Improvements in the Manufacture of Linoleum and Cork Carpets, and Apparatus or Machinery therefor.
Year: 1894

page_text: Improvements in the Manufacture of Linoleum and Cork Carpets,
and Apparatus or Machinery therefor.
i i
I JOHN INGLEBY of 12 Bainbrigge Road Headingley Leeds in the County of
York do hereby declare the nature of this invention to be as 'follows:-
This invention relates to the manufacture of that.class of goods which are made
by the compression to adhesion or consolidation of loose particles of prepared
ingredients (as, for instance a mixture of cork and oil as used in the manufacture
of cork carpets or linoleum) in such a manner that the pattern completely
penetrates the fabric; and it relates more, especially to that part of the process
which may be, termed the moulding and pressing.
In the first place my invention consists essentially in the manufacture of linoleum
or cork carpets by forming a mould with retractile webs, filling the various sections
with different coloured material according to the desired design, withdrawing said
webs either previously or simultaneously with the compressing movement of 'the
compressing plate and compressing the material either subsequently to
simultaneously with the withdrawal of the said webs.
or
A machine or apparatus for carrying out my invention comprises as an essential
part the construction of a mould formed either of flat or cylindrical blocks of
wood or metal having the outline of the design marked out on the surface by
vertical retractile webs or flanges or ribs of thin sheet metal vulcanite or other
suitable material either continuous, or in sections or both. These webs or flanges
have a vertical motion, receeding into the spaces between or in the blocks, and
when fully, receded are. flush with. the surlace of the block.
The supporting or carrying of the blocks and the production of the retractile
motion may be effected in various ways, of which the following is perhaps the
simplest and most efficient: The retractile motion of the webs may be brought
about by means of rods connected. at various points to the webs and which pass
through the bed plate or foundation supporting the blocks. These rods are con-
nected to a horizontal frame or plate, which latter is connected ontside or at the
edge of the frame containing the blocks to vertical sliding rods or plates, the
upper edge of which is slightly above the top level of the webs. The sliding rod
Connections are adjustable so that the difference of level can be varied.
The block frame having the webs or flanges set up above its surface to the
required height the material which is to form the carpet, stained to the proper
colours is filled in loosely up to the top of the different compartments now formed
on the surface of the block by the webs. This filling or charging of the block
may be done by covering up certain portions of the design at a time with
a stencil and brushing the material into the exposed parts. This operation is
repeated with other stencils. until the whole, of the compartments are filled, when
the design of the intended fabric will be seen in louse material with the lines of
the webs dividing one colour from another. Canvas will now be laid over the
design and the mould frame is pushed beneath a hot press plate which is forced
down heating and compressing the material. This plate in its descent, will, before
reaching the material to be compressed first c
come in contact with the upper,ends
of the sliding rods or plates on the outside of the design and on its further, descent
the webs will commence to recede into the spaces in the block frame and will
し

page_text: continue to do so until they are flush with the surface of the blocks. The
material now consolidated and attached to the canvas by heat and pressure will
lie as a finished carpet between the plain surfaces of the hot plate & the blocks,
the latter having no longer any portion of the webs protruding into the material
of the fabric.
If cylindrical blocks are used the hot plate is replaced by a hot roller which
depresses the sliding rods or plates in sections as they come in contact with it.
Continuous lengths of carpet may also be made with the flat block, and the
design may extend over any number of them. In this case the junction between
one block and another would have a retractile web between them. A series of
blocks would be laid on a tramway or table with proper guides and clamped
together at the junctions. They would be moved forward under a compressing
plate or roller and as the foremost block had passed under it and the carpet
detached the block would be removed and brought back to the end of the series
and there clamped to the last, and in its turn be charged again. The charging
would be done irrespective of the junction of the blocks.
As above mentioned other methods of supporting the blocks and of effecting
the retractile motion of the webs may be employed. For example. The raising
and lowering of the webs and of the hot pressing plate may be effected at the
proper times independently of each other by means of screw lever or cam arrange-
ments. Or the webs may be lowered from above direct on to the canvas which is
supported upon a fixed undivided plate. The compartments are then filled as
above described, and the blocks with recesses between them for the webs, is lowered
on to the material to compress and consolidate it, whilst the webs are simultaneously
raised to the saine level as that to which the blocks are lowered. In this case
the fixed undivided plate would preferably form the hot plate. Or the block
frame might be lowered only so far as to compress the material sufficiently to
cause it to adhere to the canvas back, and the full compression completed on
moving the canvas forward so as to bring it beneath a closely adjoining bot press.
As in the previous case provision would be made for passing the rods or bars
carrying the web through the spaces between the blocks.
1
Lastly the invention may be modified by dispensing entirely with the blocks in
the last case, merely raising the web frame after the compartments have been filled,
and carrying the canvas forward beneath an adjoining hot press. This arrangement
might be found most suitable, where it was desired to have the dividing lines
between the different colours more or less indistinct.
The surface of the linoleum may if desired be grained or embossed by suitably
roughening, moulding, or otherwise shaping the surface of the blocks or of the hut
press plate, according as the one or the other is the surface which comes in contact
with the face of the linoleum.
Dated this 28th day of September 1901
Improvements in the Manufacture of Linoleum, Cork Carpets, and
Apparatus or Machinery therefor.
JOHN INGLEBY of 12 Bainbrigge Road Headingley Leeds in the County of
York late of The Ceylon Civil Service do hereby declare the nature of this inven-
tion and in what manner the sanie is to be performed, to be particularly described
and ascertained in and by the following statement :-..
}
This invention relates to the manufacture of that class of goods, which are made
by the compression to adhesion of consolidation of loose particles of prepared
ingredients, (as for instance a mixture of cork and oil as used in the manufacture
:

page_text: of cork carpets or linoleum), in such a manner, that the-pattern completely.
penetrates the fabric; and it relates more especially to that part of the process..
which may be termed the moulding and pressing.
In the first place my invention consists essentially in the manufacture of linoleum.
or cork carpets by forming a mould with retractile webs, or fences, filling the
various sections with different coloured material. according to the desired design,
withdrawing said webs either previously to, or during the compressing; movement
of the compressing plate, and compressing the material either subsequently to-or
during the withdrawal of the said webs.
A machine or apparatus for carrying out my invention comprises as an essential
part, the construction of a mould formed either of blocks of wood or metal, having
the outline of the design marked out on the surface by vertical retractile webs or
flanges of thin metal, vulcanite or other suitable material, either continuous, or in
sections, or both. These webs or flanges have a vertical motion, receding and
closely fitting into the spaces between or in the block; and when fully receded are
flush with the surface of the block. :
1
The supporting or carrying of the blocks and the production of the retractile
motion may be effected in various ways, of which the following is perhaps the
Bimplest and most efficient. The retractile motion of the webs may be brought
about by means of rods connected at various points of, and (to) the webs, and
which rods pass through the bed plate or foundation supporting the blocks. These
rods are connected to a horizontal frame or plate, or cross bars, which are connected
outside or at the edge of the fraine containing the blocks to vertical sliding rods or
plates, the upper edges of which are above the top level of the webs, by a distance
corresponding to the thickness of the intended fabric when compressed. The
sliding rod connections are adjustable, so that the difference of level can be varied,
and thus allow fabrics of different thicknesses to be manufactured.
The block frame baving the webs or flanges set up above its surface to the
required beight, the material which is to form the carpet, stained to the proper
colours, is filled loosely into the different compartments now formed on the surface.
of the block by the webs. This filling or charging of the block may be done
by covering up certain portions of the design at a time with a stencil, and
brushing the material into the exposed parts. This operation is repeated with
other stencils until the whole of the compartments are filled, when the design of
the intended fabric will be seen in loose material, with the lines of the webs
dividing one colour from another. Canvas may now be laid over the design,
and the mould frame is pushed beneath a (hot) press plate, which is forced
down (heating and) compressing the material. This plate in its descent, will
before reaching the material to be compressed, first come in contact with the
upper ends or the sliding rods or plates on the outside of the design or mould;
and on its further descent, the' webs will commence to recede into the spaces
or grooves in the block, and will continue to do so, until the tops of the webs.
are flush with the surface of the block. The material now consolidated and
attached to the canvas by (heat and) pressure, will lie as a finished carpet or
fabric between the plane surfaces of the press plate and block; the latter
having no longer any portion of the webs protruding into the material of the
fabric.
Continuous lengths of carpet may be made, and the design extended over any
number of moulds in accordance with the invention described in the Provisional
In this case the
Specification No. 12433 filed by me on the 27th June 1895.
junction between one block and another adjoining block will have the cross
partition between them formed as a thin retractile web. A series of such blocks
or moulds would be laid on a tramway, or table, or slide bed, provided with
suitable guides, and the blocks or moulds would be securely clamped together
at the junctions. The blocks or moulds, thus secured together, are moved
forward under a press; and when the foremost block or mould has passed
sufficiently far beyond the press, so that the carpet or fabric may be and is
'

page_text: conveniently detached, the block or mould is removed (disengaged) and brought
back to the commencing end of the tramway or slide hed, and there clamped to the
last block or mould, to be again charged with material.
My invention may be modified by reversing that is inverting, the relative
positions of the press plate and block, as is referred to in my Provisional
Specification; the press plate being replaced by an under stationary plate, and the
blocks or moulds with attachments placed above, and arranged capable of being
raised and lowered. As this modification appears to be practically much inferior
to that above described, no further description is added.
:
The surface of the fabric may if desired be grained or embossed, by suitably
roughening, moulding, or otherwise shaping the surface of the block or of the hot
press plate according as the one or other is the surface which comes in contact with
the face of the fabric.
And in order that my invention and the manner in which the same is to be
performed may be more readily and clearly understood, 1 have annexed hereto as
an illustration, drawings of a machine constructed in accordance with my invention.
I have herein exhibited the best mode of carrying out such invention, and
accordingly have shewn in connextion therewith, the arrangements for making the
fabric in continuous lengths which from part of my said application for Provisional
protection No: 12433 dated the 27th June 1895.
Fig is a general plan view.
Fig 2is a general side elevation.
Fige: 3, 4 and 5, are respectively a longitudinal vertical section, a transversé
vertical section and a plan to a larger scale all about the press.
Fig 6 is a plan of 'a.corner portion of a mould to a still larger scale, and
Figs. 7 and 8 are vertical sections on lines X X-and Y Y respectively of Fig. 6.
Figs: 9; 10 and 11 are respectively a longitudinal section, a transverse section,
and a longitudinal or side elevation about the junction of two adjoining mould
'plates.
In all the figures the same reference letter refers to the same or corresponding
part or parts; with the exception Figs. 1 and 2.
'
The machine or apparatus comprises a series of moulds A, Figs. 1 and 2; which
are mounted on a bed slide B, (lettered n in Figs. 3 and 4); and which as they are
'locked together and filled with ninterial; are traversed up to and under a press C.
After the material is compressed, the moulds: A are moved from under the press C,
the compressed fabric D is raised and coiled round a drum K, or guided over drums
to be passed to a drying room, or to be cold rolled; whilst the mould is disengaged
from the next succeeding mould; and by means of carriages E, on transverse
rails F, and a return bed slide G, is traversed back to the starting end of the bed
slide B: is a roll of canvas or other backing material, which is lowered on to
the top, ie. the back of the material, passing under the press C; where it is firmly
attached as a backing to the fabric material by heat and pressure.
In some cases the fabric is manufactured without any backing, or the backing
may be subsequently attached on either side of the fabric.
The moulds A are formed of a block or blocks a, Figs. 3 to 11, of wood or
inetal, or other suitable material, and are provided with deep vertical grooves or
dividing spaces b, shaped to the outlines between the different colours and shades of
the design or pattern, and closely fitting against the retractile webs.
In these grooves or spaces b, and capable of moving vertically therein, are fitted
the retractile webs c, of thin metal preferably brass, or other suitable material.
These webs are of such a depth, that when in their highest position their upper
edges stand above the upper surface of the blocks a by a height equal to the
thickness of the material before compression; and at the same time their lower
edges are a sufficient distance within the grooves or dividing spaces b, to obtain the
necessary lateral support. The depth of the grooves or dividing spaces balso, in
such as to admit of the webs c being drawn down until their upper edges liẹ
perfectly flush, i.e. level with the surface of the blocks a.

page_text: The retractile webs c are connected at various sufficiently numerous points of “
their lower edges with the bars or rods d, which pass through recesses in the
underside of the blocks a, and through holes in the mould bed plate e. The lower
ends of the rods d are attached to cross bars f, and the outer ends of the latter to
side rods g. The side rods y pass through guide holes g', Fig. 7, in the side frames
of the moulds, and are free at their upper ends as shewn in Fig. 7, or are attached
to retractile side plates h, Fig. 4. In the latter case, the rods g may be attache:l
on the inner sides of the plates and recesses to permit of their vertical movement
are formed in the corresponding blocks a. The depth of the side frame plates h
is made approximately equal to the thickness of the blocks a plus the thickness of
the fabric after compression. The upper edges of the plates h before, during, and
On compression are level with the top of the fabric material.
The mould frame for each mould plate e, comprises two retractile side plates /
and only one end plate ; the latter being connected to a cross bar f¹ (Figs. 3
and 9) in a similar manner to the retractile wobs c. Each plate e is tightly locked
to the next adjoining plate by means of some locking arrangement, 'as for example
by means of the right and left hand screws j, which enter the loose nuts k carried.
in rectangular recesses in the lugs l. By rotating the small hand wheel on the
screws in que direction or the other, the adjoining mould plates can be tightly
locked together or disengaged! As only one end plate i is required for each mould
plate e, when the plates are locked together; it is necessary to make provision to
prevent the blocks a at the opposite end becomming displaced, when the mould
plate is disengaged. This will generally be avoided by securing the blocks a to
the mould plate by screws as indicated at s¹ Fig. 7. I propose to adopt this
method of securing all the blocks in position.
The mould plates e are mounted on V'eed grooves in of the bed slide n, in a
similar manner to that common in metal planning machines. 'Ou the inner sides of
the bed slide n are provided the supporting rails o, Figs. 1, 2 and 4, on which the
ends of the cross bars are supported, so as to keep the webs and the frame
plates and i set up to the full height, whilst the plates e are on and are traversing.
along the bed slide n towards the press.
ני
0
To provide for cases where it is desired to have certain of the outlines between
different colours or shades more indistinct than the others, a second inner set of
rails pare provided, which do not extend up to the press as do the rails o, and
which terminate preferably with a gradual incline downwards. The webs c¹
corresponding to such indistinct outlines are not connected to the other webs c, and
are also attached to independent cross bars f". These cross bars f" are shorter
thau the others, so that whilst resting upon the rails p, they do not extend up to
the rails o. When therefore the inould plate e reaches the point where the rails
terminate, or the commencement of the terminal'downward incliue of the same, the
cross bars and the attached webs cl begin to fall, so that before the compression
of the fabric commences, these webs care completely receded.
ע
The press comprises a supporting bed s, Figs. 3 and 4 attached by brackets t to
the ends of the bed slide n, facing the gap left in the bed slide for the press. The
strengthening ribs of the plate e, slide on to and rest upon the planed surface of the
press bed or buttom plate s. Four vertical shafts connect the press beds with a top
cross frame v, which carries the press cylinder w. The plunger of this cylinder is
attached to a top plate c, to which is attached a lower plate y, with an
intermediate wood or non conducting packing in the usual case of the lower plate y
being heated, which may be effected by steam pipes z cast in the plate as shewn in
Figs. 3 and 4, or by other usual means for heating such press plates.
The depth of the side plates A Fig. 4, or the length of the side rods g Fig. 7, is
such, that the tops of the same are reached by the underside of the plate y, and -
the webs e thereby pushed down by the thickness of the compressed fabric, before
the underside of the plate y reaches the surface of the uncompressed material.
In case it is found desirable to lock the webs c in their lowest position on
compression taking place, the following or other suitable locking mechanism may
'
-

page_text: te provided. A locking bar 1 Fig. 4, carried at the ends by linged levers 2, is
provided on each side of the gap in the bed n left for the press. By means of
weights 3 attached either to the levers 2 or the bars 1, the latter are pressed
inwarde, but are forced back by the descent of the ends of the cross bars, until
the latter reach their lowest position; when they (the ends of the cross hars) are
just below the lower edges of the locking bars 1, which now swing inwards. This
position is shewn by the right side of Fig. 4, in which the press plate y is shewn in
its lowest position; whilst the left side shews the plate y in its top position. The
left side of Fig. 3 shews the press plate y in its lowest, and the right side in its top
position.
In order to avoid any distinct mark between successive portions of the fabric
carried on adjoining plates e, one end of the press plate y is inade somewhat longer
than one of the mould plates e. In the following reference is to be had to
Figs. 9 to 11. The vertical side rods g' of the first three or four cross bars, are
not connected to the side plates, but (are bent it necessary so as to) pass outside,
so that each side rod gl is depressed independently; first (ie. ou coming next to
the press), by the overhanging inclined or stepped edge of the press plate y to
different extents in a stepwise fashion, and the surface of the fabric is left at this
part correspondingly inclined. When this portion afterwards comes under the
opposite straight end of the press plate y; these side rods and the surface of
the fabric are depressed level. It will be understood, that the portion of the web c,
attached to any one of the three or four cross bars, is not continuous with the
portion attached to the adjoining bar or bars; this condition being necessary to
IE
allow of the stepwise displacement of these different portions of the webs c.
necessary springs 4 may be added to balance these cross bara and connections, aud
retain them for the time being in the stepwise position, should the friction of these
parts not be sufficient for this purpose.
The return bed slide G, Figs. 1 and 2, is also provided with supporting rails.
corresponding to the rails o and previously mentioned, and which commence with
an incline upwards, in order to set up the webs c, to permit of the filling of the
moulds being commenced whilst on the slide G.
It will be understood that the mould plates e, locked together, are moved
forward on the bed slide B (n) in an intermittent manner. The movement along
either or both bed slides B and G may be effected by hand or inechanism, but as
do not wish to limit myself to any special means, no description of such is added.
The modus operandi of my improved manufacture of linoleum and the like
fabrics, in connection with apparatus or mechaniem as above described, is as
follows:-
:-
The disengaged or unlocked mould plate on passing on to the return bed slide G,
(Figs. 1 and 2), has the retractile webs c set up to their full height by the sliding
of the cross bars f up the inclines at the commencement of the rails o and p of the
bed slide G. The loose removable end plate is attached, to temporarily close
the open end of the mould; so that the mould now formis à shallow rectangular
frame or box; divided into compartments by the set up webs along lines
corresponding to the outlines of the desired pattern. The first stencil plate is now
placed over the mould, and part of the fabric material of the proper colour is
raked or brushed over the openings in the stencil, filling the corresponding
compartments. The mould is then pushed forward, and covered with a second
stencil, (the first stencil having been removed to be placed over the next
succeeding inould), and the compartments left uncovered by the openings in the
second stencil are filled in a like manner by material correspondingly coloured.
This operation is repeated until the moulds are filled, or reach the end of the
return bed slide G. By means of the carriage E on the transverse rails F, the
mould is transferred to the bed slide B (n). This carriage is provided also with
supporting bars, (corresponding to rails o and p), to retain the webs c in the set up
position. The filling of the compartments, if not completed, is continued on the
bed slide B, (n), or it may be first commenced and completed on this bed slide.

page_text: The stencils if desired may be fixed to the bed slides, so that the monid plates
are intermittently and successively pushed under them.
As the mould plate reaches the bed, slide B, (a), it is locked as previously
described to the next préceding mould plate.
Before renching the press C, Figs. 1; and 2, the webs el, if any, corresponding to
the indistinct outlines of the pattern, having moved past the ends of the rails p,
have completely receded to their lowest position. On reaching the press, the cross
bars having moved past the ends of the rails o, the descending press plate y
catches against the top edges of the side plates h, Fig. 4, (or side rods g Fig. 7),
and side rods, depressing these slightly in advance as the material is com-
pressed. When the side plates / come to rest upon the mould plate e, the webs c
are fully depressed' and the compression is completed. The press is then operated
to raise the plate'y. As I do not wish to limit myself to any partionlar type of
press, all details of and for operating such press are omitted:
The mould, with the compressed material now forming the fabric, (without or
with a canvas or other backing on the top), is moved away from under the press,
(still locked to the preceding and succeeding moulds); and when sufficiently clear
off the press, the fabric is raised from the mould to be led away for drying or
other finishing operations. The preceding mould has in the meantime been
unlocked, and the mould under consideration is now in its turn disconnected from
the next succeeding mould, and run on to the carriage E, to be traversed on to the
return bed slide G, and thence to the commencing end of the bed slide B (a), to be
again claniped to the other end of the series.
The material may if desired be moulded and compressed of a thickness sufficient
to forin several carpets or other fabrics, and afterwards split by a splitting machine,.
in a similar manner to that in which leather is split.
It will be evident that instead of the webs being retracted, the bottom of the
mould may be advanced, provided that due provision is made for causing this.
movement to be contemporaneous with the application of pressure to the fabric
material, for instance the advance of the bottom of the mould may press the fabric
against a plate supported by springs or otherwise, which yield on the advance of
the bottom of the mould.
The linoleum material may be used lot or cold, and in such a grade of
disintegration, that is, coarse or fine, as is required by the pattern. The age of the
material up to several months appears to be immaterial.
Having now particularly described and ascertained the nature of my said inven-
tion and in what manner the same is to he performed I declare that what I
claim is :-
1. The method of manufacturing linoleum, cork carpets and the like fabrics by―
charging with correspondingly coloured or shaded material by means of stencil
plates or any other suitable means the various compartments of a mould provided
with retractile webs which when set up divide the mould into said compartments.
along the outlines between the different colours or shades of the pattern to be
produced-withdrawing the whole or a portion of the webs either previously to
or during the compressing movement of the press plate of a press; and com-.
pressing the material either subsequently to or during the withdrawal of the whole
or a portion of the said webs.
2. In a machine.or apparatus for the manufacture of linoleum, cork carpets and
the liko fabrics, a mould or moulds consisting of a block or blocks grooved or
subdivided along the outlines of the desired pattern and provided with retractile
webs fitting the grooves or subdivisions and capable of retractile movement so that.
the webs can be set up to the height of the uncompressed material and withdrawn
into the said grooves or subdivisions until their upper edges are flush or perfectly
level with the surface of said block or blocks, preferably during the compressing
movement of the press plate of a press.
3. In a machine or apparatus for the manufacture of linoleum, cork carpets aud.

page_text: the like fabrics, the combination of a compartment mould or moulds as specified in
Claim 2, means for setting up and withdrawing the retractile webs, and a press for
compressing the fabric material in said mould or moulds..
4. A machine or apparatus for carrying out the processes referred to in Claim 1
comprising a bed slide B Figs. 1 and 2 carrying capable of being slid thereon
moulds A formed of side and end pieces and and a grooved or subdivided block
or blocks a Figs. 3 to 11, provided with retractile webs c, means for Betting up,
supporting, and withdrawing said pieces hand and webs c, to wit rails o and p,
cross bars, vertical and side rods d and g, and a press having a press plate v
acting during the compression movement on the side plates h or rods g. substantially.
as herein set forth.
5. In compartment moulds as specified in Claim 2 used for the manufacture of
linoleum, cork carpets and the like fabrics, the combination of retractile webs
connected to side plates or side rods depressed only by or from the movement of
the compressing plate and supported in a set up position up to the press by.
supporting rails, such as o, with independent retractile webs, which are forced
down or drop freely before reaching the press,, substantially as and for the purpose
herein specified.
6. The modification of my invention produced by causing the bottom of the,
mould to advance relatively to.the webs instead of the latter being retracted as.
described.
Dated this 27th day of June 1895.
J. CLARK JEFFERSON,
2 East Parade, Leeds, Agent for Applicant.