US2636542A - Inlaid floor covering and method of making same - Google Patents

Description

A rll 28, 1953 H. s. HUMPHREYS 2,636,542

INLAID FLOOR COVERING AND METHOD OF MAKING SAME Filed June 20. 1949 5 Sheets-Sheet 1 dOJ.

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INLAID FLOOR COVERING AND METHOD OF MAKING SAME Filed June 20, 1949 5 Sheets-Sheet 2 glwucmfm HuMPHREYs AP? 8, 1953 H. s. HUMPHREYS 2,636,542

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Patented Apr. 28, 1953 UNITED STATES PATENT OFFICE INLAID FLOOR. COVERING AND METHOD OF MAKING SAME Harry 8.. Humphrey's; Lancaster, Pa., assignor-to Armstrong Cork Company, Lancaster, Pa., a corporation of Pennsylvania Application June 20., 1949,. Serial No, 100,167

10' Claims. (CL. 154*26) This invention. relates. to the manufacture 01.;- surface coverings of the inlaid type, such as linoleum floor coverings. It i particularly concerned with the manufacture of a covering in simulation of a so-called spatter floor butv in which the covering has spatter-representing areas inlaid into the body of the covering.

spatter design floors have been used since early colonial times, particularly in New England. They have generally been created by applying a base color of paint to a wooden floor and then spattering a plurality of paints of variegating colors over the base color. A paint brush is usually dip ed. into paint of the variegating color and the. brush. is then struck flatwise against a short stick. or the like This results in. av discharge of small globules of paint which. are permitted to. fall in. random arrangement. upon the base coat. Some designs of this type have but one or two variegating colors applied. over. the base color in this manner, but others have numerous colors so applied.

This type of painted floor is not very durable and the variegating colorsv soon wear away in trafiicareas, leaving the base coat and eventually the floor board exposed.

An object of this invention is to provide an inlaid, surface covering in simulation of a spatter paint design in which the spatter design will extend substantially throughout the thickness. 01 l the wearing layer and will not. be subject to wearingoff before the covering has been completely worn out.

Another object of the invention is. to provide a processor making an inlaid spatter floor which provides for the. formation of spatter; areas of srally of. smaller size than the inlaid areas, are

heterogenecusly distributed throughout the thickness of the body layer.

An additional object is to provide a process of making. a spatter design utilizing conventional stenciling equipment of the type customarily employed in linoleum manufacture.

According to this invention there are prepared a. number of mixes of granulated inlaying composition or a base color and a plurality of varie- 2. gating colors. For purposes ofillustration, linoleum mixesv will be referred to throughout the specification. Other types of mixes which may be fed through stencil openings and subsequently consolidated into a sheet may be employed. The base color composition and the variegating color compositions are mottled together to' form a body mix of base color composition with the variegating color compositions heterogeneouslydistributed throughout the base color composition. The granules of variegating color compositions are of irregular shape and of varying size, being for the most part visually discernible. The body mix is strickled through a stencil, preferably onto a foundation orbaclsing layer of burlap or felt. The stencil is cut to provide open areas in the layer of base mix into which inlays of variegating color compositions may be deposited"; These inlays are formed of color compositions similar to the varie gating c0101" compositions of the body layer insofar as color is concerned but may be of finer granulation since they are deposited into the openings in the body layer as a mass of monocolor, and the individual granules are not necessarily visually discernible as such. Each of the variegating colors applied a inlays is deposited into openings in the body layer by strickling through stencils with appropriately spaced openings. Generally only one color composition will be deposited into each opening in the body layer, but. for a realistic spatter effect some of the openings may be partially filled .with one variegating color composition and the remainder filled with asecond variegating color composition. This will give the effect of two relatively large spatter areas, one overlying a portion of the other, similar to spatter paint areas where one paint is spattered over another. Of course the smaller spatter areas represented by the variegating color composition of the body layer will in many instances lie contiguous to the larger inlaid spatter areas because the body mix is formed of a plurality of variegating color compositions distributed throughout a base color composition.

A preferred embodiment of the invention will I be described in conjunction with the attached drawings, in which:

Figure l is a diagrammatic view of a molded inlaid linoleum. production line;

Figure 2 is a schematic layout for the stencils of the production line of Figure 1;

Figure 3 is a plan view of a portion of a stencil for the application of the body layer;

Figures 4 through 9 are plan views of portions of stencils for the application of the inlays into Figure 13 is a diagrammaticview similar to Figure 12 illustrating the stencilling of one of the inlays of the body mix.

Referring to Figure 1 there is shown a production line for the manufacture of inlaid surface coverings such as inlaid linoleum. This is a diagrammatic view, and mechanical strickling which make up the variegating color composition are of such size as to be visually discernible as particles when intermixed with the base color composition. Preferably they are of the same size as the base color, namely, fine enough to pass a 5-mesh screen to avoid any possibility of particle segregation which. might-occur if the average size of the base color and vari'egating color particles varied greatly. This size is larger than customarily used in molded inlaid linoleum manu ai l l rebut is necessary in order to produce visually discernible granules in the finished article. Care is used to obtain as great a proportion-as possible of particles near the upper equipment which may be employed'has not been" shown. In the manufacture of the covering, a

foundation is customarily employed; and in Figure 1 there is shown'arollz offoundation material which may be burlap or a waterproof felt, for example. The'foundation [is carried over a suitable support beneath a plurality of stencils 3 to 9, inclusive, whichare provided with openings through which the inlaying composition may-pass onto the foundation 2. In the manufacture of inlaid linoleum,- the stencils are generally about six feet one or two inches by about fifty-four inches. The width of the stencil is greater than six feet because additional width is required in the finished sheet of linoleum for trimming, the finallinoleum product being normally six feet wide, after trimming, and of indefinite length. After the application of the various color compositions to the foundation through the stencils, the foundation with its applied inlayingcomposition is pressed lightly at press Iii to prevent the granules of inlaying composition from shifting as the backing passes into a dipbetween the inlaying table and the first hydraulic press ll. Press H; consolidates the layer'of inlaying composition onto the backing. If desired, a second press 12 may beprovided for finishing the surface and further .consolidating the material. Where the product is linoleum which requires heat. curing, the foundation with its applied layer ishung. in festoons I3 in a stove and heat is applied for a period of time sufficient to cure the mass.

. The foregoing description of the inlaying. line is of a general nature to indicate how the process of the present invention may be practiced utilizing conventional molded inlaid linoleum manufacturing equipment. T

As an example of the method of this invention, reference is made to Figures 3 to 9, inclusive, showing a series of stencils for the manufacture of a spatter design surface covering in molded inlaid linoleum. For purposes of illustration it will be assumed that the base color is white and the variegating colors are red, yellow, green, blue, brown, and black. In the manufacture of the product,a mass of granulated white molded inlaid linoleum composition will be first produced, the granules being of such size that all will pass through a 5-mesh per inch screen, thus including particles varying in size from fine dustlike granules up to those which will just pass through'the 5-"mesh screen. Similar batches of variegating color composition will be prepared, each batch consisting of irregularly shaped .granulesof mono-colored composition,.one batch being red, a second yellow, and so on, one for each of the variegating colors. The granules limit on size and avoid the formation of too large a proportion offinegranules. 4

The proportioning of the variegating color compositions inthebase color may vary widely. A black base color, for example, may require a smaller proportioning of variegating colors than a- .white base color... ,Asa typical embodiment, the following'proportioning is given Pound? Base color-white 30" Variegating colors: H 1

Red 1 Yellow 1' Green' 1 Blue 1 Brown i 1 Black 1 The base and var'iegatin'g colors are mottled together'to produce a relatively free-flowing mass in which the variegating color compositions are heterogeneously distributed throughout the body of'the mix. 5 i j 7 The body layer of theI surfacecovering is formed by distributingtlie body mix described above through va'stencil suchas the section of a stencil shown in Figure 3 and to an enlarged scale in section in Figure 12, and which may be the stencil 3 of Figure 1. It will be notedthat the, stencil is made up of a plurality of stencil wires l4 disposed in one direction and other wires l5 disposed at right angles thereto to form an open gridwork through which color composition may pass, In those areas where it is desired to provide openings in the body layer'for'the reception ofinlays, solid members lfi'are provided and are fixed to the wires. 14 andJii. f In the first inlaying station, therefore, the body mix, includ ing the .base. color. composition. .and the individually discernible granules or variegating color. composition, is disposed upon the backing} and, substantially covers the'sam'e except inlthe areas below the solid members 16 of the stencil, which areas remain as'openings in 'the'body layer. Atthe first stencil about 92% of the total weight of the inlaying compositionconstituting the wearing layer of the coverin is applied, leaving 8%. of the weight to be completed by inlaid areas. Since the color composition of the body layer is relatively free fio'wing there is some tendency for the mix to slough at the edges ofthe openings and fall' onto the foundation at the base of --the openings; thus, the openings may not extend to the full depth of the body layer; but they will normally extend substantially throughout the full depth. This 'sloughing is minimized where mechanical strickling is accomplished.

The foundation with the body'layer thereon is moved into position, below the stencil 4,. and in that station. green iinlays 'may j be .insei ted' into acsaua i I 5. openings provided for their reception in the body layer. Figure 4 shows a section of a stencil cor-- responding -'to stencil 4 of. Figure 1 for the deposit of green-colored inlays.

The number and size of the openings in the stencils for the inlaid spatter colors will depend upon the proportioning of colors desired by the designer. A very attractive effect is obtained with the following proportioning in the white back- The inlays being generally larger than the individual granules of variegating color in the body layer standv out in greater contrast; and, by

having 2% red and 2% yellow, these two colors appear to predominate in the spatter efi'ect, with:

the white base color, of course, characterizing the whole design.

The preparation of the mix for the inlays is generally similar to that employed in the preparation of the body layer, except that the color composition is generally more finely granulated so that the particles are not individually discernible. The openings in the stencil are relatively. small in. area, and this too requires that the color composition be relatively line in order to properly strickle through the stencil openings and fill'the areas provided for their reception in the body layer. The inlaying color compositions maybo sieved to remove all particles larger than will pass through a 6 to S-mesh per inch screen; and, insofar as possible, the granules will be on the fine side with very few in the range which will just pass through the sieve. Since the inlays are monocolored. and are made up of a mass of.

granules, there is not the need for large granules in the inlaid areas that there is in the body: layer where the varietgating color composition.

granules must be individually discernible for the desired efiect.

The stencil shown in Figure 4 is provided with a plurality of openings H in a plate i8 which: is solid and maybe formed of zinc, for example; The openings ll are so disposed that when the founwith the openings ll being cut therein.

dati'on 2 with the body layer disposed thereon is brought into the station of stencil It the openin s i'i will overlie openings which have been left in the body layer due to the presence of, certain-oi.

the solid members E6 of the stencil of Figure 3. A small portion or the stencil including. one or the stencil openings ll is shown in the enlarged sectional view of Figure 13. Green inlaying cornposition is fed through the stencil openings IT at station 4, substantially completely filling those corresponding openings in. the body layer which lie below the stencil openings i't. As pointedout;

above, some few of the openings in the body layer may be filled with two or more inlay colors. joined with an irregular juncture line, but the majority will be inlaid with a single color.

The foundation 2 with the body layer and. the green inlays now moves into station where the stencil plate. is shown in Figure. 5 is positioned. This stencil is provided with openings 20,, and blue inlayi'ng composition is fed through these openings and is received within complementary openings provided in the body layer which is dis-- posed. below the stencil. This operation is repeated for stencils 6, l, 8, and 9 of Figure 1. The stencils are shown in Figures 6 to 9, inclu sive. Stencil plate 2! which is shown in Figure 6 applies brown. inlaying color composition through openings 22 provided in the plate; stencil plate 23 of Figure 7 applies black inlaying composition through openings 24 in the plate; stencil plate 25 shown in Figure 8 applies red inlaying composition through stencil openings 26 provided in that plate: and stencil 21 applies yellow inlaying composition through openings 28 in that stencil plate.

The stenciling of the inlaying color compositions into the openings in the body layer substan-- tially completely fills all of the openings provided: in the body layer. The foundation with the op,-

iied composition is then fed into press all where heat and pressure applied to consolidate the in lays and the body layer to form a flat-surfaced sheet. of the desired density, securely afiixed to the foundation. 2. A second pressing may be accomplished in press it to finally consolidate the mass and provide a smooth, dense surface. If the mass is formed of linoleum composition the material will then be hung into testoons it in a stove and cured, after which the material may be coated with lacquer or was or both.- trimmedv to the desired width, and rolled, ready.

for shipment and use.

The ortions of stencils shown in Figures. 3 to 9' may represent, for example, 18" x 18" sections of a '72" x 54" stencil plate. Figure 2 illustrates the manner of disposing such sections in the prepara* tion of a iuil-size stencil from an 18 x l8 master section. The top of. each. section. shown in Figures 3 to 9, inclusive. will be disposed in. the

orientation indicated in Figure 2. and will thus produce an irregular or random disposition of the inlays without readily discernible repeats in the full length and width of the stencil.

Reference is now made to Figures 3.0 and 1.1

-- which show the finished product. The body layer has been designated 29 and is composed of a white base composition 30' with particles M of variegating color compositions heterogeneously dis tributed therethroughout. described, there are particles of six variegating color compositions in the white base mix. It will be observed by reference to Figure 11 that the particles: of. variegating color. composition do not individually extend from the race to theback. of the. body layer; however, since the particles are randomly disposed throughout the thickness of the body layer some of the variegating particles. will always be disposed at the upper surface asv the covering wears away. The inlays 32" extend throughout the" thickness of the base layer as shown in Figure iii, and in the embodiment described there are inlays 32' in each of the six variegating' colors. No attempt has been made to show these by color in Figures 10' and 11 because of the small size of the illustration. The inlays are irregular in shape and have irregular edges as shown, thus. faithfully reproducing; the desired spatter effect. Some of the inlays are in. con

tiguous relationship, as those numbered 33, 34,.

and 35 in Figure 10 whichmay be areas or blue,

yellow. and black, for example, inlaid into an opening of appropriate shape provided in the body layer. Others of the inlays may also be made up 013 two-or more contiguous areas each of. monocolor.

In the embodiment- Figuresgi3 and .10 have been placed one above the other on the drawing to give a general indication. of the extent of the lateral spreading of the inlaying color compositions and the sloughin of the body layer. It will be noted that the solid portions I6 of the stencil of Figure 3 are relatively smaller than the inlaid areas. With large particles constituting the body layer, close conformity with the stencil is not obtained; and there is some minor sloughing. These factors result in inlays of somewhat larger uppersurface area than the surface areas of the solid portions l6 and in inlays having irregular edges, both desirable results in achieving a characteristic spatter design.

Thcvisu-al appearance of the finished product simulates a spatter floor having large and small spatters of the same colors upon a background color, The inlays representing the large spatters extend throughout the thickness of the wear layer of the covering, and the smaller but visually discernible particles -of the same colored variegating compositions extend throughout the thickness of the wear layer in random orientation and the design efiect will persist as the cover-- ing is worn. I

Because it is customary in spatter designs to have both large and small spatter areas of the same colors, the use of inlays of colors corresponding to the variegating colors of the body layer is desirable, although for some purposes some of the inlays may be of a color different from the variegating colors; and in other in-' stances more body variegating colors may be employed than inlaid colors to produce an effect similar to what might be achieved by spattering paints of different viscosities where all of the spatters of one particular color of paint may be relatively large or relatively small. Generally, however, as mentioned above, it is preferred to use inlaying colors the same as the variegating colors with inlays of all of the variegating colors being present at the surface and extending throughout substantially the whole thickness of the coverings,

While I have illustrated and described a pre ferred embodiment of the invention, itwill be understood the same is not limited thereto-but may be otherwise embodied and practiced within the scope of the following claims.

I claim: 1 1. In a method of making an inlaid material in simulation of a spatter painted surface, the steps comprising: forming a body layer of granulated inlaying composition having randomly disposed and irregularly shaped inlay-receiving openings therein, which openings are individualj ly substantially larger than thefgranules of sai body layer, by delivering granulated inlaying composition made up of heterogeneously intermingled granules of a base color and individually discernible, irregularly shaped granules of each of a plurality of variegating colors to a stencil and depositing the same through openings in said stencil, and forming in said body layer irregularly shaped monocolored inlays corresponding in colors to variegating colors of said individually discernible granules of said body layer by depositing through openings in other stencils and into said irregularly shaped inlay-receiving openings inf said body layer a plurality of monocolored masses of granulated inlaying composition, the colors of which correspond to variegating colors of said individually-discernible granules of said body layer.

=-2. In a method of making an inlaidmaterial in simulation of a spatter painted surface, the steps comprising: ;forming a body mix of heterogeneously intermingled granules of a base color composition and individually discernible,

irregularly shaped granules of a plurality of monocolored variegating color compositions, with the base color composition predominating by volume; forming upon a foundation a body layer having randomly disposed and irregularly;

' stencil onto said foundation; and forming in said body layer irregularly shaped monocolored inlays corresponding in colors to variegating colors of said individually discernible granules of said body layer by depositing through openings in other stencils and into said irregularly shapedinlay-r'eceiving openings in said body layer a plurality of monocolored masses of granulated in-. laying composition, the colors of which correspond to variegating colors of certain individually discernible granules of said body layer.

3. In a method of making an inlaid material in simulation of a spatter painted surface, the steps comprising: forming a body mix of individually discernible, irregularly shaped granules of abase color composition and a plurality of variegating color compositions, with the base color composition predominating by volume; forming upon a foundation a body layer having randomly disposed and irregularly shaped inlay-receiving openings therein, which openingsare individually substantially larger than the granules of said body layer,-by delivering said body mix to a stencil and depositing the same through openings in said stencil onto said layer irregularly shaped monocolored inlays by depositing through openings in other stencils and into said irregularly shaped inlay-receiving openings in said body layer said granulated variegating color composition mixes.

4. In a method of making an inlaid material in simulation of a spatter painted surface, the steps comprising: forming. upon a foundation 8. body layer of granulated inlaying composition having randomly disposed and irregularly shaped inlay-receivingopenings therein, which openings are individually substantially larger than the granules of said body layer, by delivering granulated inlaying composition made up of heterogeneously intermingled granules of a base color and individually discernible, irregularly shaped granules of each of a plurality of variegating colors to a stencil and depositing the same through openings in said stencil onto said foundation; forming in said body layer irregularly shaped monocolored inlays-corresponding in colors to variegating colors of said individually discernible granules of said body layer by depositing through openings in other stencils and into said, irregularly shaped inlay-receiving openings in said body layer a plurality of monocolored masses-of granulated inlaying composition, the colors of which correspond to variegatcolors of said individually discernible granules of said bodylayer, with each of said openings being filledewith. inlaying color composition which;'

9. extends substantially throughout'the thickness of the body. layer; and consolidating said body layer and inlays into a homogeneous sheet.

5. In a method of making an inlaid material in simulation of a spatter'painted surface, the

steps comprising: forming a body layer of granulated inlaying composition having randomly disposed and irregularly shaped inlay-rcceiving openings therein, which openings are individually substantially larger than the granules of said body layer, by delivering granulated inlaying "composition made up of heterogeneously intermingled granules of a base color and individually discernible, irregularly shaped granules of each of apluralityofyariegating colors to a stencil and depositing the same "through openings'in said stencil, and forming in said body layer irregularly shaped monocolored inlays corresponding in colors to variegating colors of said individually discernible granules of said body layer by depositing through openings in another stencil and into certain of the irregularly shaped inlay-receiving openings in said body layer a monocolored mass of finely granulated inlaying composition, the granules of which are nonindividually discernible and the color of which corresponds to one of the variegating col rs of said individually discernible granules of said body layer, and repeating the application of similar monocolored masses through other stencil openings until all of said openings in the body layer have been filled with inlaying color compositions corresponding in colors to the variegating color compositions of the body layer.

6. In a method of making molded inlaid linoleum in simulation of a spatter painted surface, the steps comprising: forming upon a foundation a body layer of granulated molded inlaid linoleum composition having randomly disposed and irregularly shaped inlay-receiving openings therein, which openings are individually substantially larger than the granules of said body layer, by delivering granulated molded inlaid linoleum composition made up of heterogeneously intermingled granules of a base color and individually discernible, irregularly shaped granules of each of a plurality of variegating colors to a stencil and depositing the same through openings in said stencil onto said foundation, and forming in said body layer irregularly shaped monocolored inlays corresponding in colors to variegating colors of said individually discernible granules of said body layer by depositing through openings in other stencils and into said irregularly shaped inlay-receiving openings in said body layer a plurality of monocolored masses of granulated molded inlaid linoleum composition, the colors of which correspond to variegating colors of said individually discernible granules of said body layer.

7. In a method of making molded inlaid linoleum in simulation of a spatter painted surface, the steps comprising: forming upon a foundation a body layer of granulated molded inlaid linoleum composition having randomly disposed and irregularly shaped inlay-receiving openings therein, which openings are individually substantially larger than the granules of said body layer, by delivering granulated molded inlaid linoleum composition made up of heterogeneously intermingled granules of a base color and individually discernible, irregularly shaped granules of each of a plurality of variegating colors to a stencil and depositing the same through openings in said stencil onto said foundation; and forming in said body layer irregularly shaped monocolored inlays corresponding in colors to variegatin'g colors of said individually discernible granules of said body-layer by depositing through openings in another stencil and into portions only of some of said irregularly shaped inlay-receiving openings in said body layer a-monocolored mass of granulated molded inlaid linoleum composition,

the color of which corresponds to a *v-ariegating.

color composition of the body mix, while com- "pletely filling ethers of said openings with said monocolored inlay composition, and thereafter complet ng the filling of said partially filled'openings with monocolored-masses composed of granules of molded inlaid linoleum composition of a different color, corresponding to another variegating color of the individually discernible granules of the body layer and completely filling others of said openings with said composition of a different color.

8. An inlaid material simulating a spatter painted surface comprising: a body layer formed of granulated inlaying composition made up of heterogeneously intermingled granules of a base color and individually discernible, irregularly shaped granules of each of a plurality of variegating colors extending irregularly throughout the thickness of said body layer, and irregularly shaped monocolored inlays, the colors of which correspond to variegating colors of said individually discernible granules of said body layer, randomly disposed in said body layer and extending from the upper surface thereof substantially throughout the thickness of said body layer, said inlays being formed of a plurality of monocolored masses of granulated inlaying composition inlaid into openings provided in the body layer, said inlays being individually larger at the upper surface of the body layer than the individual surface areas of said discernible granules of variegating color composition disposed in the upper surface of the body layer.

9. An inlaid material simulating a spatter painted surface comprising: a body layer formed of granulated inlaying composition made up of heterogeneously intermingled granules of a base color and individually discernible, irregularly shaped granules of each of a plurality of variegating colors extending irregularly throughout the thickness of said body layer and irregularly shaped monocolored inlays, the colors of which correspond to variegating colors of said individually discernible granules of said body layer, randomly disposed in said body layer and extending from the upper surface thereof substantially throughout the thickness of said body layer, said inlays being formed of a plurality of monocolored masses of non-individually discernible granules of inlaying composition inlaid into openings provided in the body layer, said inlays being individually larger at the upper surface of the body layer than the individual surface areas of said discernible granules of variegating color composition disposed in the upper surface of the body layer.

10. A molded inlaid linoleum simulating a spatter painted surface comprising: a body layer formed of granulated molded inlaid linoleum composition made up of heterogeneously intermingled granules of a base color molded inlaid linoleum composition and individually discernible, irregularly shaped granules of each of a plurality of variegating colors extending irregularly throughout the thickness of said body layer, and irregularly shaped monocolored inlays, the colors of which correspond-to variegating colors of said individually discernible granules of said body layer, randomly disposed in said body layer and extending from the upper surface thereof substantially throughout the thickness of openings provided in the body layer, said inlays being individually larger at the upper surface 'of the body layer than the individual surface areas of said discernible granules of variegating color composition disposed in the upper surface 10f the body layer.

HARRY s. HUMPHREYS.

12 References Cited in the file of this patent 4 UNITED STATES PATENTS Number Name Date Ekstrom Mar. 15, 1904 Jackson June 24, 1930 Ledeboer Feb. 3, 1931 Hartman et-al "Apr. 19, 1932 Humphreys May 30, 1933 Humphreys June 6, 1933 Phelan June 27, 1933 Kessler Nov. 28, 1933 Kaufman et al. Dec. 19, 1933 Berger May 6, 1941 Berger Dec. 22, 1942 Berger Nov. 27, 1945

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