US2274851A - Wall covering - Google Patents

Description

Patented Mar. 3, 1942 UNITED STATES .PATENT OFFICE I 2,274,851

WALL COVERING George Schneider, Montclair, N. J., assignor to Celanese Corporation of America, a corporation of Delaware No Drawing.

Application July 23, 1938,

Serial No. 221,024

2 Claims.

composite material suitable for wall and ceiling decoration and which may be applied in a manner.

similar to that of hanging wall paper and which will have good adhesion to the surface on which it is mounted.

A still further object of my invention is the preparation of a composite material for hanging on walls and ceilings which'is substantially unaltered by atmospheric conditions, and which does not wear off from abrasion when chair backs and the like are rubbed against it, whieh may be washed with a wet cloth making it exceptionally useful in decoration of walls in public places such as bars, hotel lobbies, etc.

' limited because no satisfactory means of applying a fabric to a wall in a suitable manner was known. Tapestry and other heavy fabrics are some times applied to the walls by stretching the same in a frame and using the same as a panel but this did not give the desired effect in all cases. Other attempts were made to hang a fabric in a manner similar to that applied in hanging wall paper. The properties of the fabric are so entirely different from those of paper, however, that the effect produced was not satisfactory due to the fact that there was no suitable cementing material for the purpose. Either the cementing materials were not of a type suitable to effect adhesion between the fabric and the wall, or the cementing material penetrated the fabric and showed up on the surface as discolored blotches and-patches of glazed appearance. Furthermore, due to the porosity of fabric moisture often penetrated to the adhesive, and where the adhesive was sensitive to water, caused the fabric to peel from the wall in blisters. Another difiiculty met with was that many of the cements attempted to be employed had haddeleterious efiects uponthe fabric if the same was made of synthetic yarns as many of these cements were dissolved in solvents or swelling agents for the synthetic yarns of the fabric.

In accordance with my invention I overcome all of the aforementioned difficulties and produce a sheet material well adapted for the decoration of walls and ceilings. This material may be applied to the wall in a manner similar to that employed in hanging of wall paper and with the same -wall paper paste formerly employed. This material although it may have any suitable paper backing is preferably made with a cheap grade of paper which is adapted to form good adhesion between the paper and the surface to which it is to be attached. The fabric is permanently attached to the paper in such a manner that the adhesion is not affected by changes in atmospheric conditions and so that the supporting paper is substantially insulated from moisture applied to the wall from the fabric side when the wall covering is washed.- The fabric may be of any suitable material including those containing synthetic yarns and the method of forming the wall covering does not affect the appearance of the exposed face of the fabric.

In accordance with my. invention I produce a wall covering formed of a. composite sheet material made by laminating 1a fabric to paper by means of a layer or sheet of thermoplastic material. In carrying out this invention I apply a coating of thermoplastic material, preferably an organic derivative of cellulose, onto the paper. This paper may bethen sold to wall paper manufacturers, decorators or the like who may apply any selected fabric to the paper by passing a fabric in contact with the coated side of the paperthrough heated nip rolls of a temperature sufficient to effect anadhesion between the coating on the paper and the fabric. The coating on the paper is preferably formed of an'organic derivative of cellulose having va relatively large proportion of plasticizer, say from to 200 parts by weight of plasticizer to parts of an organic derivative of cellulose, and substantially no active solvents. Such a coating is, therefore, suitable for uniting the paper and fabric containing an organic derivative of cellulose as the heat requiredto effect the lamination need be suflicient only to soften the thermoplastic coating containing the relatively high proportion of plasticizer and lower than the temperature which will affect adversely the thermoplastic filaments of the fabric. The coating may be of any suitable thickness from just suflicient to hold the fabric together to a substantially heavy coating which, if the temperature and the pressure during the as the backing of the laminated wall covering.

For economy and for best adhesion to the wall, however. a paper corresponding in nature to a relatively cheap wall paper is mostisuited. Although this paper may lack strength, strength is not required as the fabric and coating prevents any tearing of the paper during processing and hanging. Although these cheap wall papers are greatly affected by moisture, the compositesheet if it is hung on a wall or ceiling is substantially insulated by the moisture proof coating. Other types of paper such as those ranging from the porous wall papers through wrapping papers to the relatively stiff heavy glazed craft papers may be employed.

Any suitable organic thermoplastic compound may be employed as the coating material in accordance with this invention. For instance, I may employ thermoplastic organic derivatives of cellulose such as cellulose esters and cellulose ethers. Examples of organic esters of cellulose are cellulose acetate, cellulose formate, cellulose propionate and cellulose butyrate, while examples use is toconcurrently calender a film and apply it to the paper. I have found that it is almost impossible to form by film-casting methods a film having sumciently high plasticizer content for the purpose of this invention. Thus, in attempting to apply preformed film to the paper, there results a relatively poor adhesion between the film and the paper and substantially no penetration of the film into the interstices or pores of the paper. In attempting to laminate thefabric to a paper coated with the film the same difiiculties arise. In coating paper by applying succesive coatings of thermoplastic material disolvedin a volatile solvent there are the toxic effects of the solvent and the fire hazards to be taken into consideration as well as the recovery of the solvent. Furthermore, when applying the liquid to the paper it is essential that the paper he held taut as the liquid tends, especially when applied to an inexpensive wall paper, to create a more or less crepe effect in the paper due to uneven wetting and also to shrink upon removal of the volatile solvent.

By applying the coating to the fabric'in a manner fully described in my Patent No. 2,236,766. no distortion of the paper results and the coating penetrates the paper. to a strong and of cellulose ethers are methyl cellulose, ethyl cellulose and benzyl celluou. I-may. also employ mixed organic esters of cellulose such as cellulose nitro acetate. cellulose acetyl propionate. etc. or the mixed ether esters of cellulose such as ethyl cellulose acetate. Other thermoplastic materials may be employed such as the heat sensitive syn-.

thetic vinyl resins or resins containing the vinyl radical made by condensing or polymerizing one or a mixture of vinyl acetate. vinyl chloride, vinyl alcohol, crotonol, methyl methacrylate. acrylic acid, etc.

Any desired modifying agent for the thermo- I plastic compound may be incorporated therewith prior to applying the coating to the paper. By modifying agent I mean any substance which is adapted to impart any desired properties such as softness, elasticity, flexibility, hardness, gloss, color, stability, etc. tothe finished product. Such modifying agents may be plasticizers, dyes, pigments, lakes, filling materiala'resins, oils, etc. Ehramples of plasticizers are camphor, diethyl phthalate, triacetin, dimethoxy ethyl phthalate,

tricresylphosphate, triphenyl phosphate, ethyl orthotoluene sulphonamide. ethyl 'paratoluene sulphonamide, etc. The choice of plasticlzer depends upon the properties of the thermoplastic compounds employed as the base. Oils may be -employed to provide a softening effect. amoisture proofing effect .or to prevent sticking of the plastic'material to calendars, malaxating rolls and the like. The oil employed may be a mineral oil, vegetable oil or animal oil and may be, either I oxidized or unoxidiz'ed. Olls which I have found to be particularly suitable are formal of castor oil, blown oil, oxidized olive .oil, acetylated polymerized castor oil. rape seed oil, Russian mineral oil and olive-oii. -Soaps such as lead oieate and stearafe. etc. may also be employed. Many methods may be employed for applying tive of cellulm or other thermoplastic compounds together with otherdesired constituents, but containing no, or substantially no, volatile solvents, directly to the paper by means of heat and suitable pressure and without the aid of adhesives. In order to obtain the proper bonding action and to avoid overheating of the thermoplastic composition with its consequent deleterious eil'ects the paper may be preheatedto a temperature at least equal to that required to render plastic the compositions to be applied. while the thermoplastic composition itself may also be preheated so that upon the application of pressure a firm union is obtained. After the application of heat and pressure the coated or laminated paper may be chilled in any suitable manner. This particular product of the invention is well adapted for use as a glazed paper for magazine covers. etc. in which case the coating as applied reasons would be employed for wall decorations.-

to a printed paperusually of a grade a little better than cheap wall paper which for economic By .the preferred method of this invention coating may be applied to printed paper without blurring-or marring the printing and with- 4 out the use of solvents or adhesives so that the fect the lamination of a fabric' therewith by the coating to the paper such as pressing a preformed film of thermoplastic material onto the paper or by applying successive coatings of thermoplastic material dissolved in a suitable solvent. However, the method which I prefer to 76 passing the paper and superimposed fabric, with the coated side of the paper in; the center, through heated nip rollers or by hand pressing as desired. In this manner the interior decorator is permitted a wide latitude in selecting his drapes. curtains and upholstery as well as his wall covering to obtain the desired decorative composition and the process is such that no great overhead for laminating machines is required.

The product of the present invention may be employed by establishments producing-wall coverings in which case fabrics having desired patholstery materialand the like.

terns may be laminated therewith. Furthermore, the application of the fabric to the coated paper may take place on the same machine in which the coating is applied to the paper or in sue still soft from that operation. For instance, a strip of paper may be lead through nip rollers at the end of a suitable calender in which a film is formed and then pressed with the film to form the coated paper and passed directly to a second pair of nip rollers where a fabric is pressed into the soft coating and the whole assembly then passed about a drum to chill the same after which it may be rolled into suitable size packages for distribution to decorators.

According to my preferred process foils, films or sheets of thermoplastic material are' formed in an operation which is concurrent with that in which they are applied to the paper. In this case a thermoplastic,composition in the form of a fully converted mass and in a plastic state is passed between heated rolls of a calender that are so spaced as to form the foils, films or sheets of desired thickness. The foils, films or sheets thus produced are then continuously applied to the surface of the paper to be coated and sub- Jected to the action of heat and pressure to bind the same to said surface. In this manner coatings which contain a relatively large amount of plasticizer are applied to the paper and, if de sired, so large amount of plasticizer that foils or films could not be made commercially as such without the paper backing. Furthermore, in applying the coating as a film continuously with the formation thereof a great saving in time is effected since only a short contact under pressure is required to obtain the proper bonding action, particularly when the paper is suitably preheated. By this method, due to the fact that the composition contains no volatile solvents, there are no blisters produced, and the coating is of uniform texture throughout and is free of air bubbles regardless of its thickness. Excessive heat and/or pressure is not required by this operation and there is, therefore, no danger of undue flow of material causing uneven application of the plastic composition on the paper or of deleterious effects on the paper resulting from the use of agents contained in the plastic composition.

As stated above by employing relatively large amounts of plasticizer in the coating, textile fabrics containing organic derivatives of cellulose may be applied thereto without affecting the exposed face thereof because the coating softens at a much lower temperature and the adhesion of the fabric to the paper is effected before any melting of the fabric' takes place. The fabric, however, need not be of an organic derivative of cellulose but may be of cotton. silk, wool, regenerated or reconstituted cellulose, linen or mixtures of these. The fabrics may be colored, printed or otherwise treated so that the parts thereof have a modified luster prior to lamination with the paper. In this way decorators may employ as the fabric coating for the wall the same material as was used for drapes, up-

It is not necessary, however, that the fabric be colored or printed or otherwise modified prior to lamination as this can be preformed in a. normal manner after lamination. The fabric may be of any suitable weave or stitch. For example it may be a fabric close proximity thereto that the coating is scription is given merely by way of illustration of jacquard weaves, satin, twill, taffeta, or it may be circular knitted or warp knitted or it may be' one containing a nap such as velour, velvet,

brushed-up knitted fabric, etc.

In order further to illustrate my invention but without being limited thereto, the following specific example is given:

7 Example A doughy mass consisting of parts by weight of cellulose acetate, 25 parts of dimethoxy ethyl phthalate and 75 parts of a mixture of ethyl orthotoluene sulphonamide and ethyl paratoluene sulphonamide and 5 parts of formal of castor oil is calendered in a five roll vertical calender at a temperature of C. to C. to a film .002" in thickness. A relatively inferior grade of wall paper is preheated to about 145 C. and passed with the film as it is drawn from the calender through nip rolls. The film and paper are so well bonded together that an attempt to separate the two results in a'tearing of the paper. This laminated sheet, while the film is still soft, is passed through a second nip roller, operating at about 145 C. and at a pressure of 45 pounds per square inch, together with a .tafieta fabric made of yarns of cellulose acetate. The composite sheet material comprising paper, film and fabric is then drawn over a chilling roller and wound into a package. The resulting composite material has a paper'backing suitable for adhesion to walls and ceiling by the use of ordinary wall paper paste and a face of fabric unmarred and unglazed. The composite product is supple, flexible and strong. The elements of the composite sheet material are bonded firmly to each other and will not separate when placed on a wall and subjected to great variations in atmospheric conditions.

Although one preferred formula is set forth in the above example, any suitable formula may be employed especially those referred to in my copending application S. No. 182,391 referred to above.

It is to be understood .that the foregoing deand that many variations may be made therein without departing from the spirit of my invention.

Having described my invention what to secure by Letters Patent is:

1. Composite sheet material adapted for decoration of walls and ceilings comprising a paper backing and a woven fabric facing containing filaments of an organic derivative of cellulose bonded together with a preformed film .002 of an inch in thickness containing a thermoplastic derivative of cellulose and more than '75 parts by weight of a plasticizer for every 100 parts by weight of the cellulose derivative, said paper backing being attached to the film with a strong and permanent bond without any of the material of the film penetrating to the exposed surface thereof.

2. Composite sheet material adapted for decoration of walls and ceilings comprising a paper backing and a fabric facing containing filaments of cellulose acetate bonded together with a film containing cellulose acetate and more than 75 Darts by weight of a plasticizer for every 100 parts by weight of cellulose-acetate.

I desire GEORGE SCHNEIDER.

1 CERTIFICAZI'E 0F CORRECTION. Patent no.'2; 27l ;,851. March-'3, 191m.

. GEORGE SCHNEIDEIL.

It is hereby certified that 51 1-01 appears in the printed specification of the above numbered patent requiring correction as follows: Page 1, sec- 0nd column, line 17, before the word "paper" insert wall--; page 3, sec- 0nd column, line 67, claim 2, beginning with "backing" strike out all to and including "acetate" in line 71, sanie claim, and insert instead the following --backing and a woven fabric facing containing filements of cellulose acetate bonded together with a preformed film .002 of an inch in thickness containing cellulose acetate and more than 75 parts by weightof. a plasticizer for every-I00 parts by weight of cellulose acetate, said p aper backing being attached to 'the film with a'strong and permanent bond without any df'the material of the film penetrating to the exposed surface thereof"; I

andthat-the said Lettens Patent should be read with this correction there in that the same may conform to the record of the case in the- Patent Office.-

Signed and sealed this 21st day of april, A, D. 191 .2.

Henry Van Arsdale, (Seal) Acting Connniss'ioner of Patents.