US1939275A - Manufacture of linoleum - Google Patents
Manufacture of linoleum Download PDFInfo
- Publication number
- US1939275A US1939275A US618972A US61897232A US1939275A US 1939275 A US1939275 A US 1939275A US 618972 A US618972 A US 618972A US 61897232 A US61897232 A US 61897232A US 1939275 A US1939275 A US 1939275A
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- United States
- Prior art keywords
- die
- pieces
- backing
- roll
- linoleum
- 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
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- 238000004519 manufacturing process Methods 0.000 title description 22
- 239000000203 mixture Substances 0.000 description 39
- 239000000463 material Substances 0.000 description 28
- 238000005520 cutting process Methods 0.000 description 23
- 239000004579 marble Substances 0.000 description 14
- 238000003490 calendering Methods 0.000 description 9
- 238000007599 discharging Methods 0.000 description 8
- 239000012467 final product Substances 0.000 description 8
- 230000000717 retained effect Effects 0.000 description 8
- 239000003086 colorant Substances 0.000 description 4
- 230000001050 lubricating effect Effects 0.000 description 4
- 238000009825 accumulation Methods 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 238000007689 inspection Methods 0.000 description 3
- 239000000314 lubricant Substances 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 235000020030 perry Nutrition 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 238000009966 trimming Methods 0.000 description 2
- 230000001464 adherent effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000003467 diminishing effect Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000010438 granite Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
Images
Classifications
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- 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
- Y10T156/1062—Prior to assembly
- Y10T156/1075—Prior to assembly of plural laminae from single stock and assembling to each other or to additional lamina
-
- 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
- Y10T156/1062—Prior to assembly
- Y10T156/1075—Prior to assembly of plural laminae from single stock and assembling to each other or to additional lamina
- Y10T156/1077—Applying plural cut laminae to single face of additional lamina
-
- 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
- Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
- Y10T156/1092—All laminae planar and face to face
- Y10T156/1097—Lamina is running length web
- Y10T156/1098—Feeding of discrete laminae from separate sources
-
- 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
- Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
- Y10T156/1317—Means feeding plural workpieces to be joined
- Y10T156/1322—Severing before bonding or assembling of parts
- Y10T156/133—Delivering cut part to indefinite or running length web
- Y10T156/1335—Cutter also delivers cut piece
Definitions
- the backing passes under the several die rolls, pattern elements or each' color in the design are laid on the backing until the design is complete, and then after passing over an inspection table the several pattern elements, which up to this time are loosely adherent to the backing, are consolidated therewith and at their margins with one another, in a calender.
- the several webs are each of full thickness and of an area corresponding to the area of the goods, neglecting the selvage trimming scrap which is a very small proportion of the whole sheet. Consequently there is discharged by the dies as scrap a volume of linoleum mix equal to the full thickness of a web times the area of the goods times one less than the number of webs employed.
- a 6 inch block cannot be produced by this method of indexing because this would divide the circumference into nine equal die cavities.
- each cavity would receive a cutout block of,:let us say, the darker element in the pattern. It would be necessary to discharge as scrap those blocks in alternate cavities, let us say in the even numbered cavities. This would leave cavities, 1, 3, 5, 7 and 9 containing dark colored blocks to be laid on the backing, but cavities land 9'are immediately adjacent, and therefore instead of the pattern having alternate light and dark blocks throughout its length there would be two dark blocks side by side every 54 inches.
- I have overcome the difficulties with excessive die scrap and have materially enlarged the potentialities of machines of this character.
- I instead of originally forming webs of the desired full thickness, I form a sheeted linoleum composition whose thickness is only a fraction of the desired full thickness, accumulate sufiicient pieces cut by a die to make a piece of the full thickness, and then lay the accumulated pieces on the backing.
- I may feed webs of half thickness to the die roll and actuate the stripper which discharges cut-out material from a die cavity only on every second revolution.
- the cavities 2, 4, 6 and 8 which already contain one thickness of the web, will receive another cut-out prior to actuation of the strippers. There will thus be accumulated in each of these die cavities two plies which are simultaneously discharged onto the backing, thus making up a pattern element of the desired full thickness.
- the cavities 1, 3, 5, 7 and 9 will receive a cut-out from the web, and on the third revolution prior to actuation of the strippers of the odd numbered cavities they will receive a second ply. It will thus be' seen that the operation may be continued indefinitely.
- the several die cavities receive pieces cut out of successive areas of sheeted linoleum composition, which pieces are accumulated until the desired full thickness is attained, after which the accumulation of pieces is removed from the die cavities and laid on a backing in superimposed relation.
- this die roll is accumulating and ejecting cut-out pieces of dark colored material
- another die roll on the machine will have been accumulating and ejecting in proper position on the backing the light colored elements, thus making up the complete pattern. All of the material which is ca-lendered, waiving any considerations of selvages, will have been laid on the backing as product, all scrap thus being eliminated.
- More complex patterns may be laid in a like manner.
- a three-color pattern may, for example, be laid without scrap by making webs of one-third the full thickness and effecting discharge on every third revolution. Such procedures as this, however, represent only a relatively small proportion of the uses of the invention. It may be desirable in cases to actuate some of the die rolls in the usual manner and with webs of full thickness, while using other of the die rolls with webs of fractional thickness. For example, in a patternnhaving marbled pattern elements and plain pattern elements, it may be desirable to calender the marble to fractional thickness so as-to eliminate or reduce the amount of the marble scrap, while discharging the plain colors to scrap inthe ordinary fashion and reworking the material.
- Figure 1 is a-view of a rotary machine set up to lay an ordinary two-color block pattern without scrap s s
- Figure 2 is a view corresponding to a portion of Figureil, but showing the machine set-up for a more complicated pattern;
- Figure 3 is a cross sectional View through a die roll showing the manner in which a web of fracticnal thickness is cut and the pieces thereof acthe machine and on its travel. therearound re ceives thepattern elements making the design.
- the material is taken from the drum 3 around a roll 4 over an inspection table 5 to a calender 6, from which it is taken to the stoves for maturing. Die rolls '7 are arrangedadjacent the drimi 3.
- Each dieroll has knives arranged on its peripheral 1.50
- a platen roll 8 cooperates with die roll 7 to force the web into the knives and, if desired, stifi rotary brushes 9 may be employed to complete the cutting and force the cut up pieces into the die cavities.
- the webs W are fed on belts 10 from roll.
- Figure 1 shows two roll calenders which are supplied with linoleum composition of the desired colors.
- Figure 3 shows essentially in diagram but in more detail the construction of the die roll. The die roll of Figure 3 is arranged for use in the production of a pattern such as illus tratedin Figure 5.
- Figure 5 shows a pattern of black and white squares 6 inches across. The circumferential length of the die is indicated on Figure 5 and it will be notedthat in any given longitudinal row of pattern elements the first and last squares in such row are of the same color.
- the die roll of Figure 3 consists of a hollow cylindrical body 12 having on its surface knives 13 held in place by filler blocks 14.
- the knives divide the surface of the die roll into die cavities, a circumferential row of which cavities is shown in the cross section.
- Each cavity is provided with one or more strippers indicated generally by the reference character 15.
- Figure 3 shows only one stripper for each cavity.
- Each stripper has a plate 16 substantially coextensive with its die cavity and an inwardly extending pin 17.
- Within the body 13 of each stripper there is a spring (not shown) for retracting the stripper after it has been urged outwardly.
- the strippers are actuated by a roll 19 which is shown as having pins 20 adapted to engage the pins l'7.
- the die roll and the pattern roll are geared together, and the gearing ratio is such that the pins 20 engage the pin or pins inevery second cavity. Therefore, as the die roll rotates the strippers are actuated in the order C1, C3, C5, C7, C9, C2, C4, etc.
- the stripper for the cavity C1 is shown as urged to its outermost position for the purpose of laying an accumulation of cut-out pieces on the backing B. It will be noted that the cavities C3 and C5 contain two plies of material and are therefore ready for discharge, whereas the cavities C2, C4 and Cs contain but a single ply.
- the cavity Ca which was emptied immediately prior to the cavity C1, is empty but will receive a thickness of material as it passes by the platen roll 8.
- the cavity C6 is shown in the act of receiving its first ply, while the cavity C1 which contains a single ply, shall shortly receive the second thickness of material.
- FIG. 4 illustrates, to an exaggerated scale, a. possible theory explaining the good joints obtained by the multiple-ply method.
- Each of the plies, P has a tapered edge as indicated at 21. This tapering is due to the tapering of the knife edges as indicated in Figure 3.
- the bottom dimension of the upper ply is probably greater than the top dimension of the bottom ply, the bottom dimension of each ply-closely approximating the developed dimensions of the die cavity at its periphery; As a consequence the top surface of each pattern element closely approximates the desired theoretical dimensions, thus resulting in good joints. Itwill be understood, of
- Figures 2, 6 and 7 illustrate other applications of the invention wherein a certain amount of scrap is produced, but the amount of which is materially less than would be required if the pattern were produced in the ordinaryfashion.
- Figure 6 shows a four-color pattern in which two of the colors are marbles. The pattern is made up of squares D of plain color, rec tangles E of plain color, square blocks, F of dark marble and square blocks G of light marble. It is desired to minimize the amount of marble scrap.
- Figure 2 shows the machine set up for producing this pattern. The die rolls for the respective colors D, E, F and G are shown at D3, E3, F3 and G3. In this case the usual scrap conveyors 22 are provided, as are scrap rolls 23 with pins suitably placed thereon.
- the scrap rolls 23 lie inside the die rolls and eject undesired material from the die cavities into the scrap conveyor 22.
- the pattern rolls and the rotary brushes have been omitted. The general construction and operation of these rolls are well known and require no further description.
- the die rolls D3 and E3 are operated in the usual fashion; that is to say, a webof full thickness is fed to each die roll and cut up into pattern elements and scrap. The scrap is discharged and the pattern elements are laid on the backing in the usual way.
- the die rolls F3 and G3 are supplied with Webs of halfthickness. There is discharged as scrap fromeach of the die rolls F3 and G3 a material in volume equivalent to onehalf the aggregate volume of the pattern elements D and E.
- lubricating roll As is well known, it is customary practice to actuate all the strippers at-each revolution of a die roll so that the plates 16 are projected outwardly to receive a thin film of lubricant, such as parafiin oil, which minimizes any tendency of the pattern elements to stick to the stripper plates instead of adhering as they should to the backing. Ordinarily a plane cylindrical roll is provided within the die roll for the purpose of urging the stripper pins outwardly.
- lubricant such as parafiin oil
- the invention can be practiced with relatively little change in dies and equipment ordinarily employed in machines of this character.
- the machine may also be operated in certain case at relatively high speeds, particularly on heavy gauges.
- calendering to thinner gauges necessarily requires great care in maintaining proper and uniform thickness, it is also a fact that where heavy gauges of material are being made a marked limitation on the capacity of the machines lies in the limitation of mixing capacity.
- mixing capacity As stated, when making a four-color pattern in the ordinary way the volume of die scrap is three times the volume of mix laid, and
- the steps consisting in presenting successively to a cutting die different areas of sheeted linoleum composition, cutting pieces out of successive areas, aocumulating the several cut out pieces in the die and simultaneously ejecting the accumulated pieces onto a backing.
- the steps consisting in forming a web of linoleum mix of a thickness only a fraction of the desired full thickness in the final product, utilizing a die to cut pieces from the web, accumulating a sufficient number of pieces cut by the same die to make a piece of full thickness, and laying the accumulated pieces on a backing.
- the steps consisting in forming a web of linoleum mix of a thickness only a fraction of the desired full thickness in the final product, utilizing a die to cut pieces from the web, accumulating a sufficient number of pieces cut by the same die to make a piece of full thickness, laying the accumulated pieces on a backing, and consolidating the accumulated pieces with one another and with adjacent pattern elements.
- the steps consisting in feeding a web of linoleum composition to the die so as to cut the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness in the final product, effecting discharge of material to a backing successively from die cavities circumferentially spaced apart in one revolution of the die, effecting discharge of material to the backing from intermediate die cavities on a subsequent revolution of the die and thus discharging pieces to the backing, in a desired sequence, from all the die cavities in a circumferential row.
- the steps consisting in feeding a web of linoleum composition to the die so as to cut the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness in the final product, eiTecting discharge of material to a backing successively from die cavities circumferentially spaced apart in one revolution of the die, effecting discharge of material to the backing from intermediate die cavities on a subsequent revolution of the die, thus discharging pieces to the backing, in adesired sequence, from all the die cavities in a circumferential row, cutting another web and accumulating pieces thereof in like manner and laying them on the backing between the pieces laid as first above recited.
- the steps consisting in feeding a web of linoleum composition to the die so as to out the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness in the final product, effecting discharge of material to a backing successively from die cavities circumferentially spaced apart in one revolution of the die, efiecting discharge of material to the backing from intermediate die cavities on a subsequent revolution of the die, thus discharging pieces to the backing, in a desired sequence, from 5 all the die cavities in a circumferential row,
- the steps consisting in feeding a web of linoleum composition to the die so as to cut the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness inthe final product, effecting discharge of maa subsequent revolution of the die, the entire web, except the selvages thereof, being cut and .laid on the backing.
- a die roll having die cavities on its surface, means for feeding a backing material alongside the die roll so as to receive material from the die cavities, means for supplying to the die roll a web of linoleum composition whose thickness is only a fraction of the desired thickness, the cavities being adapted to temporarilv retain and accumulate a plurality of pieces cut from the web, and means effective when such a die cavity is adjacent the backing for ejecting the accumulated pieces from such cavity so as to deposit on the backing a pattern element made of a plurality of plies.
- Apparatus for making linoleum comprising a die for cutting pieces from different areas of sheeted linoleum composition, means for supplying a backing material, means for effecting relative movement between the die and the backing so as to bring successive portions of the backing into position alongside the die, the die having a cavity adapted to temporarily retain cut-out pieces, and means effective when the die is alongside the backing material for ejecting the cut-out pieces after a plurality thereof have been accumulated in the die cavity.
- a die roll having a die surface eifective for cutting a web of linoleum composition into pieces retainable within die cavities and dischargeable therefrom onto a backing, means for feeding a web of linoleum to said die roll, which web has a thickness of only a fraction of the desired full thickness, the die cavities being adapted to retain a plurality of cut out pieces, and means for ejecting onto a backing cut out pieces from a die cavity after a sufficient number thereof to aggregate the desired full thickness of material have accumulated therein.
- a die roll having a die surface effective for cutting a web of linoleum composition into pieces retainable within die cavities and dischargeable therefrom onto a backing, means for feeding a web of linoleum to said die roll, which web has a thickness of only a fraction of the desired full thickness, the die cavities being adapted to retain a plurality of cut out pieces, means for ejecting onto a backing cut out pieces from a die cavity after a sufficient number thereof to aggregate the desired full thickness of material have accumulated therein, and a second die roll adapted to eject cut out pieces onto the backing intermediate the pieces laid thereon by the first mentioned die roll.
- a die roll having a die surface effective for cutting a web of linoleum composition into pieces retainable within die cavities and dischargeable therefrom onto a backing
- the die cavities being adapted to retain a plurality of cut out pieces
- a lubricating means for: supplying lubricant to the strippers, and means for moving strippers into position to be operativelyengaged by the lubrieating means, said stripper moving means being arranged to actuate strippers only in those die cavities which are free of cut out material as they pass the lubricating means.
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Description
Dec. 12, 1933. A, c, PERRY MANUFACTURE OF LINOLEUM 3 Sheets-Sheet Filed June 23, 1932 INVENTOR 1933- A. c. PERRY MANUFACTURE OF LINOLEUM Filed June 23, 1932 3 Sheets-Sheet 2 VENTOR 5 w my t 4g x; 2
I g mm DEC. 12, A C PERRY MANUFACTURE OF LINOLEUM Filed June 23, 1932 3 Sheets-Sheet 3 INVENTOR Patented Dec. 12, 1933 MANUFACTURE OF LINOLEUM Arlington C. Perry, Lancaster, Pa., assignor to 1 Armstrong Cork Company, Lancaster, Pa., a corporation of Pennsylvania Application June 23, 1932. Serial No. 618,972
19 Claims.
machine of the well known rotary type. In the manufacture of straight line linoleum in the rotary machine, webs of linoleum mix are fed to die rolls which cut the webs into pieces. In the machine as usually constructed, the pieces thus cut are retained in the die cavities between the cutting knives on the periphery of the die roll until ejected by the actuation of strippers. The .20. strippers are arranged to eject scrap material at a proper point in the rotation of the die roll and to thereafter eject the desired pattern elements onto a backing. As the backing passes under the several die rolls, pattern elements or each' color in the design are laid on the backing until the design is complete, and then after passing over an inspection table the several pattern elements, which up to this time are loosely adherent to the backing, are consolidated therewith and at their margins with one another, in a calender. In such operation, the several webs are each of full thickness and of an area corresponding to the area of the goods, neglecting the selvage trimming scrap which is a very small proportion of the whole sheet. Consequently there is discharged by the dies as scrap a volume of linoleum mix equal to the full thickness of a web times the area of the goods times one less than the number of webs employed. Thusina four so color pattern the volume of linoleum mix discharged as scrap is three times the volume laid. The re-working of they scrap adds to the expense of the operation and scrap product is particularly undesirable when dealing with multi-colored webs, as, for example, mottled, granite striated or marbled goods. Scrap from such webs cannot always be re-worked into a new web of the same color. There is a degradation of the mix and at times the scrap production is so'large that no commercial outlet for it is available.
7 Another limitation on the rotary machine is'in the character of the patterns produced. 'The circumferential distance around a die roll is, by
accepted trade practice, 54 inches. There is an indexing roll inside the die roll and geared there with for actuating the strippers which lay the cut-outs on the backing. Usually, by reason of limitations of space, this indexing roll makes three revolutions for each revolution ofthe die roll, and therefore the pattern is repeated three times around the circumference, making a repeat distance of 18 inches in the pattern produced; An example of the limitations imposed on a machine of the rotary type by an index roll operating like this follows: Considering a relatively simple pattern, such as a tile pattern made up of alternate light and dark blocks, laid with index rolls'making three revolutions for each revolution of the die roll, the length of the blocks must be such that it divides into 54 inches an even number of times. For example, a 6 inch block cannot be produced by this method of indexing because this would divide the circumference into nine equal die cavities. In a single revolution of the die roll each cavity would receive a cutout block of,:let us say, the darker element in the pattern. It would be necessary to discharge as scrap those blocks in alternate cavities, let us say in the even numbered cavities. This would leave cavities, 1, 3, 5, 7 and 9 containing dark colored blocks to be laid on the backing, but cavities land 9'are immediately adjacent, and therefore instead of the pattern having alternate light and dark blocks throughout its length there would be two dark blocks side by side every 54 inches.
I have overcome the difficulties with excessive die scrap and have materially enlarged the potentialities of machines of this character. Instead of originally forming webs of the desired full thickness, I form a sheeted linoleum composition whose thickness is only a fraction of the desired full thickness, accumulate sufiicient pieces cut by a die to make a piece of the full thickness, and then lay the accumulated pieces on the backing. For example, in the making of a two-color pattern I may feed webs of half thickness to the die roll and actuate the stripper which discharges cut-out material from a die cavity only on every second revolution. For example, in a simple twocolor pattern made up of 6 inch blocks, such as above referred to, and considering successive die cavities around the circumference as numbered from 1 to 9 inclusive, I may actuate the strippers so as to discharge material from the die cavities in the order 1, 3, 5, 7 and 9, 2, 4,6, 8, 1, 3, 5, etc. On the first revolution at the beginning of the operation of the machineeach die cavity will re= ceive a'cut-out portion of web, which, as stated, is only half the desired thickness. These cut outs will be discharged from cavities 1g 3, 5, '7 and 9, and this portion of the goods will be wasted, unless the additional ply is laid on by hand at the inspection table. At the second revolution, however, the cavities 2, 4, 6 and 8, which already contain one thickness of the web, will receive another cut-out prior to actuation of the strippers. There will thus be accumulated in each of these die cavities two plies which are simultaneously discharged onto the backing, thus making up a pattern element of the desired full thickness. On this same revolution of the die roll the cavities 1, 3, 5, 7 and 9 will receive a cut-out from the web, and on the third revolution prior to actuation of the strippers of the odd numbered cavities they will receive a second ply. It will thus be' seen that the operation may be continued indefinitely. The several die cavities receive pieces cut out of successive areas of sheeted linoleum composition, which pieces are accumulated until the desired full thickness is attained, after which the accumulation of pieces is removed from the die cavities and laid on a backing in superimposed relation. At the same time that this die roll is accumulating and ejecting cut-out pieces of dark colored material, another die roll on the machine will have been accumulating and ejecting in proper position on the backing the light colored elements, thus making up the complete pattern. All of the material which is ca-lendered, waiving any considerations of selvages, will have been laid on the backing as product, all scrap thus being eliminated.
More complex patterns may be laid in a like manner. A three-color pattern may, for example, be laid without scrap by making webs of one-third the full thickness and effecting discharge on every third revolution. Such procedures as this, however, represent only a relatively small proportion of the uses of the invention. It may be desirable in cases to actuate some of the die rolls in the usual manner and with webs of full thickness, while using other of the die rolls with webs of fractional thickness. For example, in a patternnhaving marbled pattern elements and plain pattern elements, it may be desirable to calender the marble to fractional thickness so as-to eliminate or reduce the amount of the marble scrap, while discharging the plain colors to scrap inthe ordinary fashion and reworking the material. In the case of a continuously extending interliner, it will, so far. as I am now advised, be necessary to calender it to full thickness and to discharge scrap in the usual manner. Of course, it would be possible to use two webs of thesame color on an ferent die rolls and obtain continuity of coio; I in the design while minimizing scrap, by having the die rolls alternately lay such color on successive 54 inch lengths of material. However, where any piece of a given color in the pattern does not ex:
,ceed a length of .54 inches, it can be calendered calenders used in the production of marbled effects are provided with two rolls, the face roll being refrigerated and the back roll being heated. The graining in the thin sheet is produced by cross rolling a thicker striated sheet. The thickness of the first rolled sheet is substantially the same for the production of either light or heavy gauges. When thin sheets are to be made, the reduction in thickness, of course, is greater and there results a clouded effect, which is caused by-the flow of the differently colored compositions under the compression of the calender rolls. The heat of the backing roll renders the composition more plastic. When thin sheets are produced, more heat is transmitted through to the face of the sheet from the hot back roll and a more desirable graining is produced than is obtained when thicker sheets are rolled.
It is also found that the quality of the goods is improved, and very good joints are obtained between adjacent pattern elements. It will be understood that that face of the web which is innermost of the diecavity forms the exposed surface of the goods. While the knives on the die are made very thin, they must be of sufficient 100 thickness to withstand the severe operating conditions. The sides of the knives are tapered up to the cutting edge so thatthe cross sectional area of the die cavities diminishes as the bottom of'the cavity is, approached. Therefore, when a web of linoleum composition is cut by the knives bounding a given die cavity, the edges, instead of being truly square, have a certain amount of draftor taper due to the plastic composition being forced into a die cavity of diminishing cross sectional ar a. The thinner the web the less is the taper, and it is found in practice that when webs of fractional thickness are cut and accumulated in the die cavities the innermost ply is of substantially the same dimensions as the outermost. Therefore, when the accumulation of plies is laid on a backing, the edges of pattern element at the exposed face very nearly approach the theoretical dimensions. It is found that upon calendering very close joints are obtained.
In the accompanying drawings which illustrate my invention more orless diagrammatically,
, Figure 1 is a-view of a rotary machine set up to lay an ordinary two-color block pattern without scrap s s e Figure 2 is a view corresponding to a portion of Figureil, but showing the machine set-up for a more complicated pattern;
Figure 3 is a cross sectional View through a die roll showing the manner in which a web of fracticnal thickness is cut and the pieces thereof acthe machine and on its travel. therearound re ceives thepattern elements making the design. The materialis taken from the drum 3 around a roll 4 over an inspection table 5 to a calender 6, from which it is taken to the stoves for maturing. Die rolls '7 are arrangedadjacent the drimi 3.
Each dieroll has knives arranged on its peripheral 1.50
surfacefor cutting a web W of linoleum composifar described permits of making the goods withtion fed thereto. A platen roll 8 cooperates with die roll 7 to force the web into the knives and, if desired, stifi rotary brushes 9 may be employed to complete the cutting and force the cut up pieces into the die cavities.
The webs W are fed on belts 10 from roll.
calenders 11. .Figure 1 shows two roll calenders which are supplied with linoleum composition of the desired colors. Figure 3 shows essentially in diagram but in more detail the construction of the die roll. The die roll of Figure 3 is arranged for use in the production of a pattern such as illus tratedin Figure 5. Figure 5 shows a pattern of black and white squares 6 inches across. The circumferential length of the die is indicated on Figure 5 and it will be notedthat in any given longitudinal row of pattern elements the first and last squares in such row are of the same color.
The die roll of Figure 3 consists of a hollow cylindrical body 12 having on its surface knives 13 held in place by filler blocks 14. The knives divide the surface of the die roll into die cavities, a circumferential row of which cavities is shown in the cross section. In Figure 3 I have numbered these cavities, successively, as C1 to C9 inclusive. Each cavity is provided with one or more strippers indicated generally by the reference character 15. For simplicity, Figure 3 shows only one stripper for each cavity. Each stripper has a plate 16 substantially coextensive with its die cavity and an inwardly extending pin 17. Within the body 13 of each stripper there is a spring (not shown) for retracting the stripper after it has been urged outwardly. The strippers are actuated by a roll 19 which is shown as having pins 20 adapted to engage the pins l'7. The die roll and the pattern roll are geared together, and the gearing ratio is such that the pins 20 engage the pin or pins inevery second cavity. Therefore, as the die roll rotates the strippers are actuated in the order C1, C3, C5, C7, C9, C2, C4, etc. In Figure 3 the stripper for the cavity C1 is shown as urged to its outermost position for the purpose of laying an accumulation of cut-out pieces on the backing B. It will be noted that the cavities C3 and C5 contain two plies of material and are therefore ready for discharge, whereas the cavities C2, C4 and Cs contain but a single ply. The cavity Ca, which was emptied immediately prior to the cavity C1, is empty but will receive a thickness of material as it passes by the platen roll 8. The cavity C6 is shown in the act of receiving its first ply, while the cavity C1 which contains a single ply, shall shortly receive the second thickness of material.
' Figure 4 illustrates, to an exaggerated scale, a. possible theory explaining the good joints obtained by the multiple-ply method. Each of the plies, P has a tapered edge as indicated at 21. This tapering is due to the tapering of the knife edges as indicated in Figure 3. The bottom dimension of the upper ply is probably greater than the top dimension of the bottom ply, the bottom dimension of each ply-closely approximating the developed dimensions of the die cavity at its periphery; As a consequence the top surface of each pattern element closely approximates the desired theoretical dimensions, thus resulting in good joints. Itwill be understood, of
1 course, that in any case a certain amount of flow occurs when the goods passes throughthe calender, but a close and strong union will result from the above described relationship at the edges of theplies.
The specific embodiment of the invention thus out any scrap. Figures 2, 6 and 7 illustrate other applications of the invention wherein a certain amount of scrap is produced, but the amount of which is materially less than would be required if the pattern were produced in the ordinaryfashion. Figure 6 shows a four-color pattern in which two of the colors are marbles. The pattern is made up of squares D of plain color, rec tangles E of plain color, square blocks, F of dark marble and square blocks G of light marble. It is desired to minimize the amount of marble scrap. Figure 2 shows the machine set up for producing this pattern. The die rolls for the respective colors D, E, F and G are shown at D3, E3, F3 and G3. In this case the usual scrap conveyors 22 are provided, as are scrap rolls 23 with pins suitably placed thereon. The scrap rolls 23 lie inside the die rolls and eject undesired material from the die cavities into the scrap conveyor 22. For sake of clarity in the drawings, the pattern rolls and the rotary brushes have been omitted. The general construction and operation of these rolls are well known and require no further description. The die rolls D3 and E3 are operated in the usual fashion; that is to say, a webof full thickness is fed to each die roll and cut up into pattern elements and scrap. The scrap is discharged and the pattern elements are laid on the backing in the usual way. The die rolls F3 and G3 are supplied with Webs of halfthickness. There is discharged as scrap fromeach of the die rolls F3 and G3 a material in volume equivalent to onehalf the aggregate volume of the pattern elements D and E.
It will be noted that in each longitudinal row R of marbled blocks in the pattern, of Figure 6, two light marble blocks alternate with two dark marble blocks. Instead of calendering the dark marble Web of full thickness and discharging, in addition to the amount reviously mentioned, scrap corresponding to the areas of .the light marble blocks, the web is made half thickness and the blocks are accumulated and laid double thick, each of the die cavities for the block elements being arranged to discharge on every second revolution. The light marble web is similarly calendered to half thickness and similarlycut and laid. In this particular pattern the z aiggiunt of marble scrap is reduced approximately 125 Figure 7 shows another type of pattern consisting of dark marble squares H, light marble squares J, pattern elements of a plain field color K, and an interliner of plain color L. In this 130 case the interliner L and the plain color K are calendered as sheets of full thickness, while the marbles are calendered to half thickness. In this particular pattern the reduction in amount of marble scrap is'approximately 75%.
Reference has been made above to the satisfactory keying of the multi-ply pattern elements. It is found that this is obtained where a multi-ply pattern element joins a pattern element of single full thickness as well as in the case where two pattern elements, consisting of accumulated plies, are joined. h
Certain changes will be found necessary in' adapting a rotary machine of ordinary construc tion to'my invention, although these are all relatively simple incharacter. Reference has previously been made to the arrangement of the pattern roll so that it will actuate a given stripper. only at intervals greater than the time required for one revolution of the die roll. The scrap roll, 150
I peatsof 36 inches and 108 inches can be obtained,
in those patterns where some scrap is produced, may be actuated in the usual way, or in a fashion corresponding to the operation of the pattern roll.
Special provision must also be made for the so-called lubricating roll. As is well known, it is customary practice to actuate all the strippers at-each revolution of a die roll so that the plates 16 are projected outwardly to receive a thin film of lubricant, such as parafiin oil, which minimizes any tendency of the pattern elements to stick to the stripper plates instead of adhering as they should to the backing. Ordinarily a plane cylindrical roll is provided within the die roll for the purpose of urging the stripper pins outwardly. Wherea web of linoleum composition is calendered to fractional thinness'and pieces'are retained in the die roll throughout a full revolution, this arrangement of lubricating roll cannot be employed, as only those strippers for empty cavities may be lubricated. In Figure 3"1 have shown a roll 24, having pins 25 and similar in all respects to the roll 19, for urging the stripper pins outwardly at the proper time so that the plates 16 engage a soft cloth 'roll 26 which supplies the desired lubricant. It will be noted from Figure 3 that the stripper for the cavity C7, which cavity-contains a single ply of linoleum composition, is not actuated as it passes under the roll 26, but that one of the pins 25 will, upon continued rotation, engage the pin of the stripper for the empty cavity 08 so as to lubricate its stripper plate.
In addition to the advantages apparent from what has been said above, it will also be seen that the invention can be practiced with relatively little change in dies and equipment ordinarily employed in machines of this character. The machine may also be operated in certain case at relatively high speeds, particularly on heavy gauges. -While calendering to thinner gauges necessarily requires great care in maintaining proper and uniform thickness, it is also a fact that where heavy gauges of material are being made a marked limitation on the capacity of the machines lies in the limitation of mixing capacity. As stated, when making a four-color pattern in the ordinary way the volume of die scrap is three times the volume of mix laid, and
therefore four times the volume of the linoleum in the goods must be calendered, neglecting the volume of selvage trimming scrap. With the marked reduction in scrap attaintable by the use of my invention, the burden on the mixing apparatus is very greatlyreduced, thus improving the whole operation.
In addition to the ordinary 18 inch pattern and color repeat which is most usually found in goods made on the ordinary rotary machine, color rethus opening up a wide possibility of new pattern designs. The number of patterns in which my invention may find applicationis obviously very great, anditwillbeunderstood, therefore, thatthe foregoing description is by way of example only and that the invention may be otherwise embodied or practiced within the scopeof the following claims. 7 I claim:
1. In the method of making linoleum the steps consisting in presenting successively to a cutting die different areas of sheeted linoleum composi tion, cutting pieces out of successive areas, acoumulating the several cut-out pieces in the die,
removing the accumulated pieces and laying them on a backing in superimposed relation.
2. In the method of making linoleum the steps consisting in presenting successively to a cutting die different areas of sheeted linoleum composition, cutting pieces out of successive areas, aocumulating the several cut out pieces in the die and simultaneously ejecting the accumulated pieces onto a backing.
3. In the method of making linoleum in a rotary machine having a rotary die cylinder with a die surface thereon effective for cutting a web of linoleum composition into-pieces 'retainable within die cavities and'dischargeable therefrom onto a backing, the steps consisting in accumulating a plurality of pieces in a die cavity, the aggregate thickness of the accumulated pieces being a multiple of the web thickness, and simultaneously discharging the same onto a backing.
4. In the method of making linoleum in a rotary machine having a rotary die cylinder with a die surface thereon effective for cutting a web of linoleum composition into pieces retainable within die cavities and dischargeable therefrom onto a backing, the step consisting in discharging cut out pieces from the die cavity at intervals equal to the time required for a plurality of revolutions of the die roll.
5. In the method of making linoleum, the steps consisting in forming a web of linoleum mix of a thickness only a fraction of the desired full thickness in the final product, utilizing a die to cut pieces from the web, accumulating a sufficient number of pieces cut by the same die to make a piece of full thickness, and laying the accumulated pieces on a backing.
6. In the method of making linoleum, the steps consisting in forming a web of linoleum mix of a thickness only a fraction of the desired full thickness in the final product, utilizing a die to cut pieces from the web, accumulating a sufficient number of pieces cut by the same die to make a piece of full thickness, laying the accumulated pieces on a backing, and consolidating the accumulated pieces with one another and with adjacent pattern elements.
7. In the method of making linoleum in a rotary machine having a rotary die cylinder with a die surface thereon effective for cutting a web of linoleum composition into pieces retainable within diecavities and dischargeable therefrom onto a backing, the steps consisting in forming a web of linoleum mix of a thickness only a fraction of the desired full thickness in the final product, accumulating in a die cavity on the die cylinder sufiicient pieces to make a piece of full thickness, and laying the accumulated pieces on a backing.
- 8. In the method of making linoleum in a rotary machine having a rotary die cylinder with a die surface thereon effective for cutting a web of linoleum composition into pieces retainable within die cavities and dischargeable therefrom onto a backing, the steps consisting in forming a web of linoleum mix of a thickness only a fraction of the desired full thickness in the final face is divided by cutting edges into die cavities, the steps consisting in feeding a web of linoleum composition to the die so as to cut the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness in the final product, effecting discharge of material to a backing successively from die cavities circumierentially spaced apart in one revolution of the die, and effecting discharge of material to the backing. from intermediate die cavities on a subsequent revolution of the die.
10. In the method of making linoleum in a rotary machine having a rotary die whose sur face is divided by cutting edges into die cavities, the steps consisting in feeding a web of linoleum composition to the die so as to cut the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness in the final product, effecting discharge of material to a backing successively from die cavities circumferentially spaced apart in one revolution of the die, effecting discharge of material to the backing from intermediate die cavities on a subsequent revolution of the die and thus discharging pieces to the backing, in a desired sequence, from all the die cavities in a circumferential row.
11. In the method of making linoleum in a rotary machine having a rotary die whose surface is divided by cutting edges into die cavities, the steps consisting in feeding a web of linoleum composition to the die so as to cut the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness in the final product, eiTecting discharge of material to a backing successively from die cavities circumferentially spaced apart in one revolution of the die, effecting discharge of material to the backing from intermediate die cavities on a subsequent revolution of the die, thus discharging pieces to the backing, in adesired sequence, from all the die cavities in a circumferential row, cutting another web and accumulating pieces thereof in like manner and laying them on the backing between the pieces laid as first above recited.
12. In the method of making linoleum in a rotary machine having a rotary die whose surface is divided by cutting edges into die cavities, the steps consisting in feeding a web of linoleum composition to the die so as to out the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness in the final product, effecting discharge of material to a backing successively from die cavities circumferentially spaced apart in one revolution of the die, efiecting discharge of material to the backing from intermediate die cavities on a subsequent revolution of the die, thus discharging pieces to the backing, in a desired sequence, from 5 all the die cavities in a circumferential row,
forming another Web of desired full thickness, cutting the same into pattern elements and scrap, discharging the scrap, and laying the pattern elements on the backing intermediate the pieces laid as above described.
In the method of making linoleum in a rotary machine having a rotary die whose surface is divided by cutting edges into die cavities, the steps consisting in feeding a web of linoleum composition to the die so as to cut the same into pieces which are temporarily retained by the die cavities, the web of linoleum composition being only a fraction of the desired full thickness inthe final product, effecting discharge of maa subsequent revolution of the die, the entire web, except the selvages thereof, being cut and .laid on the backing.
14. In a rotary inlaying machine, a die roll having die cavities on its surface, means for feeding a backing material alongside the die roll so as to receive material from the die cavities, means for supplying to the die roll a web of linoleum composition whose thickness is only a fraction of the desired thickness, the cavities being adapted to temporarilv retain and accumulate a plurality of pieces cut from the web, and means effective when such a die cavity is adjacent the backing for ejecting the accumulated pieces from such cavity so as to deposit on the backing a pattern element made of a plurality of plies.
15. Apparatus for making linoleum comprising a die for cutting pieces from different areas of sheeted linoleum composition, means for supplying a backing material, means for effecting relative movement between the die and the backing so as to bring successive portions of the backing into position alongside the die, the die having a cavity adapted to temporarily retain cut-out pieces, and means effective when the die is alongside the backing material for ejecting the cut-out pieces after a plurality thereof have been accumulated in the die cavity.
16. In a rotary inlaying machine, a die roll having a die surface eifective for cutting a web of linoleum composition into pieces retainable within die cavities and dischargeable therefrom onto a backing, means for feeding a web of linoleum to said die roll, which web has a thickness of only a fraction of the desired full thickness, the die cavities being adapted to retain a plurality of cut out pieces, and means for ejecting onto a backing cut out pieces from a die cavity after a sufficient number thereof to aggregate the desired full thickness of material have accumulated therein.
17. In a rotary inlaying machine, a die roll having a die surface effective for cutting a web of linoleum composition into pieces retainable within die cavities and dischargeable therefrom onto a backing, means for feeding a web of linoleum to said die roll, which web has a thickness of only a fraction of the desired full thickness, the die cavities being adapted to retain a plurality of cut out pieces, means for ejecting onto a backing cut out pieces from a die cavity after a sufficient number thereof to aggregate the desired full thickness of material have accumulated therein, and a second die roll adapted to eject cut out pieces onto the backing intermediate the pieces laid thereon by the first mentioned die roll.
18. In a rotary inlaying machine a die roll having a die surface effective for cutting a web of linoleum composition into pieces retainable within die cavities and dischargeable therefrom onto a backing, means for feeding a web of linoleum to said die roll, which web has a thickness of only a fraction of the desired full thickness, the die cavities being adapted to retain a plurality of cut out pieces, means for ejecting onto a backing cut out pieces from a die cavity after a sufficient number thereof to aggregate the dethe time required for one revolution of the die roll whereby cut out pieces are retained in the die roll through at least a full revolution thereof, a lubricating means for: supplying lubricant to the strippers, and means for moving strippers into position to be operativelyengaged by the lubrieating means, said stripper moving means being arranged to actuate strippers only in those die cavities which are free of cut out material as they pass the lubricating means.
- ARLINGTON C. PERRY.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US618972A US1939275A (en) | 1932-06-23 | 1932-06-23 | Manufacture of linoleum |
GB22977/32A GB384959A (en) | 1932-06-23 | 1932-08-16 | Improved method of and apparatus for making linoleum |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US618972A US1939275A (en) | 1932-06-23 | 1932-06-23 | Manufacture of linoleum |
Publications (1)
Publication Number | Publication Date |
---|---|
US1939275A true US1939275A (en) | 1933-12-12 |
Family
ID=24479908
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US618972A Expired - Lifetime US1939275A (en) | 1932-06-23 | 1932-06-23 | Manufacture of linoleum |
Country Status (2)
Country | Link |
---|---|
US (1) | US1939275A (en) |
GB (1) | GB384959A (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3850724A (en) * | 1969-08-29 | 1974-11-26 | H Lehmacher | Apparatus and method for fabrication of carrying bags |
US5571372A (en) * | 1992-07-21 | 1996-11-05 | Kabushiki Kaisha F.C.C. | Process and apparatus for manufacturing clutch friction plate |
-
1932
- 1932-06-23 US US618972A patent/US1939275A/en not_active Expired - Lifetime
- 1932-08-16 GB GB22977/32A patent/GB384959A/en not_active Expired
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3850724A (en) * | 1969-08-29 | 1974-11-26 | H Lehmacher | Apparatus and method for fabrication of carrying bags |
US5571372A (en) * | 1992-07-21 | 1996-11-05 | Kabushiki Kaisha F.C.C. | Process and apparatus for manufacturing clutch friction plate |
Also Published As
Publication number | Publication date |
---|---|
GB384959A (en) | 1932-12-15 |
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