US2317504A - Artificial fiber board - Google Patents

Description

April 27, 1943. H. E. WALTER ARTIFICIAL FIBER BOARD Filed Feb. 5, 1940 2 Sheets-Sheet 1 2 SheetsSheet 2 H, E. WAYLTER ARTIFICIAL FIBER BOARD Filed Feb. :5, 1940 April 27, 1943.

Patented Apr. 27, 1943 2,317,504- ARTIFICIAL FIBER BOARD Henry E. Walter, Cloquet, Minn, ,assignor to Wood Conversion Company, OIoquet, MimL, a

corporation of Delaware Application February 3, 1940, Serial No. 317,063 7 Claims. (CI. 41-24) Th present invention relates generally to I marking temporarily plastic material in the proc-' ess of manufacture to produce permanent markings. It has particular reference to the manuiacture of fibrous felts, such as thick paper or artificial board to give decorative surfaces.

The use of artificial board for walls in certain places is limited by the fact that the common boards giving a desirable fibrous texture are too soft, at the surface to resist scarring and sending, and are not sufficiently resistant to water to avoid spotting and to permit washing. Thus, for example, in the position of Wainscot, boards of desirable decorative appearance lack qualities for such usage. The present invention aims also to produce wall boards which are suitable for use as decorativev Wainscot.

One object of the present invention is to produce intaglio impressions not of a definite pattern, but of a characteristic appearance in nonrepetitive form; and to provide a means for that end.

Another object of the invention is to produce such boards with a hard surface which is resistant to spotting with water, to marring and scuffing, and which may be washed. 1

A particular object is to produce a decorative Wainscot panel of the fibrous wallboard type.

The invention will be described with particular reference to artificial board made from an aqueous slurry' of fibers, but it is to be understood, and it will be pointed out, that it has otherapplications; and that the device of the invention, and the manner of using it may vary considerably. Havirlg reference to the accompany drawings, the invention will he illustrated and explained as it is applied in marking artificial board In the drawings:

Fig. 1 is a reproduction of a photographed pic In order to attain a non-repetitive pattern the impression means is multiple and each element is in part mobile and free to assume different positions. Each element is also in part constrained and fixed in part with respect to a carrier of the multiple elements, so that there is pro duced by the constraint, a generalidentity, or individual character in the design, and a pleasing non-repetitive variation in the design produced by the mobile parts. I

This is readily accomplished where a design of lines is desired, by having one or more carrier elements to which a multiplicity of strands or cords is attached at points spaced along the strands or cords, each strand or cord being loose relative to the carrier between each two adjacent spaced points of attachment to the carrier, the looseness being due both to non-attachment to the carrier and to the cord or strand having a length greater than the distance measured in the carrier between adjacent points of attachment. Therefore, when the carrier is taut, the strands are not taut, and they may assume any free position between the points of attachment.

The carrier is one or more elements adapted to be pulled taut, in one direction. The carrier is preferably a sheet backing. It may be a felt, or canvas, or rigid or flexible net, or merely be a plurality of parallel cords without lateral connections between them in the area used for impressions. The latter arrangement, and a coarse netting, can therefore be used in a taut position with varying widths coverable by the same backing, giving a finer. or coarser pattern in the lateral direction.

The strands or cords may be of fiber; such as rope, yarn or cord, or flexible wire or even rubher, and the latter may be smooth or marked, as desired. One strand, for example, may be attached to the backing at evenly spaced intervals in a straight line, running generally in the direction of the taut backing, or definitely angular to it, or in some irregular line. Other cords may have an exactly similar attachment, and all points of attachment be arranged in parallel lines across the taut length. Some may be staggered with respect to others. There may be strands across the taut length. These may be attached to the backing, or even be a part of the backing, as

where a coarse net is'used, and not stretched laterally when it is pulled taut lengthwise.

In other words, the character of the backing, or the manner in which it is applied as a carrier, coupled with the pattern of the fixed points of attachment, is the means to;provide the desired character or general identity to a design. The manner in which the cords or strands are free to assume difierent positions, is the cause of variation in the pattern, and the particular cause of a non-repetitive pattern.

In order to avoid showing the many possible variations of the pattern, one illustrative form is selected, which gives a pleasing effect. In Fig. 2.there is shown a carrier which is a coarse net having a warp of heavy cords l adapted to be pulled taut to apply the carrier. Lighter weight transverse cords II are shown and at the intersections, any type of connection may be applied. When the net is expanded laterally to the full permissible width the transverse cords ll will be taut, but for the purpose of illustration the net is shown slightly contracted laterally wit a taut warp, whereby the transverse cords tween the warp cords are irregularly arranged, and will make a variable design where they may penetrate the plastic material.

In Fig. 3 the diagrammatic block l2 indicates the edge of a carrier, and the single cord II thereon is representative of the strands which make the design. Cord II is shown with three spaced attachments II, I! and ii, of which I! and II are points, while I4 is a length of cord l3 secured to carrier l2. On any carrier, the places of attachment, like It and It, may be repetitive or non-repetitive in design. The repetitive design for attachment may be such as to give always an individual characteristic to the resulting effect, with uncontrollable variations from the loose parts. In Fig. 2, the strands or cords are designated l1, and the places of attachment are points iii, in a row across or otherwise disposed on the backing. Each strand I1 is shown with its series of spaced attachments alined, not in a straight line, but in staggered relation, with looseness of strand between adjacent points in the taut carrier. Thus the strands may fall into wavy lines generally, but not mathematically or regularly, or repeatedly. From the foregoing it is obvious how the arrangement may be varied.

Where the carrier or backing is a flexible sheet relatively closed, like canvas, the strands are located on the impressing surface thereof. But where the carrier is more open, like a net, the strands may be on either side thereof, or both sides. Where the strands cross the net on the non-impressing side, the cords of the net may be utilized as part of the impression means. Likewise, the cords of the net may function where they are exposed on the impression side, between strands l'l.

Fig. 4 represents one way in which such an impression fabric may be used in a continuous machine for making artificial board,

Numeral indicates a Fourdrinier or forming wire or screen on which the wet fiber mat 2| is formed and on which it is yet quite plastic through the retention of water. This screen runs along over supporting rolls 22, then through a set of heavier press rolls 2! and 24, lighter press rolls 26 and 21, heavy squeeze rolls 2!,and 28, and a second set of squeeze rolls 20 and II. The wire returns over the lower roll 20, and the moist or damp fiber layer 32 is quite self-supporting, and ready to be dried. As the plastic mat 2| enters these rolls it receives on its top a stretch of an endless impression carrier 32 according to this invention, and an endless thick felt 24 which takes up water squeezed out. Rolls 3|, 3! and 20 carry the felt 24. Rolls ll, 25, 21, it, 3!, and II carry the impression blanket. Roll 30 depresses the blanket into washing tank 42, so that it may be cleaned of adherent fiber to assure impressions now set in the mat. Then the board goes to drier N.

In the manufacture of board as described in the machine of Fig. 4, it is obvious that the felt 34 may itself provide the carrier generally described without departing from the invention. A separate carrier is preferred for many reasons. It is also to be understood that in many boardmaking machines there is used a top-wire as well as the lower forming-wire. The top-wire also may be used as the carrier for the present invention.

It is further to be understood that I have described the invention in terms of carrier" and loose elements in order to explain clearly the function as a carrier, and belong to set I] at is used again. At the roll II the loose impression material is removed from the permanent another part of the structure to function as a mobile element. It is therefore to be understood that the invention in its broadest aspect provides a marking structure which as a whole is capable of being pulled in a taut relation to fix the position of the flxations of the mobile elements, so as to present mobile elements for self-positioning. The pattern designed, and the questions of construction with ease and economy determine the exact construction of the device.

It is of course to be understood that a single length (not an endless belt) of impression blanket, may be used where a non-continuous process is used. For example, it may be used in the press shown in U. S. Ziska Patent No. 1,690,152, which is used in an intermittent operation in making artificial board, serving at the same place as the press rolls above described.

In the preferred operation of the process, the wet board marked as above described, is dried by the use of a drier whichhas hot flattening or pressing means. These operate to reduce the higher spots to the same level, giving a uniform caliper to the board. The depth of the depressions in the surface from the caliper surface has a great eifect upon the appearance of the board for ornamental effect. When the depressions are of depth of about 0.02 inch, the depression becomes capable of indicating high lights and shadows on proper lighting, such as any wall is normally subjected to. This is practically the minimum depth, but of course, the high lights and shadows depend upon a rather abrupt drop in the surface from the caliper level or any lower general level, adjacent the depression. It isthe form of the depression and the size and depth as well, which are factors to give this eflect.

For a board involving the present invention the depth of the depressions may vary from .005 to .04, with a predominant number of them from .02 to .04 inch deep to give high lights. The width of the depressions may vary up to twice the depth to give the high lights and shadows, and preferably the width is not greater than the depth.

The board with the design illustrated is particularly useful for Wainscot, with the lines of the pattern running vertically. In such use it is subjected to considerable scufling. Therefore, it is desirable to increase its utility by v pressed mat before drying.

hardening the surface. This may be done by a coat of paint, varnish or other substance applied to the dry board. It may also be done by applications of suitable coating to the wet im- Such coatings may contain pigments to cover the fibers, as described in the copending applications which may later be referred to. 'Theseinclude aqueous base coats of pigments and binder, which binder may be protein, resinous, starch, or other s able substance. However, the board may be coated with a non-pigment material effective to harden the surface of the board.

For example, a drying oil may be applied in the form of an oil emulsion, under conditions to induce drying or hardening of the surface while the processing of the board is being completed. By incorporating a drying oil and a drier in an aqueous emulsion, the emulsion may be spread onto a wet mat which ultimately provides the board with the oil limited to and concentrated in the surface layer of the board. Thus, the wet mat before or after the making of design impressions, is treated with such an emulsion, so thatv in hot pressing the board the oil is hardened while the fibers are still wet in the coreof the board, thus concentrating the cu. ft. It may be applied up to'30 pounds per 1000 sq. ft. and in practice from 11 to 22 pounds of China-wood oil is used for such wood fiber boards. i

A suitable emulsion is as follows:

Per cent by weight Water 69.4

China-wood nil 27.8 Japan drier 2 Sodium carbonate .4

Dyestuifs (for color) .4

The sodium carbonate and water at 90 to 110 F. are used as a liquid vehicle to which the mixed and oil are added with emulsifying agitation. Not only'the vegetable drying oils such as Chinawood oil, soya bean oil, linseed oil, perilla oil, 'oiticica oil and others may be used, but also the synthetic drying oils produced from non-drying vegetable oils and from petroleum and other bydrocarbon bases; By the term drying oil as used herein is meant any oil not miscible with water which by oxidation, with or without a drier, will form a solid substance, as in paint.

The oil emulsion may be used before or after the impressing of a design into the board, so long as it is applied while the board is wet. The

Such a a finished board of which the. natural surface felt is cut to make a design.

The present application is a continuation in part of myapplication Serial No. 220,355, filed July 20, 1938. The subject matter relating to the use of drying oil is describedand claimed in my 4 application Serial No. 317,105, filed February 3,

It is of course to be-understood that th same method and impression material may be used in cement, plasterboard, gypsum board, and other temporarily plastic body-materials having a decorative surface. These are impressed while plas- V tic, partially set to hold the impressions, and then completely setafter removal of the impressionmaking means.

The invention obviously is not limited to sub facing fiber boards, but may be used on any plastic material. Therefore the invention is broadly defined in the appended claims.

I claim:

1. An artificial decorative 'board for use on walls and the like in position subject to marring or scufiing having a surface of felted fibers with intaglio markings therein, the felted connection of the fibers of said surface being unbroken by the depressions of the markings, said continuous felt of surface fibers embodying a dried oil, the main body of the board beneath said surface'be ing softer and being free from dried oil,,the depressions being in the nature of grooves from .005 to .04 inch deep, the width of -a groove be ing not mor than twice the depth, the majorportion of the high spots between the said grooves being substantially in the same plane, whereby a fiat surface is provided with decorative high lights and shadows upon illumination.

2. An artificial decorative board for use on walls and the like in position subject to marring or scuffing having a surface of felted fibers with intaglio markings therein, the felted connection of the fibers of said surface being unbroken by the depressions of the markings, the depressions extending in the same general direction, said continuous felt surface fibers embodying a hardening agent, the main body of the board beneath said surface being softer than said surface layer andbeing free from said hardening agent, the depressions being in the nature of grooves from .005 to .04 inch deep, the width of a groove being not more than twice .the depth, the major portion of the high spots between the said grooves being substantially in the same plane, whereby a fiat surface is provided with decorative high lights and shadows upon illumination. 3. An artificial decorative board for. use on walls and the like in Position subject to marring oil-particles of the emulsion are thus filtered out trationof oil. making a small amount very efor scufiing having a surface of felted fibers with intaglio markingstherein, the felted connection of the fibers of said surface being unbroken by the degressions of th markings, the depressions extending in the same general direction, said continuous felt of surface fibers embodying a dried oil, the main body of the board beneath said surface being softer and being free fromdried 11, the depressions being in the nature of a groove being not more than twice the. depth,

th major portion of the'high spots between the said grooves being substantially in the same plane,

whereby a flat surface is provided with decorative high lights and shadows upon illumination.

' 4. An artificial decorative board for use on walls and the like in position subiect to marring and scufllng comprising a body of felted fibers having a surface with intaglio markings therein, the felted connection a: the fibers of said surface being unbroken by the depressions of the markings, and dried-oil in the surface layer as a hardening agent, the main body of the board beneath said surface-being softer than said surface layer and being free'from said dried oil.

5. An artificial decorative board for use on.

- having a surface with inta glio markings therein,

' the felted connection of the fibers of said surface being unbroken by the depressions of the markings, and dried oil in the surface layer as a hard- CERTIFICATE 'OF comcnon. Patent No, 2, 17, ou. April 27, 1915.

HENBY E. WALTER.

Ibis hereby certified that error appears in the printedgpecifigatip n of the a gye numbered pater rb requiring correction as follows: Page 3- first -co1umn, 1ine 51,:tor fwshing" r --wash1ngline 51+,after "mixed" in--' sert --dr1er--; and second column, line 70, claim 3, for "deg1 -essions" read L the Patent Office.

-depr ss and that the said Letters Pate'nt should be read with an; correction thereinthat the same may confdrm to the record'ofthe case' in Signed and. sealed this 8th'daj of June,.A. D. 191), 4

Hnry Vgn Ar s da1e 5 (Seal) I Acting Commissioner offat en ta.

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