US1970503A - Floor surfacing structure - Google Patents

Description

1934- A. w. HAWKES ET AL 1,970,503

FLOOR SURFACING STRUCTURE Filed June 30', 1934 11v VENTOKS 445507 14/. HAM K55 BY 05527- 0. Bow/5r Patented Aug. 14, 1934 1,970,503 FLOOR SURFACING STRUCTURE Albert W. Hawkes,Montclair, and Robert 'D. Bonney, Glen Ridge, N. J., assignors to Congoleum-Nairn York Inc., a corporation of New Application June 30, 1934, Serial No. 733,308

11 Claims.

The present invention relates to smooth-surfaced coverings of the linoleum or felt base type, or the like, and has for its major purpose the provision of an improved surface covering of this class which is adapted to be simply, easily, and

. substantially all of its area.

end, the prior practice has been to first cut the linoleum to fit the space to be covered. The covering is then removed and a heavy coating of the sticky paste is laboriously applied to the sub-floor. The paste is very viscous in its consistency because it is desirable to avoid any excess of solvent which mustevaporate, and the thickness of the layer thereof so spread is necessarily not uniform. After the paste is applied the linoleum is brought back and put into place. To obtain an. eflicient contact of the covering with the necessarily somewhat uneven paste layer, and as an inadequate effort to make the distribution of the cement more uniform, the linoleum is permanently installed on a floor, wall, or other sub-surface without the use of cement or paste in the fashion heretofore employed and without requiring the services of experienced layers.

According to the prior art practices linoleum, felt base, or similar smooth-surfaced flexible surface-covering is commonly laid in strip or in tile form. When the installation of coverings heretofore available is accomplished by the individual purchaser or home owner, the surface covering is usually simply cut to fit the area to be covered and laid upon the sub-surface without fastening, or it may be secured at the edges or seams by tacks orother mechanical fastening. Such installations, while giving a degree of service, are not entirely satisfactory, for surface coverings of the class mentioned have the property of absorbing and giving off moisture with changes in humidity or by contact with water, causing the material to swell and contract. Upon swelling, if the edges are confined by walls or the edges or seams are secured by nails, or limited areas only are prevented from moving as by objects resting upon the covering, buckling frequently occurs producing bulges or ridges. Or if the seams are unsecured, curling of the edges of thefloor covering may result. Walking or moving objects over such bulges is not only hazardous to safety but subjects the surface covering to repeated fiexure and to creasing and severe strain with resulting disintegration and destruction. In order to overcome these difiiculties and to provide a thoroughly satisfactory installation, it is essential to uniformly secure the surface covering to the sub-surface throughout To accomplish this thoroughly rolled with a heavy roller. The difficult as well as unpleasant features of spreading the thick, sticky, malodorous cement and of placing the surface covering thereon and of rolling it to cause the linoleum to adhere, require experience, skill, and special tools not possessed by or available to the ordinary user of linoleum. Accordingly, the services of experienced linoleum layers are required in order to secure satisfactory results and even where such services are available the method is an expensive one, frequently costing as much asv the linoleum itself. Such trouble, expense, and need for experience and special tools as are incident to the cementing of such covering are reasons for that omission of the securing of such covering to the sub-surface or for that resort to improper securing which have prevented individual users from obtaining sat-.-

isfactoryand efficient results from the use of coverings of the class mentioned.

In accordance with the present invention, there is provided as a marketable, unitary, ready-to lay product, a smooth-surfaced covering of the class mentioned, possessing such features of construction that the afore-mentioned difficulties are avoided or overcome, and additional advantages, some of which are hereinafter mentioned, are afforded. Thus, in accordance with this invention, there is provided a covering of the class referred to, which embodies a layer or stratum of cementitious material on the back thereof, and such layer of cementitious material may be of such composition and form that thecovering material may be permanently bonded in varying degrees of rigidity with the sub-surface, and the covering thus simply, easily, and permanently installed.

More specifically, in accordance with this invention the surface-covering comprises in composite form a body portion characterized by a surface which is wear-resisting or ornamental or both and which may be a layer of suitable coating or molded material, such as paint, lacquer, enamel, or linoleum composition or other dryingoil product; and such body portion preferably in- 1 0 cludes a foundation layer which carries on one of its faces the layer which is wear-resisting or ornamental or both and. carries upon its other surface the layer of cementitious material. Such a foundation layer is preferably of sheet-like ma- .105 terial suitable as a backing or support for such a surface layer, such, for example, as woven fabric or fully impregnated felt or a combination of felt and fabric or the like, to the end that the foundation will be resistant to tearing and substantially non-stretchable transverse or in the plane thereof and resistant to distortion by compression. Thus, a surface structure, ready-to-lay in bonded relation to a sub-surface and embodying this invention may comprise in composite forni a body portion made up of a foundation layer or member and a surface layer on one side thereof comprising a layer which is wear-resisting or decorative or both, in combination with a layer of cementitious material applied to the back or lower face of the foundation and adapted to bond the body portion permanently to a sub-surface that is to be protected or ornamented. The body portion may comprise a wear-resisting layer of varying thickness and durability carried on one surface of a foundation layer, while the cementitious layer is carried on the other surface of the foundation layer.

A'variety of satisfactory cements will suggest themselves to those skilled in the art, and the present invention is not to be construed as limited to the specific types herein described, except in so far as the appended claims are so limited, several specific cements being herein described which respectively possess advantageous characteristics. Thus, there may be employed a cement which retains its original stickiness or tackiness for a sufficient time to permit of marketing and laying the covering material, such cement providing a bond of more or less elasticity. Also, there may be employed cements which are normally non-sticky or non-tacky and which are activated, or of which the adhesive character is stimulated, by the application of suitable solvents, these cements provicling bonds of varying degrees of rigidity and the activation or stimulation thereof being effected by solvents which include water-miscible solvents capable of evaporating or being dissipated through moist sub-surfaces. Also, suchsolvents include non-aqueous solvents which effect a minimum of swelling or distortion of wooden subsurfaces. When normally tacky or sticky cements are employed, they are preferably protected by a protecting sheet during storage and shipment and handling of the covering material.

The manner of laying or otherwise applying this improved type of covering to a sub-structure will be apparent. A strip or sheet of the material is first fitted to the surface to be covered. If the covering material embodies a cementitious layer that is protected by a protecting sheet, that sheet will then be removed; or if the material embodies a normally non-tacky cementitious layer, the adhesive characteristics of that layer are stimulated or activated by application of a suitable solvent. The fitted strip or sheet is then pressed firmly on to the surface which it is to cover and the cementing material unites with such surface, securely bonding the covering thereto in a permanent manner.

A desirable cement for the particular purposes here involved comprises a mixture of 100 parts by weight of raw rubber'and 130 to 200 parts of rosin, thinned with naphtha, varnolene, kerosene, or the like. This mixture may be prepared by combining the rosin and rubber by means of calender rolls and then soaking and kneading the r solvent into the mixture. The rubber-rosin-solvent mixture may be easily and uniformly applied to the back of the floor covering by means of a doctor. Upon evaporation of the solvent, the rubber-rosin combination resumes and maintains its original tackiness and provides a very effective cement. To protect the cement layer and to prevent the face of the covering material rial. The use of this type of cement is especially advantageous in connection with installations in which one desires the type ofbond which results from elasticity and other characteristics of this cement.

A further embodiment of this invention possessing further features of this invention resides in the employment of cementitious material which, when in bonding relation between the surfacecovering and the sub-surface, hardens to a hard, strong, rigid or relatively rigid body, the expression relatively rigid being employed herein to indicate that the hardened cementitious layer has a hardness and resistance to distortion substantially equal to or greater than those properties of the body portion of the covering structure. More particularly, adhesives of this type reduce the susceptibility of the surface covering to become dented by heavy localized pressures, and they effect a. more thorough and permanent bond between the covering and the sub-surface. We have also found that the employment of a cementitious material which is normally nonsticky and non-tacky until activated, is advantageous both from a manufacturing standpoint and from an installation standpoint. Particularly is the cutting and fitting of the surface covering facilitated when adhesives of this type are employed. Furthermore, we have found that the employment of cementitious material of the character above described renders unnecessary the use of a protective covering for the adhesive backing thereby reducing the bulk of the goods when rolled; stored, and shipped and also eliminating an item of expense.

Briefly stated, the embodiment of our invention wherein normally non-tacky cement is employed comprises a surfacing structure including a body portion having a wearing surface, for example, linoleum, in combination with a back- 125 ing layer of a normally non-sticky, non-tacky cementitious material adapted to be activated only when desired to develop the latent adhesive properties therein. As a further feature our invention contemplates the employment, in such 1 0 combination, of a cementitious material which is adapted to harden upon the evaporation of such activating solvent to form a rigid or relatively rigid bond between the body of the surfacing structure and the sub-surface to which it may 5 be applied.

A variety of cementitious materials will suggest themselves to those skilled in the art for use in the embodiment of this invention wherein the cementitious material is normally non-tacky 140 and is adapted to be activated to adhesiveness when desired, and this embodiment is not to be construed as limited to any specific material. In this embodiment of the invention it will be found desirable that the cementitious material should 113 possess the following characteristic properties, namely ((2) remain dry, non-sticky, and nontacky under normal conditions of storing, shipping, and merchandising, (b) be substantially unaffected by atmospheric thermal or humidity 153 variations and by small amounts of moisture, (c) be readily activated to adhesiveness, as by application of an appropriate solvent, and (d) possess high bonding strength when activated; and, if it be desired, the cement should possess the property that it will (e) so harden after activation that the bond formed by it is rigid or relatively rigid. Preferably, should also be unaffected by alkalies inasmuch as floor surface coverings are frequently required to be installed over moist concrete where. they are subject to the action of alkaline solutions. The cement may be activated in any suitable manner and is preferably of such composition as to be activated by either a non-aqueous solvent or by water. When employing a cementitious material adapted to be activated by a non-aqueous solvent it will be found preferable to select an adhesive which may be activated with a watermiscible solvent in order to facilitate the evaporation of' the solvent and the hardening of the adhesive in those cases where the sub-surface may contain moisture.

One suitable type of cementing material adapt ed to be activated by a non-aqueous solvent comprises a mixture of a cellulose ester and a resin with sufficient plasticizer to render the mixture non-brittle. A typical example of such an adhesive consists of nitro-cellulose 25%, rosin 25%, and dibutyl phthalate The cementing material may be prepared for application to the back of the floor surfacing structure by dissolving these constituents in a solvent comprising ethyl acetate three parts, toluol one part, and ethyl alcohol two parts. If desired, pigments may be added. The fluid cement is applied with any convenient device such as a roll coater, doctor coater, or spray and in the amount of about one pound per square yard. The coating is then dried to evaporate the solvent and leave a uniform, non-sticky, non-tacky layer of cementitious material. The appropriate solvent to be employed in activating the adhesive when the covering is to be installed will obviously depend upon the constituents of the cement and the solvent employed in rendering the same fluid for the purpose of the original application. In the above typical example the adhesive will preferably be activated by alcohol or similar watermiscible solvent.

One suitable type of water activated cementi tious material, fulfilling the general requirements of our invention as above outlined, comprises a mixture of clay and lignin with the addition of a small amount of plasticizing agent. A typical formula for such adhesive is clay lignin 42%, and glycerine 3%. an article of commerce obtained by evaporation of waste sulphite liquors from the wood pulp industry. This cement may be preparedfor application to the back of the surface covering by forming a paste comprising two to three parts of the above clay-lignin-glycerine mixture and one part of water. The composition is doctored or otherwise spread onto the back of the linoleum in the amount of approximately one pound per square yard to provide a uniform coating of substantial thickness. Upon evaporation of the water, a smooth, uniform layer of non-sticky,

non-tacky cementitious material integral with the back of the surface covering is obtained.

' Water will of course be used to activate this adhesive material when the surface covering is installed.

Surfacing structures prepared as above dethe cementitious material The term lignin refers toscribed with a normally non-tacky cementitious layer. may be rolled-up, shipped, stored, and merchandised in the usual manner, since normal variations in atmospheric temperature and humidity conditions occurring during such handling have substantially no effect on the cementitious layer. The solvent for activating the cementitious layer may be applied in any suitable manner, as with a sponge. After activation of the cementitious layer and laying 'of the surfacing 81 structure, the solvent evaporates or is otherwise dissipated, water-miscible solvents being dissipated through damp sub-structures more readily than water-immiscible ones; and the adhesive forms a rigid or relatively rigid bond substantial- 9 1y permanently uniting the surface covering and the sub-surface. The layer of cementitious material is of substantially unform thickness, a condition readily achieved in the factory operation in which it is applied, and as a consequence, the dif- 9 ficulties encountered from buckling'caused by the uneven and excessive application'of liquid cement to the sub-surface by methods of the prior art are avoided. The uniformity of the layer of cementitious material eliminates the bulgingdue to uneven application of viscous cement to the sub-surface and eliminates the unequal distribution of solvent or moisture that must be evaporated and therefore uneven swelling of the covering material. Substantially less solvent is required to activate the cementitious layer than is normally present in the pastes or cements heretofore used and which are manually spread at the time of installation. This feature is of importance for two reasons. First it causes the activated adhesive to set and harden more quickly than the ordinary paste or cement. Secondly the smaller quantity of solvent present and which must be dissipated greatly facilitates installations on sub-surfaces which are deleteriously affected 11 by a larger quantity of solvent. Thus, it has been found practicable to bond the ready-to-lay floor surfacing structures of the present invention directly to wood surfaces, whereas according to prior practices this could not readily be done since the quantity of solvent normally present in the conventional paste not infrequently caused the wood sub-surfaces to swell and warp. Furthermore, it will be found that because of such uniform application of the adhesive the surface covering can be perfectly bonded to the sub-surface with the application. of little pressure and without the use of the heavy roller heretofore required.

From the foregoing it will be apparent that we have provided as a new article of manufacture a pre-formed ready-to-lay surfacing structure which comprises a body portion having a wearing surface in combination with a backing layer of normally sticky, or potentially adhesive but I normally non-sticky, cementitious material, the body portion being adapted to constitute a protective surface or an ornamental effect.

Many advantages of this invention will be obvious in view of the foregoing description, some of such advantages being important from a structural or manufacturing point of view, others being'important from the point of view of handling and marketing, others being important from the point of view of installation, and still others 1 being important from the point of view of the finished structure comprising the sub-surface and the bonded covering material. Consideration of tne advantages will facilitate a fuller attainment thereof in the employment of this invention, and 1 foregoing, additional advantages, among others that will be apparent, are to be considered from this point of view. A'primary advantage is the the fact that the layer of cementitious material constituting the backing layer of the finished surfacing structure performs the function of and renders unnecessary any back coating such as is commonly employed on linoleum and also performs the bonding function more effectively than does separate cement applied to the sub-surface. In this connection, it may be noted that floor coverings of the linoeum or felt-base type comprise a foundation layer of burlap or of asphaltsaturated felt or a combination of burlap and felt, and they are in -most instances provided.

with a. coating on the back of the foundation layer. Such a coating is ordinarily'applied in liquid form and has a paint-like appearance, and is ordinarily applied to the burlap in such quantities as substantially to fill the interstices and irregularities thereof and produce a relatively smooth surface. Among the reasons for such a coating are the simple but not inconsiderable one; that the public expects and therefore demands its presence, and it seals burlap against or conceas the unsightliness due to seepage of material through the burlap, such as sticky material used to secure inlaid sheets to the base or soft composition roll-ed directly upon the burlap in the making of plain linoleum. The asphaltimpregnated felt base is black and unsightly and sticky, and a back coating is almost indispensable. Especially the normally non-tacky cementitious layer, which may carry a pigment, provides the appearance which the public expects, seals the burlap against seepage through it of sticky material used to bond inaid linoleum thereto and soft composition rolled thereon. Inasmuch as the foundation layer of the covering structure may or may not, in the practice of this invention, comprise the above-mentioned paint-like backing coat, constructions having the cement layer applied directly to the back of the body portion of the covering structure and constructions having the cement layer applied to such paint-like backing coat are both within the spirit of this invention, but when the cement layer engages direct-.y the body portion instead of engaging the paint-like backing coat, a stronger and even interlaced bond may be formed between the body portion and the adhesive. In connection with this latter advantage, it is to be noted that even though one may utilize separate cement and apply it to the sub-surface and then lay upon it linoleum embodying this invention and having as its lower layer a layer of cementitious material, the superior bonding of the cement with the. linoleum is effected and superior bonding of the covering material to the sub-structure is effected, because the cement spread on the sub-structure forms a stronger bond with the cement embodied 1,970,508 I in addition to the advantages apparent from the in the surfacing material than it would with the conventional paint-like backing coat of linoleum, especially when the solvent of the separate cement activates the cement layer of the surfacing structure.

Modifications in the application of ourinvention will undoubtedly suggest themselves to those skilled in the art and we do not wish to limit the scope of -.the same except as defined in the appended claims. In this connection it is to be noted that the terms floor covering or floor surfacing structure as used herein are intended to app y equally to materials used for floors, walls, or other rigid or structural surfaces.

To assist in an understanding of this invention, the annexed drawing gives a perspective view illustrating one embodiment of our invention. In the drawing there is shown a conventional type of smooth-surfaced floor covering such as linoleum having a surface layer 1 of linoleum composition which is wear-resisting and which may be decorative, having a. layer of burlap 2, which constitutes the foundation layer, and being coated on the back thereof with a layer of cementitious material 3, which overlies that twe of the burlap which is opposite to the face thereof upon which is formed the layer of linoleum composition. In the event that the cementit'ous material 3 is of the permanently sticky type, it is overlaid with a removable protecting sheet 4, which is removed prior to the laying of the surfacing material. In the event that the cementitious material is normally nonsticky, the protective sheet 4 can be dispensed with.

claims are within the spirit of our invention.

We claim:

1. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay in bonded relation to a sub-surface, comprising a body portion characterized by a sheet-like strainresisting foundation and a layer of wear-resisting drying-oil composition integral with one side of said foundation and constituting the upper or wearing surface of the body portion, in combination with a layer of cementitious material applied to the back of said body portion and on the other side of said foundation and adapted to bond the said body portion permanently to a sub-surface to which it may be applied.

2. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay in bonded relation to a sub-surface, comprising a body portion characterized by a sheet-like strainresisting foundation and a layer of wear-resisting drying-oil compositionintegral with one side of said foundation and constituting the upper or wearing surface of the body portion, in combination with a layer of permanently sticky cementitious material applied to the back of said body portion and on the other side of said foundation and adapted to bond the body portion permanently to a sub-surface to which it may be applied.

3. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay in bonded relation to a sub-surface, comprising a body portion characterized by a sheet-like strainresisting foundation and a layer of wear-resisting drying-oil composition integral with one side of said foundation and constituting the upper or wearing surface of the body portion, in combination with a layer of cementitious material comprising a mixture of rosin and raw rubber applied to the other side of said foundation and adapted to bond the body portion permanently to a sub-surface to which it may be applied.'

4. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay in bonded relation to a sub-surface, comprising a body portion characterized by a sheet-like strain-resisting foundation and a layer of wearresisting drying-oil composition integral with one side of said foundation and constituting the upper or wearing surface of the body'portion, in combination with a layer of cementitious material comprising a mixture of 100 parts by weight of raw rubber with 130 to 200 parts of rosin applied tothe other side of said foundation and adapted to bond the body portion permanently to a sub-surface to which it may be applied. 7

5. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay in bonded relation to a subsurface, comprising a body portion characterized by a sheet-like strain-resisting foundation and a layer of wearresisting drying-oil composition integral with one sideof said foundation and constituting the upper or wearing surface of the body portion, in combination with a layer of permanently sticky cementitious material applied to the back of said body portion and on the other side of said foundation and adapted to bond the body portion permanently to a sub-surface to which it may be applied, and a protective sheet overlying said layer of cementitious material and removably held by the adhesiveness of said layer in protective relation thereto.

'6. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay in bonded relation to asub-surface, comprising a body portion characterized by a sheet-like, strain-resisting foundation member and a layer of wear-resisting drying-oil composition integral with one side of said foundation member and constituting the upper or wearing surface of the body portion, in combination with a layer of normally non-sticky cementitious material adhering to the back of said-body portion on the other side of said foundation member and adapted to be activated to impart thereto adhesiveness to bond the body portion permanently to the sub-surface to which it may be applied.

'7. As a new article of manufacture, a -preformed floor surfacing structure ready-to-lay in bonded relation to a sub-surface, comprising a bodyportion including a sheet-like, strain-resistant foundation member and a layer of linoleum composition integral with one side of said foundation member and constituting the upper or wearing surface of the body portion, in combination with a layer of non-sticky cementitious 'materialadhering to the back of said body portion on the other side of said foundation member and adapted to be activated by an appropriate solvent to impart thereto adhesiveness.

8. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay. in

bonded relation to a sub-surface, comprising a body portion characterized ,by a sheet-like,

strain-resistant foundation and a layer of wearresisting drying-oil composition integral with one side of said foundation member and constitutingthe upper or wearing surface of the body portion, in combination with a layer of nonsticky cementitious material adhering to the back of said body portion on the other side of said foundation member and adapted to be activated by a water-miscible solvent to impart thereto adhesivenessto bond the body-portion constituting the upper or wearing surface of,

the body portion, in combination with a layer of normally non-sticky cementitious material adhering to the back of said body portion on the other side of said foundation and adapted tobe 'activated by an appropriate solvent to impart thereto adhesiveness to bond the body-portion permanently to a sub-surface to which it may be applied.

10. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay in bonded relation to a sub-surface, comprising a body portion characterized by a sheet-like, strain resisting foundation member and a layer of wear-resisting drying-oil composition integral with one side of said foundation member and constituting the upper or wearing surface of the body portion, in combination with a layer of normally non-sticky cementitious material adhering to the back of said body portion on the other side of said foundation member and adapted to be activated to impart thereto adhesiveness for forming a bond between the body portion and the sub-surface to which it may be applied.

11. As a new article of manufacture, a preformed floor surfacing structure ready-to-lay in bonded relation to a sub-surface, comprising a body portion characterized by a sheet-like, strain-resisting foundation member and a'layer of wear-resisting drying-oil composition integral with one side of said foundation member and constituting the upper or wearing surface of the body portion, in combination with a layer of normally non-sticky cementitious material adhering to the back of said body portion on the other side of said foundation member and adapted to be activated to impart thereto adhesiveness and adapted to unite with a relatively rigid bond the body portion to a sub-surface to which it may be applied. V

ALBERT W. HAWKES. ROBERT D. BONNEY.

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