Abstract:
An application for an apparatus for manufacturing wallpaper with erasable match marks on a front surface includes an input roller for accepting a continuous sheet of wallpaper, an ink tray for holding erasable ink and a match mark print cylinder in fluid communication with the ink tray for accepting the erasable ink. A pressure roller in communication with the match mark print cylinder to press the wallpaper between itself and the match mark print cylinder. Guide rollers route the wallpaper from the input roller between the match mark print cylinder and the pressure roller through additional guide rollers and to an output roller. The match mark pattern is printed on the face of wallpaper with the erasable ink.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This application is related to U.S. application titled, “WALLPAPER WITH ERASABLE FRONT MATCH MARKS,” which was filed on even date herewith; attorney docket number 2380.0 and inventor Patrick J. Bluett. 
       FIELD OF THE INVENTION 
       [0002]    This invention relates to the field of positioning wallpaper and more particularly to a method of manufacturing wallpaper with marks for assisting in the matching of two abutting sheets of wallpaper. 
       DESCRIPTION OF THE RELATED ART 
       [0003]    Wallpaper is applied to a surface such as a wall in wide varieties of ways. Typically, wallpaper is applied to the entire wall surface and often to all or most of the wall surfaces in a room. 
         [0004]    Wallpaper is typically provided in rolls. Sheets of the approximate height of the wall are cut, water is applied to pre-pasted wallpaper or adhesive applied to un-pre-pasted wallpaper and the sheet is placed on the wall, adhesive side down, each sheet next to the previous sheet until the desired area is covered. 
         [0005]    Wallpaper comes in a wide variety of designs and patterns. As an example, one such wallpaper has a paisley pattern, having designs of paisley interspersed regularly across its surface. When two strips of wallpaper are to be placed next to each other, an aesthetic or other acceptable match of the two pieces of wallpaper can be obtained if the pattern on the wallpaper is subtle e.g. does not have a large dominant feature. However if the wallpaper does have a dominant feature such as the paisley pattern, it is preferable that the abutting sheets of the wallpaper are abutted such that the pattern flows across the entire wall and/or room. 
         [0006]    Typically, a pattern on wallpaper repeats at fixed intervals such as every two feet. To align such wallpaper, often a reference line is printed on each side of the back surface of the wallpaper. To successfully align the pattern, the right reference line of the first sheet needs to line up with the left reference line of the sheet to its right, and so forth. Unfortunately, once the first sheet is hung, it is difficult to find the location of the reference line being that the reference line is against the wall. Often, the wallpaper hanger will mark the wall with a pencil next to the location of the reference mark. That withstanding, when hanging the second sheet, it is difficult to find and see the pencil mark since it is covered by the second sheet and it is difficult to see/find the reference mark on the second sheet since it is on the adhesive side of the wallpaper. 
         [0007]    U.S. Pat. No. 6,024,821 to Cousineau describes a method of matching wallpaper borders using a clear plastic sheet. This method requires extra tools and is not described for matching wallpaper, only borders. 
         [0008]    What is needed is a wallpaper matching and alignment system that will improve the ease at which wallpaper with patterns is hung. 
       SUMMARY OF THE INVENTION 
       [0009]    In one embodiment, a method of manufacturing wallpaper with match marks is disclosed including (1) providing a continuous sheet of wallpaper; (2) printing a wallpaper pattern on the face of the continuous sheet of wallpaper using at least one wallpaper printing device; and (3) printing left match marks and right match marks on the face of the continuous sheet of wallpaper using a modified wallpaper printing device. 
         [0010]    In another embodiment, an apparatus for manufacturing wallpaper with erasable match marks on a front surface is disclosed including an input roller for accepting a continuous sheet of wallpaper, an ink tray for holding erasable ink and a match mark print cylinder in fluid communication with the ink tray for accepting the erasable ink. A pressure roller in communication with the match mark print cylinder to press the wallpaper between itself and the match mark print cylinder. Guide rollers route the wallpaper from the input roller between the match mark print cylinder and the pressure roller through additional guide rollers and to an output roller. The match mark pattern is printed on the face of wallpaper with the erasable ink. 
         [0011]    In another embodiment, an apparatus for manufacturing wallpaper with erasable match marks on a front surface is disclosed including a machine for accepting a continuous sheet of wallpaper, a machine for holding erasable ink and a machine for printing match marks in fluid communication with the machine for holding the erasable ink. A machine applies pressure to the continuous sheet of wallpaper in communication with the machine for printing match marks and another machine routes the continuous sheet of wallpaper from the machine for accepting the continuous sheet of wallpaper to the machine for printing the match marks at which location a match mark pattern is printed on a face of the continuous sheet of wallpaper with the erasable ink. A machine is provided for exiting the continuous sheet of wallpaper from the apparatus and other machines route the continuous sheet of wallpaper from the machine for printing the match marks to a machine for exiting. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
           [0013]      FIG. 1  illustrates a schematic view of a match marking system of the present invention. 
           [0014]      FIG. 2  illustrates a schematic view of a match marking system of the present invention after the match marks have been removed. 
           [0015]      FIG. 3  illustrates an isometric view of a roll of wallpaper of the present invention showing the match marks. 
           [0016]      FIG. 4  illustrates a typical printing device of the present invention for printing the match marks. 
           [0017]      FIG. 5  illustrates a plan view of a typical wallpaper printing operation of the present invention. 
           [0018]      FIG. 6  illustrates a flow chart of a method of hanging wallpaper using the match marks of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. Note that although the printing devices described here within use an engraved print cylinder, other print mechanisms are known in the industry and the present invention is not limited in any way to any particular print mechanism. Examples of such print mechanisms include rotary screen and flexo screen printing. 
         [0020]    Referring to  FIG. 1 , a schematic view of a match marking system of the present invention will be described. In this typical wallpaper with a pattern  16 , it can be seen that the pattern  16  repeats, in that in each successive sheet of wallpaper  5 / 6 / 7 / 8 . To achieve a desired level of aesthetic appeal, it is important that the patterns of each successive sheet  5 / 6 / 7 / 8  align with the previous sheet  5 / 6 / 7 / 8  so that the pattern continues across the entire covered surface. For example, in the simple pattern shown, the sail boats  16  align on a slight downward angle to the right. In other words, a sail boat  16  in the second sheet  6  is slightly lower than its corresponding sail boat  16  of the previous sheet (left)  5  and that follow through to the next sheet where a sail boat  16  in the third sheet  7  is slightly lower than its corresponding sail boat  16  of the second sheet  6 , and so forth. In this way, the pattern runs across the entire surface or wall. Without a method of aligning the sheets of wallpaper  5 / 6 / 7 / 8 , the pattern (sail boats  16 ) would be random and would not be aesthetically pleasing when viewed at a distance. 
         [0021]    To achieve this alignment, match marks  12 / 13 / 14 / 15  are printed on the face of the wallpaper. When hanging the wallpaper  5 / 6 / 7 / 8 , a paper hanger will typically start by applying a first sheet to the surface (wall) using wallpaper paste (note, some wallpaper is pre-pasted and need only be wet to activate the paste). The first sheet  5  is hung vertically on the wall and a second sheet  6  is prepared and hung to the right of the first sheet  5 . In order to assure correct pattern matching, the right edge match marks  12  of the first sheet  5  is aligned with the left edge match marks  14  of the second sheet  6 . Although the match marks  12 / 13 / 14 / 15  are shown with arrows  12 / 14  and words POINT  15  and MATCH  13 , any marking is envisioned that provides for alignment of one sheet to a subsequent sheet of wallpaper. 
         [0022]    Once the wallpaper  5 / 6 / 7 / 8  is hung and aligned correctly, there is no further need for the match marks  12 / 13 / 14 / 15 . Actually, the finished wall would not look good if the match marks  12 / 13 / 14 / 15  remained. Therefore, it is important that the match marks  12 / 13 / 14 / 15  be easily removable, preferably with a soft, wet cloth, sponge or the like. This is achieved through the use of inks that do not permeate into the wallpaper and are erasable when wetted with water. 
         [0023]    Referring to  FIG. 2 , a schematic view of a match marking system of the present invention after the match marks have been removed will be described. The sheets of wallpaper  5 / 6 / 7 / 8  are correctly hung and the patterns  16  flow correctly across the multiple sheets  5 / 6 / 7 / 8 . In  FIG. 2 , there are no match marks remaining. The match marks  12 / 13 / 14 / 15  as shown in  FIG. 1  were removed using a moistened instrument such as a wash cloth, rag, sponge, etc. It is preferred that the ink used to print the match marks be capable of being erased with minimal friction using water and such an instrument. It is also preferred that the ink be such that the ink dies not sublimate into the wallpaper, especially on very porous wallpaper surfaces. 
         [0024]    Referring to  FIG. 3 , an isometric view of a roll of wallpaper of the present invention showing the match marks will be described. Wallpaper  10  is normally provided on rolls as shown in  FIG. 3 . The wallpaper  10  of the present invention has match marks  12 / 13 / 14 / 15  for example, the left side arrow  12  that matches with the right side arrow  14 . In some embodiments, words  13 / 15  are printed above or below the arrows  12 / 14  to call attention to the arrows  12 / 14 , for example, “MATCH”  13  and “POINT”  15 . Many other match markings are possible in various shapes, styles, sizes and wording, all of which are included in the present invention. 
         [0025]    Referring to  FIG. 4 , a typical printing device of the present invention for printing the match marks will be described. The wallpaper printing device  30  has an input roller  50  for accepting a continuous sheet of wallpaper from previous printing devices (see  FIG. 6 ). In some embodiments, the input roller  50  contains a chiller roller as known in the industry for cooling the wallpaper before it enters the print rollers  32 / 54 . The wallpaper is guided by guide rollers  52  to the actual print mechanism that comprises a engraved print cylinder  32  with the pattern (e.g., match marks  12 / 13 / 14 / 15 ) and a pressure roller  54  that provides pressure to the wallpaper so it can accept the pattern from the engraved print cylinder  32 . The print cylinder  32  picks up ink from an ink tray  34  as it rotates. In some embodiments, a doctor blade (not shown) wipes off excess ink before the print cylinder  32  rotates beneath the wallpaper. The wallpaper with the printed match marks  12 / 13 / 14 / 15  then passes over additional guide rollers  52  through a heating area  56  to dry the inks and finally, the wallpaper passes around an output roller  58  to the roll processing area where it is rolled, cut and packaged. In some embodiments, the output roller  58  contains a chiller roller as known in the industry for cooling the wallpaper before it enters the roll processing area. 
         [0026]    The ink used to print the match marks  12 / 13 / 14 / 15  needs to be kept at a low temperature so it does not coagulate in the ink tray  34  or on the rollers. One such ink is “Aqua Safe Removable Ink” number 7.2377 from Polytex Environmental Inks, 820 East 140th Street Bronx, N.Y. 10454. To keep the ink at a low temperature, the ink is constantly cycled from a reservoir  37  through the ink tray  34  and back to the reservoir  37  by a pump  36 . The ink in the reservoir  37  is cooled by refrigeration coils  39  that are fluidly interfaced with a refrigeration unit  38  as known in the industry. In the preferred embodiment, the refrigeration coils  39  are immersed in the ink in the reservoir  37  (as shown). In alternate embodiments, the refrigeration coils  39  are disposed around the perimeter of the reservoir  37  or as known in the industry. Other methods of cooling the ink are known in the industry and included here within. 
         [0027]    Referring to  FIG. 5 , a plan view of a typical wallpaper printing operation of the present invention will be described. A continuous sheet of blank wallpaper enters a first printing device  70  and is printed with a first print cylinder  72  as known in the industry. After passing through the drier of the printing device  50 , the continuous sheet of wallpaper exits the first printing device  70  and enters the second printing device  60  and is printed with a second print cylinder  62  as known in the industry. It is well known how to print different sections or colors of a pattern using different print cylinders (e.g., the first print cylinder  72  and second print cylinder  62 ) with different color inks, etc. It is anticipated that, depending upon the pattern and number of colors, several printing devices  60 / 70  are used. This is well known in the industry. Although the match mark  12 / 13 / 14 / 15  is preferably printed on the face of the wallpaper by the print mechanism  30  after the pattern is printed, in alternate embodiments, it is printed before the pattern or in between other print steps. 
         [0028]    In the example shown, the final print stage is a print device  30  for printing the match mark  12 / 13 / 14 / 15 . This stage uses the ink cooling mechanism as described above consisting of the ink tray  34  fluidly coupled to the ink reservoir  37  by a pump  36 . The ink in the reservoir  37  is cooled by coiling tubes/coil  39  that is/are fluidly coupled to a refrigeration unit  38 . 
         [0029]    Referring to  FIG. 6 , a flow chart of a method of hanging wallpaper using the match marks of the present invention will be described. The described process for hanging wallpaper using the match marks of the present invention is abbreviated for clarity. Those skilled in the art will realize that hanging wallpaper requires cutting the sheets to the approximate height of the walls, if needed, trimming the sheets, making sure the sheets are applied vertically using a plumb bob, etc., and after the paper is hung, trimming and smoothing the paper. These steps are well known in the industry and are omitted to clearly describe the present invention. Also, some wallpaper is pre-pasted and, instead of applying paste as in steps  132  and  136 , the paste on the backing of the wallpaper is moistened with water. 
         [0030]    Hanging  130  begins with applying water or paste to a sheet of wallpaper  132  (the wallpaper is cut slightly longer than the height of the wall). Next, the sheet is placed vertically on the wall  134  (a plumb line is often used to assure a vertical hanging). Paste or water is then applied to the next sheet  136  and it is placed on the wall next to the previous sheet such that the match marks on the face of the right side of the first (previous) sheet align with the match marks on the face of the left side of the next sheet  138 . If more sheets of wallpaper need to be hung  140 , the previous two steps  136 / 138  are repeated until the wall is covered. Once finished hanging the wallpaper, the match marks on the face of the wallpaper are removed using a moistened cloth, sponge or other instrument and a slight rubbing motion  142  and the job is finished  144 . 
         [0031]    Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
         [0032]    It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.