Improvements in the Manufacture of Floor Cloth.
Year: 1892

page_text: Date of Application, 2nd Nov., 1892
Complete Specification Left, 1st Aug., 1893-Accepted, 2nd Sept., 1893
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Floor Cloth.
We, HENRY WILLIAM GODFREY, CHARLES FREDERICK LEAKE, Engineers,
and CHARLES EDWARD LUCAS, Linoleum Manufacturer, all of Staines, in the
County of Middlesex, do hereby declare the nature of this invention to be as
follows:-
The object of the invention is to produce a floor cloth from granulated linoleum
composition in various colours arranged according to a tesselated pattern and with
the tesseræ separated the one from the other by an outline. Such floor cloths have
before been produced excepting that the tesseræ have not been outlined, this being
impracticable by the methods heretofore employed, in consequence of the difficulty
there is in causing the granulated linoleum to penetrate between the tessere in the
small quantities suitable to form an outline. We produce tesseræ by means
hereinafter described arranged in order upon a suitable carrying fabric and with
narrow spaces between them into which the granulated material to form the
outline is to be filled. We then lay over the tesseræ a sheet of wire gauze having
pieces of sheet metal corresponding to the tesseræ fixed to it on its under surface so
that every tessera is covered with a similar piece of sheet metal but the outline
spaces between the tesseræ are left uncovered. Then on the upper surface of the
wire gauze we place finely granulated linoleum of the colour desired for the outline
and with a brush we move it to and fro over the gauze so as to cause it by degrees
to pass through the gauze and to fill the outline spaces. Afterwards the linoleum
fabric is consolidated by pressure.
The manufacture is conducted in the following manner :-A metal grid is
prepared to correspond to the pattern of the floor cloth to be made; the openings
in the grid represent the tessera and the bars the outline. This grid is laid upon
the carrying fabric and the cavities of the grid which are about half an inch deep
are filled with granulated linoleum. A pressing block is then applied it has
projections entering each of the cavities, a moderate pressure is applied and the
granulated linoleum being in an adhesive state is consolidated and forms the
The pressing block and the grid are then lifted off and the wire gauze
carrying the sheet metal pieces as already explained is applied and by its use the
spaces between the tessere left by the removal of the grid are filled with granulated
linoleum of the color to be used for the outline.
tesseræ.
Finally the tesseræ are placed beneath a prepared cloth or backing and the
whole is further consolidated by hydraulic pressure between metal plates.
It is obvious that the invention as above described is not limited to the
production of an outlined pattern but that any patterns of which comparatively
fine lines form a part may advantageously be produced in a like manner.
The projections of the pressing block above referred to are required as will be
seen to fit accurately the cavities of the grid and this we arrange for in the
following manner :- We make the pressing block with a wooden back and with
wooden projections fixed to this back. The projections are somewhat smaller than
the cavities but each is provided with a sheet metal head which fits accurately and
is secured to the projection by pins entering holes bored in the wood. The holes
are made somewhat too large for the pins so that a small amount of movement is
possible. The edges of the grid bars are removed to slightly enlarge the mouths
of the cavities so that the metal heads will enter them even if in consequence of

page_text: warpage or otherwise they should not be presented to the grid with perfect
accuracy.
H. W. GODFREY.
CHAS. F. LEAKE.
C. E. LUCAS.
COMPLETE SPECIFICATION.
Improvements in the Manufacture of Floor Cloth.
We, HENRY WILLIAM GODFREY, CHARLES FREDERICK LEAKE, Engineers,
and CHARLES EDWARD LUCAS, Linoleum Manufacturer, all of Staines, in the
County of Middlesex, do hereby declare the nature of this invention and in what
manner the same is to be performed to be particularly described and ascertained in
and by the following statement:-
The object of the invention is to produce a floorcloth from granulated linoleum
composition in various colours arranged according to a tesselated pattern and with
the tessera separated the one from the other by an outline.
Figure 1 of the annexed drawings shows an example of such floor cloth
pattern. In this figure a is the outline say in white. b c and d are the tessera
forming the pattern which may be of different colours arranged as indicated by the
letters; representing one colour another colour and d a third colour. The
colour is not simply on the surface but extends through the fabric. Such floor-
cloths have before been produced excepting that the tessera have not been
outlined, this being impracticable by the methods heretofore employed, in
consequence of the difficulty there is in causing the granulated linoleum to
penetrate between the tessere in the small quantities suitable to form an outline.
We produce tessera by means hereinafter described arranged in order upon a
suitable carrying fabric and with narrow spaces between them into which the
granulated material to form the outline is to be filled. We then lay over the
tesseræ a sheet of wire gauze having pieces of sheet metal corresponding to
the tessera fixed to it on its under surface so that every tessera is covered with a
.similar piece of sheet metal but the outline spaces between the tessere are left
uncovered. Then on the upper surface of the wire gauze we place finely granulated
linoleum of the colour desired for the outline and with a brush we move it to and
fro over the gauze so as to cause it by degrees to pass through the gauze and to
fill the outline spaces.
Afterwards the linoleum fabric is consolidated by pressure.
The manufacture is conducted in the following manner :-A metal grid is
prepared to correspond to the pattern of the floor cloth to be made.
Figure 2 is a plan of a portion of such a grid suitable for making the pattern
.shown by Figure 1.
Figures 3, 4 and 5 are sections taken on the lines 3. 3. 4. 4. and 5. 5 respectively
in Figure 2.
The openings in the grid represent the tesseræ and the bars the outline. This
grid is laid upon the carrying fabric and the cavities of the grid which are about
half an inch deep are filled with granulated linoleum. The carrying fabric is
prepared in a well known manner so that the material may not adhere to it so
firmly as to prevent a subsequent separation.
In filling the cavities of the grid we employ metal plates like stencil plates which
are laid over the grid. For the pattern shown by Figure 1 three such plates are
employed; first a plate with holes in it corresponding to the parts of the pattern
but otherwise complete. Granulated linoleum of the required colour at a suitable
temperature and prepared in the usual way is laid on the plate; it is brushed into
the exposed cavities of the grid and the surplus is removed with a straight edge.

page_text: Then the plate, with the surplus material upon it, is removed from the grid and it
is replaced by another plate with holes corresponding to the parts c of the pattern.
The exposed cavities of the grid are now filled as already described with granulated
linoleum of the second colour. In this way all the cavities of the grid are filled.
A pressing block is then applied, it has projections entering each of the cavities.
The underside view of a portion of such a block is shown at Figure 6 and a section
of the same at Figure 7; the section is taken on the line 7. 7 in Figure 6.
By the aid of this block a moderate pressure is applied and the granulated
linoleum being in an adhesive state is consolidated and forms the tesseræ. The
pressing block and the grid are then lifted off. A sieve having a bottom of wire
gauze is then applied. A portion of the bottom of such a sieve is shown at
Figure 8; it has pieces of sheet metal soldered upon it so as to stop out all the
parts excepting those corresponding to the outline of the pattern. The sieve might
be otherwise termed a perforated stencil plate, it is indeed a sieve and a stencil
plate combined. This sieve is applied and by its use the spaces between the
tessere left by the removal of the grid are filled with granulated linoleum of the
colour to be used for the outline.
Care is taken that the uncovered gauze is immediately over the spaces vacated
by the bars of the grid. Granulated linoleum of the outlining colour is placed in
the sieve and it is worked about lightly by the aid of a brush until enough has
passed through to fill the vacant spaces and to heap up into contact with the
gauze say an eighth of an inch above the level of the tesseræ. Then the sieve is
lifted off.
Finally the tesseræ are placed beneath a prepared cloth or backing and the
whole is further consolidated by hydraulic pressure between metal plates, as is
usually practised in making tesselated floor cloth. The pressure consolidates the
linoleum equally throughout and as the tesseræ have previously been to some extent
consolidated a narrowing of the outline results and in the finished fabric the outline
is considerably less broad than the bars of the grid. The carrying fabric is now
removed from the face of the floor cloth.
It is obvious that the invention as above described is not limited to the production
of an outlined pattern but that any patterns of which comparatively fine lines form
a part may advantageously be produced in a like manner.
The projections of the pressing block above referred to and shown by Figures 6
and 7, are required as will be seen to fit accurately the cavities of the grid and this
we arrange for in the following manner :-We make the pressing block with a
wooden back e and with wooden projections ffixed to this back. The projections
are somewhat smaller than the cavities but each is provided with a sheet metal
head which fits accurately and is secured to the projection by pins h entering
holes bored in the wood. The holes in the sheet metal heads 9 are made somewhat
too large for the pins so that a small amount of movement is possible. The edges
of the grid bars are removed to slightly enlarge the mouths of the cavities so that
the metal heads will enter them even if in consequence of warpage or otherwise
they should not be presented to the grid with perfect accuracy.
Having now particularly described and ascertained the nature of our said inven-
tion and in what manner the same is to be performed we declare that what we
claim is :-
1. The manufacture substantially as described of floor cloth composed of tesseræ
outlined by the use of a grid and a sieve, through which latter the outlining material
is made to pass into the spaces left between the tesseræ by the removal of the grid
as herein set forth.
2. The manufacture as defined in the first claiming clause of a tesselated floor
cloth with a line pattern penetrating amongst the tesseræ as herein set forth.
3. The use substantially as described in the manufacture of tesselated floor cloth,
of a grid and a pressing block; the latter adapted accurately to fit the former by

page_text: providing the projections of the pressing block with sheet metal heads attached by
pins in such manner as to admit of a small degree of freedom as herein set forth.
Dated this 28th day of July 1893.
H. W. GODFREY.
CHAS. FREDK, LEAKE.
C. E. LUCAS.