US2389836A - Molded inlaid linoleum manufacture - Google Patents

Description

Nav. Z'i, 19%5. I J, BERGER 2,389,836

MOLDED INLAID LINOLEUM MANUFACTURE Filed July 1, 1944 2 Sheets-Sheet 1 New; 27, 1945.

MOLDED J. L. BERGER INLAID LINOLEUM MANUFACTURE Filed 'July 1, 1944 2' Sheets-Sheet 2 FIGII equipment is employed. This equipment is conventional for the most part and is sufliciently well known in the art to require no detailed description. It includes a support for a backing such as asphalt saturated i'elt or burlap, indicated by the numeral 4 in the various views and means for intermittently moving the backing thereover. Positioned above the support are a plurality of spaced stencils through which the color composition is deposited onto the backing. The number of stencils employed will be dependent upon the number of colors appearing in the finished pattern. 'For simplicity of illustration, the number of stencils has been limited in the drawings. The usual pressing and curing equipment will also be employed.

Figures 5 to illustrate the stencils provided for applying inlaying composition to form the pattern of Figure 1. The first stencil 5 is effective for defining the position of one half of the thickness of the interliner color composition I applied to the backing 4 as shown in Figure 11. The interliner inlay is indicated in Figures 8, 9, and 10. After application of the interliner color composition, the backing 4 is moved to bring'that portion of the backing to which the interliner color has been applied under a secondstencil 6 and here color composition A is applied. By comparing Figure 5 with Figure 1, it will be noted that the stencil 6 is provided with openings 1 which have an outline corresponding generally to ,the shape of the inlays A of Figure 1.

The inlaid material A may be strickled through the opening! in the stencil 6 by hand in the customary manner or may be automatically strickled by use of automatic equipment such as is disclosed in my prior Patent 2,024,203. By reference to Figure 8, it will be noted that the inlaying color composition A is deposited upon the backing 4 and completely fills the openings 1 in the stencil 6, lying substantially flush with the plane of the upper surface of the stencil 6. It will be noted also that the interiiner color I lies about midway of the distance between the stencil 6 and the backing 4. The inlaying color composition A is disposed in an area corresponding substantially with the outline of the openings I of the stencil plate 6. When the stencil 6 is elevated and the backing 4 moved to the next stencilling station, the color composition A will re main firm and will have a clear outline, for the composition has some cohesion, sufiicient to maintain the inlays against collapse. Customary practice would be to apply the second inlayins color composition onto the backing contiguone to the first color, the first color being protected and covered by the stencil. In other words, each stencil subsequent to the first would cover the areas where color composition had been previously applied.

According to my method, however, the next step is tobreak down the sharp, well-defined edges at the upper surface of the inlay A. This may be accomplished in the manner illustrated in Figure 3 where a bristle brush R is moved over the stencil and into engagement with the inlay A and is effective for breaking down the edge of the granulated material constituting inlay A.

The brush is not drivenbut is free to rotate and is merely drawn over the inlays so that the bristles may penetrate to some slight extent into the composition and breakdown or slough off a portion of the-f exposed and unsupported edges. Figure 3 shows -anedge 8 which has. been broken down, whereas t he edge 9 which has not been movement.

areas A and Bare engaged by the brush is sharp. The dotted line l0 indicates the general position the inlaying composition will assume when the edge 9 is broken down. When an automatic strickler is used, such as disclosed in my patent above referred to the brush R may be mounted in advance of the color applyi blades. In hand strickling, the brush may be mounted for travel across the stencil and pushed or drawn thereacross by the workmen prior to the application of color to the stencil plate. A flat brush may be used and brought down from above onto the color composition and then given a slight lateral The mechanism employed may vary so long as it is-efiective for breaking down the unsupported edges.

The mechanical disturbance of the edge portion is eii'ected while the backing with the inlaying composition A is' disposed at a stencilling station where stencil II is positioned. Stencil II is provided with openings l2 through which color composition is deposited upon the backing. It will be noted in Figure 9 that the inlay A has its upper surface in the plane of the upper surface of the stencil ll. After the edges of the inlaying color A have been broken down, the color B is ap-' composition through the stencil openings I: to I form inlay B and completely fill the stencil openings, a soft blending effect is obtained at the line of juncture where the contiguous areas abut due to the irregular breaking down of the edges and the subsequent filling in of such areas with inlaying color composition B.

The backing material 4 with inlay colors A and B applied moves to the next stencilling station where color C is applied. It will be noted that the openings l3 in stencil l4 are of an area corresponding to the total area of the pattern elements 2, that is, the combined areas oi inlays A, B, and C. v The first step at stencil I4 is to engage the color composition with a bristle brush or other mechanism eifective for breaking down the edges of the inlays which will abut the inlaying color composition C which is about to be applied throughout the stencil l4. Where in abutting engagement, there will, or course, be no breaking down since both are contiguous and one supports the other. After breaking down of the unsupported edges, the inlaying composition C is applied through the stencil openings l3 and an irregular blended terspersion of color compositions at the upper surface even though the previously applied color composition lies in the plane of the upper surface of the stencil plate. Thisis due to the fact that the color composition is unconsolidated and is in granular form. This may be objectionable in that the last applied color composition C in the illustrated embodiment may predominate over the whole area. For that reason, I prefer to to form a blended juncture zone between said remove the upper surface ofpthe inlaying composition. This is effected in stencil it after completion of the inlaying of color composition C. This may be accomplished by means of a rotating brush such as described in my Patent 2,241,051 which is effective for removing all of the color composition which lies above the plane of the lower surface of the stencil plate. The brush will be positioned so as to engage the color compositions after the stencilling of color composition C has been completed. I have illustrated this in Figure 4 where I have shown a bristle brushl5 which is effective for sweeping out all of the inlaying composition which lies above the plane of the lower surface of the stencil plate 14. This brush is rotated at substantial speed so as to sweep the composition out of the stencil opening I3. This presents as the exposed upper surface of the finished product a portion of the in-' laid color compositions A, B, and C which lie below the upper surface. This step also eliminates any objectionable interspersing which may have occurred. At the same time, there is some slight blending effected by the rotating brush l5 and such blending enhances the irregular interspersion which is effected at the juncture lines by breaking down the edges.

The backing material 4 then moves to a fifth stencil 16 Where the remaining portion of interliner I is applied. This completes the pattern and the material is then consolidated under heat and pressure and then stoved or cured.

The completed material is shown in Figure 2 subsequent to pressing and embossing of the interliners. Corresponding numbers and letters have been applied to this view.

In order to depict the gradual and almost imperceptible blending of the areas A, B, and C into one another at the zones of juncture, I have shown in Figure 1 the color A by small dash lines, the color B by dots, and the color C by small circles. It is difiicult to show the blending in black and white but from the foregoing description, it will be clear to those skilled in the art how my method is performed and the nature of the final product produced. Material actually produced by my method shows a blending of the colors not heretofore attainable.

While I have illustrated and described certain embodiments of my invention, it will be understood the same "is not so limited but may be otherwise embodied and practiced within the scope of the following claims.

I claim:

1. In the manufacture of molded. inlaid linoleum, the steps of applying inlaying color composition through a stencil opening to form an inlaid area, irregularly breaking down said inlay along an edge portion thereof, and thereafter applying another inlaying color composition through a second stencil opening into contiguous relationship with the first applied inlay along said edge portion to form a blended juncture zone between said inlays.

2. In the manufacture of molded inlaid linoleum, the steps of applying granulated inlaying color composition onto a backing in a predetermined defined area, mechanically disturbing the granules adjacent an edge portion of said area to irregularly break down the inlay along such edge portion only, and subsequently applying another inlaying color composition onto the backing in an area adjacent to the first applied inlay with the line of juncture betweensaidinlays defined by said broken down edge portion inlays.

3. In the manufacture of molded inlaid linoleum, the steps of applying inlaying color composition onto a backing in a predetermined defined area, pressing a brush into engagement with the color composition so applied to break down an edge portion of said area, and applying a second inlaying color composition to said backing contiguous with said broken down edge portion to form a blended juncture zone between said inlays. 4

4. In the manufacture of molded inlaid linoleum, the steps of applying granulated inlaying color composition onto a backing in a predetermined defined area, mechanically disturbing the granules adjacent an edge portion of said area to irregularly break down the inlay along such portion, and subsequently applying a second inlaying color composition over the first applied composition and in a predetermined defined area in addition thereto adjoining said first inlaid area, the irregularly disposed edge of the first area being filled with said second inlaying color composition.

5. In the manufacture of molded inlaid linoleum, the steps of applying granulated inlaying color composition onto a backing in a predetermined defined area, mechanically disturbing the granules adjacent an edge portion of such area to irregularly break down the inlay along such portion, subsequently applying a second inlaying color composition over said first inlay and into a predetermined defined area contiguous thereto with said inlays being joined by an irregular juncture line formed of the granules of both in-- lays irregularly disposed, and thereafter removing from the upper surface of said inlays a portion thereof to expose aportion therebelow.

6. In the manufacture of molded inlaid linoleum formed of a plurality of areas of molded inlaid linoleum composition irregularly joined to give a pleasing shaded effect, the steps or applying a, plurality of granulated inlaying color compositions to a backing at a series of stenciling stations, breaking down the edge portion of each area which will lie contiguous to another area and will be blended therewith, said breaking down being effected prior to the depositing of inlaying color composition into contiguous relae tionship with the broken down edge, repeating these steps until the entire shaded. area of the linoleum has been inlaid, and thereafterremoving a. portion of the upper surface of said granules of inlaying color composition to expose a portion therebelow.

'7. In the manufacture of molded inlaid linoleum, the steps of applying granulated inlaying color composition onto a backing in a predetermined defined area through a stencil opening,

moving said backing to a second stenciling station and positioning said inlay within an opening -in said second stencil having an area greater face of the stencil late, said second inlay being disposed in contiguous relationship with the first inlay with said broken down edg portion forming a blended juncture zone between said inlays.

.8. In the manufacture of molded inlaid linoleum, the steps comprising depositing comminuted inlaying composition through a serie of stencils onto separate areas of -a backin in a series of successive steps, after each successive depositing step engaging the preyiouly. applied inlaying composition to break down the edge portion thereof prior to the application of inlaying composition to a contiguous area to form a blended juncture zone between said areas.

9. In the manufacture of molded inlaid linoleum. the steps of applying mottled granulated inlaying color composition onto a backing in a, predetermined defined area, mechanically disturbing the granules adjacent an edge portion of such area to irregularly break down the inlay along such edge, applying a second mottled granulated inlayin color composition onto said backing with a portion thereof contiguous to the previously applied area along said edge portion, mechanically engaging both previously applied inlaying color compositions to break down an exposed edge portion thereof, and thereafter depositing a third mottled granulated inlaying color composition contiguous to the broken down edge portions of the first and second applied mottled inlaying color compositions.

10. In the manufacture of molded inlaid linoleum, the steps of applying granulated inlaying color composition onto a backing in a predetermined defined area, pressing a plurality of closely spaced projections into said inlaying color composition to disturb the granules adjacent an edge portion of said area and irregularly break down the inlay along such ed e, subsequently applying a second inlay in contiguous relationship with the first inlay with the broken down edge portion forming a blended juncture zone between said inlays, and further blending said inlays in the June. ture zone by brushing away a substantial portion of the linoleum composition constituting said inlays from the entire upper surface area thereof.

11. In the manufacture of molded inlaid linoleum, the steps of depositing granulated inlaying color composition onto a backing through an opening in a stencil positioned at a stenciling station to fill'the stencil opening substantially fiush with the upper surface of the stencil, mov-i ing said backing with its applied inlay to bring the inlay into a second stencilling station with 7 said inlay positioned within an opening in a second stencil with the upper surface of the inlay pletely fill the same substantially flush with the upper surface of the stencil, said second inlaying color composition being strickled directly onto the first inlay and into said adjacent area to effect a blending of the two inlaying color compositions at the zone of juncture between the first inlay and the inlayin color composition applied through said second stencil into said adjacent area defined by the broken edge of the first inlay.

7 JOHN L. BERGER.

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