Improvements in the Manufacture of Mosaic Floor Cloth and other like Mosaic Fabrics, and in Machinery to be Employed for that Purpose.
Year: 1888

page_text: The decision of the Comptroller-General, of the 9th day of March 1898, allowed,
under Section 18 of the Patents, &c. Act, 1888, an Amendment of this
Specification.
The Amandmmba
Date of Application, 10th Nov., 1888
Complete Specification Left, 12th Aug., 1889-Accepted, 9th Nov., 1889
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Mosaic Floor Cloth and other
like Mosaic Fabrics, and in Machinery to be Employed for that
Purpose.
I, FREDERICK WALTON of 4 Portugal Street, Lincoln's Inn Fields, London,
Manufacturer, do hereby declare the nature of this invention to be as follows:-
This invention has for its object improvements in machinery to be employed in the
manufacture of mosaic floor cloth and other like mosaic fabrics.
The material known as Linoleum and like oxidised oil compositions are particularly
suited for the manufacture of mosaic or inlaid fabrics in accordance with my
invention.
I provide this material in various colors rolled out into sheets preferably by
non-metallic rollers such as polished granite or porphyry rollers fitted on iron or
steel shafts made hollow to facilitate their being heated by steam. I roll these sheets
of Linoleum either on canvas or on an endless finely woven wire cloth from which
they are taken off or I roll them on thin paper and use them with this backing of
thin paper or roll very fine threads into or onto the sheets for support whilst
manufacturing.
By the improved mechanism I will describe I cut out pieces of tesserae of different
colors and of any required design and combine these upon a sheet preferably of the
sane material spread upon a backing of woven fabric or woven fabric combined with
paper. To ensure greater adhesiveness to the pieces of tesserae on the backing I
spread on the face of this backing a layer of oil cement or a quick drying cement
produced from a solution of solidified oil or Kowrie or other hard gums and rosin.
When the tesserae are set I join and consolidate the whole by beat and flat pressure.
By this latter process I produce either a smooth or figured surface as required.
The blocks for cutting out the pieces or tesserae I construct in the manner described
in my Patent No. 6039 of the 18th December 1882.
The improved machine in which I produce the mosaic fabric is constructed as
follows.
A strongly constructed cast iron drum forming a polyhedron with four or more
sides parallel with the centre shaft of the drum is mounted horizontally in bearings
in a strong framework and receives a step by step intermittent revolving motion.
On the faces or sides of this drum are fastened the cutting blocks.
Above the top
of the drum is a plate which can be forced downwards by a press for the purpose of
cutting the Linoleum sheets into tesserae. Below the bottom of the drum is a second
but steam heated press plate for setting and pressing the tesserae on to the backing.
Both presses work simultaneously each time that the drum ceases to turn. When
the drum moves the tables of the presses stand still and are clear of the faces or
cutting blocks of the drum. After each complete revolution of the drum the
backing fabric is moved a distance equal to the width of the cutting blocks.
A sheet of linoleum of any desired colour is placed on to each side of the drum
before that side comes below the upper press plate. When by the revolution of the
drum the sheet is brought below the upper press plate it is cut into tesserae by the

page_text: plate being pressed downwards on to the block. Afterwards when by the further
rotation of the drum the cut up sheet is carried away from below the plate those of
the pieces of the cut up sheet which are not to be placed on to the backing are
removed from the block by the action of plungers which are set into the block as
described in my former Patent No. 603952 or by the action of a flap or plate of thin
sheet metal which is cut out so as to fit between the knives of the block and is
caused to turn outwards from the block on a hinge joint when the pieces are to be
removed.
Afterwards when by the further revolution of the drum the block is brought into
a position over the lower press plate the backing to which the pieces are to be
caused to adhere is pressed upwards to the block and the pieces are pressed outwards
on to the backing by plungers.
By employing for instance a drum with eight sides I am enabled to work with
eight cutting blocks and produce assuming I give the blocks a width of eighteen inches
a mosaic fabric in two, four or eight colors and with one full revolution of the drum
I produce two yards with two colors or one yard with four colors or half a yard with
eight colors.
The plungers are worked by two plates for each cutting block. These plates move
inside the drum behind the cutting block and work or press on pins which traverse
this block. The plate nearest to the cutting block is perforated for the pins which
work the plungers for setting the tesserae ou to the backing to pass through. These
pins after passing through this plate come into contact with the second plate which
presses on them and drives the rejecting plungers in the cutting block forwards to
clear it of all superfluous pieces. When the blocks arrive over the bottom press plate
then the first or nearest plate behind the cutting blocks comes into action and pressés
on all pins which do not traverse this plate, pushes them forwards with their plungers,
clears the cutting block and sets the tesserae on the backing.
The sheets of Linoleum to be cut into tesserae are conducted to the machine by an
endless wire cloth which passes over a heated steam chamber.
To prevent the cutting knives becoming sticky a plate covered with a thick blanket
and kept moist with turpentine or other suitable lubricant moves against each cutting
block before such block receives the Linoleuin sheets to be cut.
For consolidating the mosaic fabric I use preferably a steam press in which the
table of the press is moved by the piston of a steam cylinder. The table and head of
this press are both steam heated. When the fabric passes through this press for the
purpose of being joined and solidified a continuous or endless shoet of japanned cloth
or an endless smooth or polished metal sheet or an endless wire cloth passes with the
fabric between its face and the head of the press.
When cutting the tesserae from different colored sheets of Linoleum it frequently
happens that the rejected tesserae are useful to form a pattern of the same design but
of different coloring. I collect these tesserae and set them by hand into a specially
constructed block, having the full design of the pattern in steel or metal bands.
When the whole pattern is set I use this block like a printing block and transfer
the tesserae onto a prepared backing and afterwards join the whole by pressure
and heat.
In some cases I use the metal cutting blocks by hand-by placing the softened
sheet of color onto a padded even surface and to obtain the necessary pressure to cut
out the pieces I employ a press somewhat similar to that used for pressing floorcloth
printing blocks. The blocks thus filled after the useless pieces are rejected can be
.applied to the prepared foundation cloth in the same manner as printing is done--and
the whole can be then consolidated by a separate process.
It is advantageous in some cases whether the pieces are set in by hand or machinery
to produce an outlined form by the method adopted in manufacture of my patent wall
decoration in which to fill the tesserae.
Dated this 10th day of November 1888.

page_text: COMPLETE SPECIFICATION (AMENDED).
Improvements in the Manufacture of Mosaic Floor Cloth and other
like Mosaic Fabrics, and in Machinery to be Employed for that
Purpose.
I, FREDERICK WALTON of 4 Portugal Street Lincolns Inn Fields London
Manufacturer 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 :-
This Invention has for its object improvements in the process and machinery to be
employed in the manufacture of mosaic floorcloth and other like mosaic fabrics.
The material known as Linoleum and like oxidised oil compositions are particularly
suited for the manufacture of mosaic or inlaid fabrics in accordance with my
Invention.
I provide this material in various colors rolled out into sheets preferably by
non-metallic rollers such as polished granite or porphyry rollers fitted on iron or
steel shafts made hollow to facilitate their being heated by steam. Or I use rollers
ocated with personer electro plated with inoxidizable metal or otherwise coated
with hard inoxidizable material. In most cases this is desirable because when
manufacturing mosaic floor cloth or like mosaic fabrics in the manner hereinafter
described the Linoleum material or likè oxidized oil compound has in many cases to
be passed several times between the rolls to be reformed into sheets before it is used-
as when pieces have been punched out from one sheet the remainder of the sheet
which is not required for the pattern to be formed has to be reworked and again
formed into sheets so that the material is often brought into contact with the rollers
and if the surface of the rollers is such that it can be at all acted on by the material
there is liability of the material becoming discolored. For the same reason also I
coat with enamel or inoxidizable metal or material both the mixing blades and the
interior of the mixing machines used for reducing the waste material to a dough
before again submitting them to the action of the rollers. I roll the sheets of
Linoleum either on canvas or on an endless finely woven wire cloth from which they
are taken off or I roll them on thin paper and use them with. this backing of
thin paper or roll very fine threads into or onto the sheets for support whilst
manufacturing.
By the improved mechanism I will describe, I cut out pieces of tesserae of different
colors and of any required design and combine these upon a sheet preferably of the
same material spread upon a backing of woven fabric or woven fabric combined with
paper. To ensure greater adhesiveness to the pieces of tesserae on the backing I
spread on the face of this backing a layer of oil cement or a quick drying cement
produced from a solution of solidified oil or Kowrie or other hard gums and rosin.
When the tesserae are set I join and consolidate the whole by heat and flat pressure.
By this latter process I produce either a smooth or figured surface as required.
The blocks for cutting out the pieces or tesserae I construct in the manner described
in iny Patent No. 6039 of the 18th December 1882.
The improved machine in which I produce the mosaic fabric is constructed as
follows:-
A strongly constructed cast iron drum forming a polyhedron with of polygonal
section having four or more sides parallel with the centre shaft of the drum is mounted
horizontally in bearings in a strong framework, and receives a step by step
intermittent revolving motion. On the faces or sides of this drum are fastened the
cutting blocks. Above the top of the drum is a plate which can be forced downwards
by a press for the purpose of cutting the Linoleum sheets into tesserae. Below the
bottom of the drum is a second but steam heated press plate for setting and pressing
the tesserae on to the backing. Both presses work simultaneously each time that the
drun ceases to turn. When the drum moves the tables of the presses stand still and
are clear of the faces or cutting blocks of the drum. After each coinplete revolution

page_text: of the drum the backing fabric is moved a distance equal to the width of the cutting
blocks.
A sheet of Linoleum of any desired colour is placed consecutively on to each
succeeding side of the drum before that side comes below the upper press plate. When
by the revolution of the drum the sheet is brought below the upper press plate it is
cut into tesserae by the plate being pressed downwards on to the block. Afterwards
when by the further rotation of the drum the cut up sheet is carried away from below
the plate those of the pieces of the cut up sheet which are not to be placed on to the
backing are removed from the block by the action of plungers which are set into the
block as described in my former Patent No. 6039 or by the action of a flap or plate
of thin sheet metal which is cut out so as to fit between the knives of the block and
is caused to turn outwards from the block on a hinge joint when the pieces are to be
removed.
Afterwards when by the further revolution of the drum the block is brought into a
position over the lower press plate the backing to which the pieces are to be caused
to adhere is pressed upwards to the block and the pieces are pressed outwards on to
the backing by plungers.
By employing for instance a drum with eight sides I am enabled to work with
eight cutting blocks and produce assuming I give the blocks a width of eighteen inches
a mosaic fabric in two, four or eight colours and with one full revolution of the drum
I produce two yards with two colours or one yard with four colours or half a yard
with eight colours.
The plungers are worked by two plates for each cutting block. These plates move
inside the drum behind the cutting block and work or press on pins which traverse
this block. The plate nearest to the cutting block is perforated for the pins which
work the plungers for setting the tesserae on to the backing to pass through. These
pins after passing through this plate come into contact with the second plate which
presses on them and drives the rejecting plungers in the cutting block forwards to
clear it of all superfluous pieces. When the blocks arrive over the bottom press plate
then the first or nearest plate behind the cutting blocks comes into action and presses
on all pins which do not traverse this plate, pushes them forwards with their plungers,
clears the cutting block and sets the tesserae on the backing.
The sheets of Linoleum to be cut into tesserae are conducted to the machine by
an endless wire cloth which passes over a heated steam chamber.
To prevent the cutting knives from becoming sticky a plate covered with a thick
blanket and kept moist with turpentine or other suitable lubricant moves against each
cutting block before such block receives the Linoleum sheets to be cut.
For consolidating the mosaic fabric I use preferably a steam press in which the
table of the press is moved by the piston of a steam cylinder. The table and head of
this press are both steam heated. When the fabric passes through this press for the
purpose of being joined and solidified a continuous or endless sheet of japanned cloth
or an endless smooth or polished metal sheet or an endless wire cloth passes with the
fabric between its face and the head of the press.
When cutting the tesserae from different colored sheets of Linoleum frequently
happens that the rejected tesserae are useful to form a pattern of the same design but
of different coloring I collect these tesserae and set them by hand into a specially
constructed block, having the full design of the pattern in steel or metal bands.
When the whole pattern is set I use this block like a printing block and pressing it on
backing coated with cement so as to transfer the tesserae on to a prepared the backing
and afterwards join the whole by pressure and heat.
In some cases I use the metal cutting blocks such as are above described for operating
by hand by placing the softened sheet of color softened by heating onto a padded even
surface and to obtain the necessary pressure to cut out the pieces I employ a press
somewhat similar to that used for pressing floor cloth printing blocks. The blocks
thus filled after the useless pieces are rejected which may be done by picking them out
can be applied to the prepared foundation cloth backing in the same manner as
printing is done and the whole can be then consolidated by a separate process.

page_text: dvantageo
ases whether the pieces are set in by hand or machinery
to produce an outlined form by means of embossed rollers as adopted in manufacture
of my Patant wall decoration in which
5
DESCRIPTION OF THE DRAWINGS.
In the several figures the same letters of reference indicate corresponding parts.
Figure I represents a side elevation of the machine.
Figure II is a vertical section.
Figure III is a plan in section of one end of the machine shewing the parts by
which the requisite movements are imparted.
Figure IV is an elevation of some of these parts.
Figures V and VI represent in plan and elevation a polyhedron box of polygonal
section for the reception of surplus material.
Figure VII is a section on a larger scale of part of a cutting and setting block with
its bed plate.
A is the principal frame of the machine. B the two ends of the polygonal
drum, these two ends are connected by cross bars a.
The drum Bis keyed on the shaft C turning in three-plumber blocks b. The drum
carries on its sides bed plates 6 which are screwed on ledges which are cast with the
ends of the drum or screwed on to them.
On these bed plates are fastened the cutting and setting blocks e which are held
and adjusted by set screws f. Behind the bed plates c are the two movable plates g
and fastened on brackets or knees k which pass through slots in the ends of the
drum B. The plates g and h with their brackets are supported either by spiral
springs as shown in Figure II or by india rubber buffers as shown in m.
Figure I.
The plates have a short outward stroke given to them when their brackets k are
as the drum B revolves caused to slide over adjustable cams X.
their motion when the drum B is at rest, it is given to them on the downward motion
The plates g receive
of the rods E by adjustable hands Y which project from these rods..
7' 7' are
In Figure VII are the cutting knives embedded in the cutting block.
plates of the shape of the tesserae-q and q are pins passed through holes drilled
through the block and screwed to the plates. Each pin has fast with it a disc which
forms a shoulder around it, these discs are received into recesses in the back of the
cutting blocks e. The shoulders on the pins q which have to reject the cuttings or
pieces not wanted in the design lie in deep recesses p in each of which a small spring
is inserted. All the pins or plungers pass through the bed plate c and the rejecting
pins pass through the plate g.
A crossheads having guidest slides in the frame of the machine. This crosshead
carries a plate D, fitted underneath with a lead, rubber or gutta percha plate. The
plate D is adjustable by screws traversing the crosshead, it forms a press and is moved
by the rods E and crank levers F.
Under the drum B is the crosshead G (see figure 2) it carries by set screws u, which
can swing in the brackets v, the steam heated box H which slides in the guides w.
The crosshead G receives its motion from crank levers I. The four angle levers F
and I swing ou the stationary shaft J.
The crank levers F and receive a rocking motion from the shaft K. On this
shaft are fastened (for each angle lever) two cams Land M which in their revolution
give an alternating motion to the bridles N. These bridles are connected by rods O
and P with the crank levers F and J and are guided at the back by guides Q. A
spur wheel R on the shaft K is driven by a pinion from the shaft S. The motion
of shafts K and S is continuous.
On the shaft K is the crank T with an adjustable crank pin (see Figure II, III
and IV). This crank pin is connected by the rod x with a head y which is jointed
to an arm that can swivel around the shaft C. The pawl a¹ in the head y works in
ts forward motion in one of the divisions or notches of the disc U and turns the disc

page_text: one eighth of a circle as shown or it might be the another arc of a circle. On its
return motion the pawl a' slides over the faces of U and falls into the next notch.
A second disc V stops each motion by the pawl W when one eighth of a full rotation
of the disc U is accomplished.
The frames Z carry bearings for drums A¹ over which runs an endless steel band B¹
covered with a rubber or leather belt. This belt is closely set with pins all along
about one quarter of an inch apart. The fabric or backing passes from a reel, not
shown in the drawings, between the rollers D¹ and E' and from there under the
runners C¹ which have a jacket of rubber. The runners C¹ press the backing into
the pins of the belts B¹ which carry the backing forwards. The backing receives
before passing the ductor blade F¹ a coating of adhesive material, the thickness of
which is regulated by the adjustable ductor F¹.
The belts B¹ are moved a determined distance after a complete pattern has been
placed by the blocks on to the backing. The frequency of the movement will vary
according to the number of colours required in a full design, for instance say 3 or 4
or more. To give the forward motion to the backing, pins G¹ are fixed in the disc U
(Figure 4). These pins act on a lever Has the drum B revolves. The lever H¹ is
connected by the rod I' with the lever J. H¹ and J'are slotted for the adjustment
of the stroke of the lever H¹: A pawl K¹ carried by J¹ works in the notches of a
disc Land by a forward stroke this disc L' receives (as it is here shown) a quarter
turn. The disc L' being fast on the shaft M¹ moves the pullies A' and consequently
the bands B¹. The lever J which swings on the shaft M¹ has a counterweight N¹.
Pulleys Z¹ and a belt connects the shaft M¹ with the roller D¹ for the purpose
of taking some of the strain off from the belts B¹ and the backing in their
motion.
On an independent framework from the machine runs an endless wire cloth T¹
round rollers 0¹ over a steam box P1. The wire cloth carries forward the linoleum
sheets to be cut into tesserae in proper order to the attendant who has to place them
on to the cutting block. Qis a moveable plate faced with thick felt kept moist with
e, when
a solvent. This plate is moved by the arm R¹ against the cutting blocks
the drum B is at a standstill and moistens the knives of the cutting blocks with the
solvent. The arm R¹ receives its motion by the bridles N which are connected with
the angle levers F.
The rejecting of the material which is not to be set on the backing takes place
when the blocks are in the position marked V₁. This material drops into a hopper c¹
and falls on an endless blanket which has a continuous notion. The blanket moves
over and returns under the belts B₁ it is carried so far forwards that the rejected
material delivered into a receiver which may be formed in the manner shown
separately in Figures V and VI. This receiver X¹ shown in plan and elevation has
as many compartments as the drum B has sides. The receiver turns on an upright
It receives its intermittent motion from the
shaft moved by a rope pulley W¹.
shaft C. As it is here the case by one eighth of the turn of B, X¹ moves one eight
and presents its eight compartments successively to the blanket b' receiving in each
compartment only one color of the rejected material. In each compartment is a
sliding box Y₁ and by drawing out these boxes the compartiments are easily
emptied.
To illustrate the working of the machine I will describe how to proceed for
producing for instance a pattern with eight colors.
The first sheet of linoleum is taken from the band T and laid on to the cutting
block which is in the position U¹ and the machine is set in motion. This block is
carried by the revolution of the drum B under the press D, the drum then stands
Whilst the
still, and the press comes down and cuts the linoleum into tesserae.
drum stands still another sheet of another color of linoleum is laid onto the block
at U¹ and so on till four blocks have received the sheets. Then the backing or
which the tesserae have to be set is brought over the press H.
Sheets of linoleum continue to be laid on the blocks coming to U¹ and as the
drum turns the blocks arrive at the position V₁. Before the drum comes to

page_text: standstill the plates h slide over the cams X and receive a short push. This pushes
the surplus material out of the blocks, which material is carried away by the
blanket b. The blocks, cleared of the surplus material arrive successively over the
heated press H.
Whilst this press is lifted the pins q in the blocks come into action
by the pressure of the hands Y on the plates g and the tesserae. left in each block
are set on the backing. After the eight blocks have set their tesserae and the pattern
is therefore completed the pin G on the disc V has arrived at the lever H¹. By the
next motion of the drum this lever is pushed forwards the bands Bare set in motion
and the backing is moved another width of the pattern.
Afterwards the backing so covered with tesserae is passed to a machine in which
the tesserae are pressed down on to the backing by heated plates or rollers and are
thereby consolidated with the backing and with one another.
As before stated cut out tesserae such for example as the waste pieces produced
in the working of a machine such as above described may be set by hand into the
divisions of a block which has steel or metal bands standing up from it giving the
full design of the pattern to be produced and afterwards this block may be fitted
with ejecting blades aud pins like the blocks herein before described and the block
may be used like a printing block and the tesserae carried by it be all simultaneously
transferred on to a prepared backing and be finally consolidated to the backing and
to one another by heat and pressure.
In some cases as before stated I use the metal blocks by hand by placing the
softened sheet of colour on to a padded even surface and press a block onto it by a
suitable press. The blocks thus filled after the useless pieces are rejected are then
applied to the prepared foundation cloth in the same manner as block printing on
oil cloth is now done.
Usually in this case the blocks employed would be of comparatively small dimensions
such that a man could lift them readily and would not be made of a length to pass
across the whole width of the backing.
The backing I cause to be led up over a roller and over the surface of a flat table.
A workman stands in front of the roller and takes the filled blocks and places them
into position above the backing where it passes over the flat table-correct register
being obtained just in the same manner as correct register is obtained with the
printing blocks used for printing oil cloth and the ejecting of the material from the
blocks on to the backing may be effected by presses such as used for pressing blocks
on to oil cloth in oil cloth printing machinery.
When a length of pattern bas been produced in this way the backing is moved a
a step onwards and another length of pattern formed in the same way and so
on. Afterwards the whole can be consolidated by heat and pressure as before
explained.
Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed, I declare that what
I claim is
1. The construction of machinery such as herein before described for the manufacture
of mosaic floor cloth and other like mosaic fabrics.
2. The combination of a polygonal drum carrying a number of cutting blocks and
having a step by step revolving movement given to it a press for pressing sheets
of material on to the blocks as each block is brought opposite to it and means for
discharging from each block the portions of material not required in the pattern and
for subsequently placing the remainder of the material in position on to a canvas or
cther backing substantially as described.
3. The construction of machinery to be employed in the manufacture of mosaic
floor cloth and other like mosaic fabrics in such manner that tesserae or pieces carried
by a series of cutting blocks are placed successively into position upon a canvas or
other backing which remains at rest until each section of the pattern that is being
made is completed.
1. A block having the full design of the pattern in steel or metal bands projecting

page_text: from it to be filled in with pieces of tessure and used subsequently as a printing
block substantially as described.
5. Forming the rolls of machinery used for rolling-linoleum or like oxidized
oil compositions into sheets with a coating of polished granite porphyry porcelain or
inoxidizable metal.
64. The manufacture of mosaic floor cloth and other like mosaic fabric by first
filling blocks such as herein before described with tesserae of the material, then
placing these blocks into position above the backing by hand obtaining correct register
as in oil cloth printing machinery and ejecting the tesserae on to the backing by
presses snbstantially as described.
7. Tre manufacture of urosaic floor cloth and other like mosaic fabrics with an
outline form around all parts of the pattern by first producing an outline form on
the surface of the backing by an embossed roller and then filling in tesserne into
the cells or compartments of this outline form from cutting blocks constructed
substantially as herein before described.

page_text: Date of Application, 10th Nov., 1888
Complete Specification Left, 12th Aug., 1889-Accepted, 9th Nov., 1889
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Mosaic Floor Cloth and other
like Mosaic Fabrics, and in Machinery to be Employed for that
Purpose.
I, FREDERICK WALTON of 4 Portugal Street, Lincoln's Inn Fields, London,
Manufacturer, do hereby declare the nature of this invention to be as follows:-
This invention has for its object improvements in machinery to be employed in the
manufacture of mosaic floor cloth and other like mosaic fabrics.
The material known as Linoleum and like oxidised oil compositions are particularly
suited for the manufacture of mosaic or inlaid fabrics in accordance with my
invention.
I provide this material in various colors rolled out into sheets preferably by
non-metallic rollers such as polished granite or porphyry rollers fitted on iron or
steel shafts made hollow to facilitate their being heated by steam. I roll these sheets
of Linoleum either on canvas or on an endless finely woven wire cloth from which
they are taken off or I roll them on thin paper and use them with this backing of
thin paper or roll very fine threads into or onto the sheets for support whilst
manufacturing.
By the improved mechanism I will describe I cut out pieces of tesserae of different
colors and of any required design and combine these upon a sheet preferably of the
same material spread upon a backing of woven fabric or woven fabric combined with
paper. To ensure greater adhesiveness to the pieces of tesserae on the backing I
spread on the face of this backing a layer of oil cement or a quick drying cement
produced from a solution of solidified cil or Kowrie or other hard gums and rosin.
When the tesserae are set I join and consolidate the whole by heat and flat pressure.
By this latter process 1 produce either a smooth or figured surface as required.
The blocks for cutting out the pieces or tesserae I construct in the manner described
in my Patent No. 6039 of the 18th December 1882.
The improved machine in which I produce the mosaic fabric is constructed as
follows.
A strongly constructed cast iron drum forming a polyhedron with four or more
sides parallel with the centre shaft of the drum is mounted horizontally in bearings
in a strong framework and receives a step by step intermittent revolving motion.
On the faces or sides of this drum are fastened the cutting blocks. Above the top
of the drum is a plate which can be forced downwards by a press for the purpose of
cutting the Linoleum sheets into tesserae. Below the bottom of the drum is a second
but steam heated press plate for setting and pressing the tesserae on to the backing.
Both presses work simultaneously each time that the drum ceases to turn.
the drum moves the tables of the presses stand still and are clear of the faces or
cutting blocks of the drum. After each complete revolution of the drum the
backing fabric is moved a distance equal to the width of the cutting blocks.
When
A sheet of linoleum of any desired color is placed on to each side of the drum
before that side comes below the upper press plate. When by the revolution of the
drum the sheet is brought below the upper press plate it is cut into tesserae by the
plate being pressed downwards on to the block. Afterwards when by the further
rotation of the drum the cut up sheet is carried away from below the plate those of
the pieces of the cut up sheet which are not to be placed on to the backing are
removed from the block by the action of plungers which are set into the block as
described in my former Patent No. 6039 or by the action of a flap or plate of thin
sheet metal which is cut out so as to fit between the knives of the block and is

page_text: caused to turn outwards from the block on a hinge joint when the pieces are to be
removed.
Afterwards when by the further revolution of the drum the block is brought into
a position over the lower press plate the backing to which the pieces are to be
caused to adhere is pressed upwards to the block and the pieces are pressed outwards
on to the backing by plungers.
By employing for instance a drum with eight sides I am enabled to work with
eight cutting blocks and produce assuming I give the blocks a width of eighteen inches
a mosaic fabric in two, four or eight colors and with one full revolution of the drum
I produce two yards with two colors or one yard with four colors or half a yard with
eight colors.
The plungers are worked by two plates for each cutting block. These plates move
inside the drum behind the cutting block and work or press on pins which traverse
this block. The plate nearest to the cutting block is perforated for the pins which
work the plungers for setting the tesserae on to the backing to pass through. These
pins after passing through this plate come into contact with the second plate which
presses on them and drives the rejecting plungers in the cutting block forwards to
clear it of all superfluous pieces. When the blocks arrive over the bottom press plate
then the first or nearest plate behind the cutting blocks comes into action and presses
on all pins which do not traverse this plate, pushes them forwards with their plungers,
clears the cutting block and sets the tesserae on the backing.
The sheets of Linoleum to be cut into tesserae are conducted to the machine by an
endless wire cloth which passes over a heated steam chamber.
To prevent the cutting knives becoming sticky a plate covered with a thick blanket
and kept moist with turpentine or other suitable lubricant moves against each cutting
block before such block receives the Linoleum sheets to be cut.
For consolidating the mosaic fabric I use preferably a steam press in which the
table of the press is moved by the piston of a steam cylinder. The table and head of
this press are both steam heated. When the fabric passes through this press for the
purpose of being joined and solidified a continuous or endless sheet of japanned cloth
or an endless smooth or polished metal sheet or an endless wire cloth passes with the
fabric between its face and the head of the press.
When cutting the tesserae from different colored sheets of Linoleum it frequently
happens that the rejected tesserae are useful to form a pattern of the same design but
of different coloring. I collect these tesserae and set them by hand into a specially
constructed block, having the full design of the pattern in steel or metal bands.
When the whole pattern is set I use this block like a printing block and transfer
the tesserae onto a prepared backing and afterwards join the whole by pressure
and heat.
In some cases I use the metal cutting blocks by hand--by placing the softened
sheet of color onto a padded even surface and to obtain the necessary pressure to cut
out the pieces I employ a press somewhat similar to that used for pressing floorcloth
printing blocks. The blocks thus filled after the useless pieces are rejected can be
applied to the prepared foundation cloth in the same manner as printing is done-and
the whole can be then consolidated by a separate process.
It is advantageous in some cases whether the pieces are set in by hand or machinery
to produce an outlined form by the method adopted in manufacture of my patent wall
decoration in which to fill the tesserae.
Dated this 10th day of November 1888.

page_text: COMPLETE SPECIFICATION.
Improvements in the Manufacture of Mosaic Floor Cloth and other
like Mosaic Fabrics, and in Machinery to be Employed for that
Purpose.
I, FREDERICK WALTON of 4 Portugal Street Lincolns Inn Fields London
Manufacturer 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 :-
This Invention has for its object improvements in machinery to be employed in
the manufacture of mosaic floorcloth and other like mosaic fabrics.
The material known as Linoleum and like oxidised oil compositions are particularly
suited for the manufacture of mosaic or inlaid fabrics in accordance with my
Invention.
I provide this material in various colors rolled out into sheets preferably by
non-metallic rollers such as polished granite or porphyry rollers fitted on iron or
steel shafts made hollow to facilitate their being Leated by steam. Or I use rollers
coated with porcelain or electro plated with inoxidizable metal or otherwise coated
with hard inoxidizable material. In most cases this is desirable because when
manufacturing mosaic floor cloth or like mosaic fabrics in the manner hereinafter
described the Linoleum material or like oxidized oil compound has in many cases to
be passed several times between the rolls to be reformed into sheets before it is used-
as when pieces have been punched out from one sheet the remainder of the sheet
which is not required for the pattern to be formed has to be reworked and again
formed into sheets so that the material is often brought into contact with the rollers
and if the surface of the rollers is such that it can be at all acted on by the material
there is liability of the material becoming discolored. For the same reason also I.
coat with enamel or inoxidizable metal or material both the mixing blades and the
interior of the mixing machines used for reducing the waste material to a dough
before again submitting them to the action of the rollers. I roll the sheets of
Linoleum either on canvas or on an endless finely woven wire cloth from which they
are taken off or I roll them on thin paper and use them with this backing of
thin paper or roll very fine threads into or onto the sheets for support whilst
manufacturing.
By the improved mechanism I will describe, I cut out pieces of tesserae of different
colors and of any required design and combine these upon a sheet preferably of the
same material spread upon a backing of woven fabric or woven fabric combined with
paper. To ensure greater adhesiveness to the pieces of tesserae on the backing I
spread on the face of this backing a layer of oil cement or a quick drying cement
produced from a solution of solidifed oil or Kowrie or other hard gums and rosin.
When the tesserae are set I join and consolidate the whole by heat and flat pressure.
By this latter process I produce either a smooth or figured surface as required.
The blocks for cutting out the pieces or tesserae I construct in the manner described
in my Patont No. 6039 of the 18th December 1882.
The improved machine in which I produce the mosaic fabric is constructed as
follows:-
:-
A strongly constructed cast iron drum forming a polyhedron with four or more
sides parallel with the contre shaft of the drum is mounted horizontally in bearings
in a strong framework and receivos a step by step intermittent revolving motion.
On the faces or sides of this drum are fastened the cutting blocks. Above the top
of the drum is a plate which can be forced downwards by a press for the purpose of
cutting the Linoleum sheets into tesserae. Below the bottom of the drum is a second
but steam heated press plate for setting and pressing the tesserae on to the backing.
Both presses work simultaneously each time that the drum ceases to turn. When
the drum moves the tables of the presses stand still and are clear of the faces or
cutting blocks of the drum. After each complete revolution of the drum the backing
fabric is moved a distance equal to the width of the cutting blocks.

page_text: A sheet of Linoleum of any desired colour is placed consecutively on to each side
of the drum before that side comes below the upper press plate. When by the
revolution of the drum the sheet is brought below the upper press plate it is cut into
tesserae by the plate being pressed downwards on to the block. Afterwards when by
the further rotation of the drum the cut up sheet is carried away from below the plate
those of the pieces of the cut up sheet which are not to be placed on to the backing
are removed from the block by the action of plungers which are set into the block as
described in my former Patent No. 603982 or by the action of a flap or plate of thin
sheet metal which is cut out so as to fit between the knives of the block and is caused
to turn outwards from the block on a hinge joint when the pieces are to be
removed.
Afterwards when by the further revolution of the drum the block is brought into a
position over the lower press plate the backing to which the pieces are to be caused
to adhere is pressed upwards to the block and the pieces are pressed outwards on to
the hacking by plungers.
By employing for instance a drum with eight sides I am enabled to work with
eight cutting blocks and produce assuming I give the blocks a width of eighteen inches
a mosaic fabric in two, four or eight colours and with one full revolution of the drum
I produce two yards with two colours or one yard with four colours or half a yard
with eight colours.
The plungers are worked by two plates for each cutting block. These plates move
inside the drum behind the cutting block and work or press on pins which traverse
this block. The plate nearest to the cutting block is perforated for the pins which
work the plungers for setting the tesserae on to the backing to pass through. These
pins after passing through this plate come into contact with the second plate which
presses on them and drives the rejecting plungers in the cutting block forwards to
clear it of all superfluous pieces. When the blocks arrive over the bottom press plate
then the first or nearest plate behind the cutting blocks comes into action and presses
on all pins which do not traverse this plate, pushes them forwards with their plungers,
clears the cutting block and sets the tesserae on the backing.
The sheets of Linoleum to be cut into tesserae are conducted to the machine by
an endless wire cloth which passes over a heated steani chamber.
To prevent the cutting knives becoming sticky a plate covered with a thick blanket
and kept moist with turpentine or other suitable lubricant moves against each cutting
block before such block receives the Linoleum sheets to be cut.
For consolidating the mosaic fabric I use preferably a steam press in which the
table of the press is moved by the piston of a steam cylinder. The table and head of
this press are both steam heated. When the fabric passes through this press for the
purpose of being joined and solidified a continuous or endless sheet of japanned cloth
or an endless smooth or polished metal sheet or an endless wire cloth passes with the
fabric between its face and the head of the press.
When cutting the tesserae from different colored sheets of Linoleum it frequently
happens that the rejected tesserae are useful to form a pattern of the same design but
of different coloring I collect these tesserae and set them by hand into a specially
constructed block, having the full design of the pattern in steel or metal bands.
When the whole pattern is set I use this block like a printing block and transfer
the tesserae onto a prepared backing and afterwards join the whole by pressure
and heat.
In some cases I use the metal cutting blocks by hand by placing the softened sheet
of color onto a padded even surface and to obtain the necessary pressure to cut out
the pieces I employ a press somewhat similar to that used for pressing floor cloth
printing blocks. The blocks thus filled after the useless pieces are rejected can be
applied to the prepared foundation cloth in the same manner as printing is done and
the whole can be then consolidated by a separate process.
It is advantageous in some cases whether the pieces are set in by hand or machinery
to produce an outlined form by means of embossed rollers as adopted in manufacture
of my Patent wall decoration in which to fill the tesserae.

page_text: Figure I represents a side elevation of the machine.
Figure II is a vertical section.
Figure III is a plan in section of one end of the.machine shewing the parts by
which the requisite movements are imparted.
Figure IV is an elevation of some of these parts.
Figures V and VI represent in plan and elevation a polyhedron box for the reception
of surplus material.
Figure VII is a section on a larger scale of part of a cutting and setting block with
its bed plate.
A is the principal frame of the machine. B the two ends of the polyhedron drum,
these two ends are connected by cross bars a.
The drum B is keyed on the shaft C turning in three plumber blocks b. The drum
carries on its sides bed plates c which are screwed on ledges d which are cast with the
ends of the drum or screwed on to them.
On these bed plates are fastened the cutting and setting blocks e which are held
and adjusted by set screws f. Behind the bed plates c are the two movable plates g
and h fastened on brackets or knees k which pass through slots in the ends of the
drum B. The plates g and h with their brackets are supported either by spiral
springs as shown in Figure II or by india rubber buffers as shown in m.
Figure I.
The plates have a short outward stroke given to them when their brackets k are
as the drum B revolves caused to slide over adjustable cams X. The plates g receive
their motion when the drum B is at rest it is given to them on the downward motion
of the rods E by adjustable hands Y which project from these rods.
In Figure VII n are the cutting knives embedded in the cutting block. rare
plates of the shape of the tesserae-9 and q¹ are pins passed through holes drilled
through the block and screwed to the plates. Each pin has fast with it a disc which
forms a shoulder around it, these discs are received into recesses in the back of the
cutting blocks e. The shoulders on the pins q which have to reject the cuttings or
pieces not wanted in the design lie in deep recesses p in each of which a small spring
is inserted. All the pins or plungers pass through the bed plate c and the rejecting
pins pass through the plate g.
A crossheads having guides t slides in the frame of the machine. This crosshead
carries a plate D, fitted underneath with a lead, rubber or gutta percha plate. The
plate D is adjustable by screws traversing the crosshead, it forms a press and is moved
by the rods E and crank levers F..
Under the drum B is the crosshead G (see figure 2) it carries by set screws u, which
can swing in the brackets v, the steam heated box H which slides in the guides w.
The crosshead G receives its motion from crank levers I. The four angle levers F
and I swing on the stationary shaft J.
The crank levers F and I receive a rocking motion from the shaft K. On this
shaft are fastened (for each angle lever) two cams L and M which in their revolution
give an alternating motion to the bridles N. These bridles are connected by rods O
and P with the crank levers F and J and are guided at the back by guides Q. A
spur wheel R on the shaft K is driven by a pinion from the shaft S. The motion
of shafts K and S is continuous.
On the shaft K is the crank T with an adjustable crank pin (see Figure II, III
and IV). This crank pin is connected by the rod with a heady which is jointed
to an arm that can swivel around the shaft C. The pawl a' in the head y works in
its forward motion in one of the divisions or notches of the disc U and turns the disc
one eighth of a circle as shown or it might be the are of a circle. On its return
motion the pawl a¹ slides over the faces of U and falls into the next notch. A second
disc V stops each motion by the pawl W when one eighth of a full rotation of the
disc U is accomplished.

page_text: The frame Z carry bearings for drums A' over which runs an endless steel band B
covered with a rubber or leather belt. This belt is closely set with pins all along
about one quarter of an inch apart. The fabric or backing passes from a reel, not
shown in the drawings, between the rollers D' and E¹ and from there under the
runners which have a jacket of rubber. The runners C¹ press the backing into
the pins of the belts B¹ which carry the backing forwards. The backing receives
before passing the ductor blade F¹ a coating of adhesive material, the thickness of
which is regulated by the adjustable ductor Fi.
The belts B' are moved a determined distance after a complete pattern has been
placed by the blocks on to the backing. The frequency of the movement will vary
according to the number of colors required in a full design, for instance say 3 or 4
or more. To give the forward motion to the backing, pins G₁ are fixed in the disc U
(Figure 4). These pins act on a lever H¹ as the drum B revolves. The lever H' is
connected by the rod I' with the lever J. Hand J are slotted for the adjustment
of the stroke of the lever H¹. A pawl K¹ carried by J¹ works in the notches of a
disc L' and by a forward stroke this disc L' receives (as it is here shown) a quarter
turn. The disc L' being fast on the shaft M' moves the pullies A¹ and consequently
the bands B¹. The lever J¹ which swings on the shaft M' has a counterweight Ni.
Pulleys Zand a belt connects the shaft M' with the roller D₁ for the purpose
of taking some of the strain off from the belts B₁ and the backing in their
motion.
On an independent framework from the machine runs an endless wire cloth T¹
round rollers O' over a steam box P¹. The wire cloth carries forward the linoleum
sheets to be cut into tesserae in proper order to the attendant who has to place them
on to the cutting block. Q₁ is a moveable plate faced with thick felt kept moist with
a solvent. This plate is moved by the arin R¹ against the cutting blocks e, when
the drum B is at a standstill and moistens the knives of the cutting blocks with the
solvent. The arm R¹ receives its motion by the bridles N which are connected with
the angle levers F.
The rejecting of the material which is not to be set on the backing takes place
when the blocks are in the position marked V¹. This material drops into a hopper c¹
and falls on an endless blanket b¹ which has a continuous motion. The blanket moves
over and returns under the belts B¹ it is carried so far forwards that the rejected
material delivered into a receiver which may be formed in the manner shown
separately in Figures V and VI. This receiver X' shown in plan and elevation has
as many compartments as the drum B has sides. The receiver turns on an upright
shaft moved by a rope pulley W¹. It receives its intermittent motion from the
shaft C. As it is here the case by one eighth of the turn of B, X' moves one eight
and presents its eight compartments successively to the blanket b' receiving in each
compartment only one color of the rejected material. In each compartment is a
sliding box Y and by drawing out these boxes the compartments are easily
emptied.
To illustrate the working of the machine I will describe how to proceed for
producing for instance a pattern with eight colors.
The first sheet of linoleum is taken from the band T and laid on to the cutting
block which is in the position U₁ and the machine is set in motion. This block is
carried by the revolution of the drum B under the press D, the drum then stands
still, and the press comes down and cuts the linoleum into tesserae. Whilst the
drum stands still another sheet of another color of linoleum is laid onto the block
at and so on till four blocks have received the sheets. Then the backing on
which the tesserae have to be set is brought over the press H.
Sheets of linoleum continue to be laid on the blocks coming to U₁ and as the
drum turns the blocks arrive at the position V¹. Before the drum comes to a
standstill the plates / slide over the cams X and receive a short push. This pushes
the surplus material out of the blocks, which material is carried away by the
blanket. The blocks, cleared of the surplus material arrive successively over the
heated press H. Whilst this press is lifted the pins 9 in the blocks come into action

page_text: by the pressure of the hands Y on the plates g and the tesserae left in each block
are set on the backing. After the eight blocks have set their tesserae and the pattern
is therefore completed the pin G on the disc V has arrived at the lever H'. By the
next motion of the drum this lever is pushed forwards the bands B are set in motion
and the backing is moved another width of the pattern.
Afterwards the backing so covered with tesserae is passed to a machine in which
the tesserae are pressed down on to the backing by heated plates or rollers and are
thereby consolidated with the backing and with one another.
As before stated cut out tesserae such for example as the waste pieces produced
in the working of a machine such as above described may be set by hand into the
divisions of a block which has steel or metal bands standing up from it giving the
full design of the pattern to be produced and afterwards this block may be fitted
with ejecting blades and pins like the blocks herein before described and the block
may be used like a printing block and the tesserae carried by it be all simultaneously
transferred on to a prepared backing and be finally consolidated to the backing and
to one another by heat and pressure.
In some cases as before stated I use the metal blocks by hand by placing the
softened sheet of color on to a padded even surface and press a block on to it by a
suitable press. The blocks thus filled after the useless pieces are rejected are then
applied to the prepared foundation cloth in the same manner as block printing on
oil cloth is now done.
Usually in this case the blocks employed would be of comparatively small dimensions
such that a man could lift them readily and would not be made of a length to pass
across the whole width of the backing.
The backing I cause to be led up over a roller and over the surface of a flat table.
A workman stands in front of the roller and takes the filled blocks and places them
into position above the backing where it passes over the flat table-correct register
being obtained just in the same manner as correct register is obtained with the
printing blocks used for printing oil cloth and the ejecting of the material from the
blocks on to the backing may be effected by presses such as used for pressing blocks
on to oil cloth in oil cloth printing machinery.
When a length of pattern has been produced in this way the backing is moved a
a step onwards and another length of pattern formed in the same way and so
on. Afterwards the whole can be consolidated by heat and pressure as before
explained.
Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed, I declare that what
I claim is :-
1. The construction of machinery such as herein before described for the manufacture
of mosaic floor cloth and other like mosaic fabrics.
2. The combination of a polygonal drum carrying a number of cutting blocks and
having a step by step revolving movement given to it a press for pressing sheets
of material on to the blocks as each block is brought opposite to it and means for
discharging from each block the portions of material not required in the pattern and
for subsequently placing the remainder of the material in position on to a canvas or
other backing substantially as described.
3. The construction of machinery to be employed in the manufacture of mosaic
floor cloth and other like mosaic fabrics in such manner that tesserae or piecès carried
by a series of cutting blocks are placed successively into position upon a canvas or
other backing which remains at rest until each section of the pattern that is being
made is completed.
4. A block having the full design of the pattern in steel or metal bands projecting
from it to be filled in with pieces of tesserae and used subsequently as a printing
block substantially as described.
5. Forming the rolls of machinery used for rolling linoleum or like oxidized

page_text: oil compositions into sheets with a coating of polished granite porphyry porcelain or
inoxidizable metal..
6. The manufacture of mosaic floor cloth and other like mosaic fabric by first
filling blocks such as herein before described with tesserae of the material, then
placing these blocks into position above the backing by hand obtaining correct register
as-in oil cloth printing machinery and ejecting the tesserae on to the backing by
presses substantially as described.
7. The manufacture of mosaic floor cloth and other like mosaic fabrics with an
outline form around all parts of the pattern by first producing an outline form on
the surface of the backing by an embossed roller and then filling in tesserae into
the cells or compartments of this outline form from cutting blocks constructed
substantially as herein before described.
Dated this 8th day of Anrust 1990
FRED. WALTON.