plastic cement composition, placing a mask comprising two separable layers of material over those zones intended to simulate the joints between the tile units to be formed in said sheet, simultaneously forming said units and said joints by subjecting the whole to substantial pressure to force said mask into said sheet until its surface is substantially flush with the surface of said sheet and thereafter to effect a compression of said composition into a dense unitary product, removing the upper layer of said mask and subjecting the sheet to a curing treatment, and a surface finishing treatment and then removing the bottom layer of said mask.

6. The method of making wall-tile sheets which comprises forming a plurality of said sheets from a suitable plastic composition, placing each of said sheets on a suitable support, placing a mask over those zones of each sheet intended to define the boundaries between separate tile units thereon, superposing said plastic sheets, with their supports, one upon the other, to form a stack, subjecting said stack to comparatively low pressure but sufficient to force each mask into its respective sheet until the surface of said mask is substantially flush with the surface of said sheet, removing said supported sheets from the stack and applying thereto the material intended to form the face of said tiles, rebuilding said stack, and subjecting it to comparatively high pressure sufficient to concrete the facing material with the body of said sheets and to compress each sheet and facing into a dense unitary structure, and thereafter removing said masks.

7. The method of making wall-tile sheets which comprises forming backings for a plurality of said sheets from a suitable plastic composition, placing each of said backings on a suitable support, placing a mask over those zones of each backing intended to define the boundaries between separate tile units thereon, superposing said backings with their supports, one upon the other, to form a stack, subjecting the stack to comparatively low pressure but sufficient to force said masks into said plastic backings until the surface of each mask is substantially flush with the surface of its respective backing, removing the supported backings from said stack, applying a dry cementitious mixture adapted to form the face of said tiles to the unmasked portions of said backings, rebuilding said stack, and subjecting it to comparatively high pressure sufficient to effect a concreting together of the facing and backing material into a dense unitary structure, and thereafter removing said masks.

. faces with said backing by the application of pressure sufficient to effect a coalescence of said facing material and said plastic backing into a dense unitary sheet, and thereafter removing said mask.

9. Those steps in making a wall-tile sheet comprising a plurality of layers of water plastic cement composition whereby said layers are concreted together and separate tile units are simultaneously outlined therein which comprises placing a mask having a water-soluble dye on the lower side thereof over those zones of said sheet intended to represent the boundaries of said. units, subjecting the whole to pressure suflicient first to completely embed said mask in said plastic material whereby said dye will be dissolved by the water in said composition and penetrate said plastic to a substantial depth and then to concrete the plastic layers in the unmasked zones into a dense unitary structure, and thereafter removing said mask.

10. Those steps in the method of making a wall-tile sheet as an article of commerce which comprise forming a backing for said sheet from a suitable plastic composition, covering the zones separating the tile units to be formed on said sheet with a mask, forcing said mask into said plastic backing by the application of moderate pressure until the surface of saidmask is substantially flush with the surface of said backing, applying to said masked backing while still plastic a dry mixture of materials constituting the faces of all of said tile units, simultaneously concreting all of said faces with said backing by the application of pressure suflicient to effect a coalescence of said facing material and said plastic backing into a dense unitary sheet, and thereafter removing said mask.

11. The method of scoring and simultaneously coloring the scores in a wall-tile sheet formed of a water-plastic cement composition to define separate tile units thereon which comprises forcing into said sheet, while plastic, and in the zones thereof intended to separate said tile units, a mask bearing a water-soluble dyeupon the embedded face thereof, whereby said dye will be dissolved by the Water in said composition and penetrate said plastic to a substantial depth, an thereafter removing said mask.

12. The method of making a wall-tile sheet which comprises forming a backing for said sheet of suitable plastic material, forming a facing for said sheet of plastic material suitable therefor, placing the facing on said backing, and si-, multaneously scoring said facing and applying a contrasting color to said scores to simulate joints between individual tile units by covering the zones of said facing to be scored with a mask carrying upon its face adjacent said facing a water-soluble coloring material, subjecting the whole, while plastic, to pressure suificient to force said mask into said facing until the face thereof is substantially flush with said facing and to compact and concrete the facing and backing together into a hard, dense, unitary structure, and thereafter removing the mask.

CLEMENTS BATCI-IELLER.

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