Патент USA US2129622код для вставки
' Sept. ‘6-, 1938. I F. H. MANCHESTER ' FLOORING MATERIAL AND METHOD FOR MAKING SAME Filed Jan. 22, 1935 2,129,622‘ ‘Patented Sept. 6, 1938 2,129,622 UNITED STATES PATENT OFFICE 2,129,622 FLOORING MATERIAL AND Marnon iron I MAKING SAME , Frank H. Manchester, Akron, Ohio, assignor to Wingfoot Corporation, Wilmington, Del., a cor poration of Delaware Application January 22, 1935, Serial No. 2,854 ' 12 Claims. (01. 154-2) are substantially uniformly This invention relatescto rubber flooring mate rial and the method of producing the same. The ?ooring material comprises blocks of rubber ?ooring which are backed upuwith a resilient 5 matrix composed of rubber and a cushioning ma terial such as ground cork. In making inlaid rubber ?ooring it has been found that if the various rubber blocks which comprise the surface are not of exactly the same 10 thickness one of two serious defects” results. (1) If the composition of the unvulcanized rub - her is quite rigid, as is usually the case, the heavy gauge blocks take all the pressure and the light gauge blocks never meet the polished curing sur ' I5 face. This results in a rough, undervulcanized, defective surface on the light gauge blocks. , (2) If the composition of the unvulcanized rub ber is plastic the pressure during cure results in making the heavy gauge blocks ?ow or spread 20 over in the low gauge areas resulting in uneven dispersed. When ~ this is placed in the press and pressure is applied the compressible material under the heavy gauge blocks is compressed to a greater extent than the compressible material under the light gauge 5 blocks so that the entire upper surface is brought into pressure contact withthe upper plate of the press during the curing’operation. This is in dicated in Fig. 2. The matrix may be backed up with any suitable material such as a rubber base 10 4. It will often be advantageous to use fabric 5 between ‘the matrix and the rubber base. The structure shown in Figs. 1 and 2 is illus trative of the invention and it is not to be under stood that the invention is limited to the struc- 15 ture shown. A modi?ed flooring is shown in Fig. 3. It comprises fabric 5 interposed between the pieces of inlay and the matrix. Any suitable means of backing up the matrix may be 20 ' employed. lines between the blocks. According to this invention the various inlaid pieces are backed up with a cushioned matrix and pressure is applied to the surface of the in It has been found that ?ne particles of cork are ordinarily .denser and less compressible than coarser particles. Cork dust of 100 mesh has a individual pieces of inlay. The matrix is formed of rubber in which ?nely divided particles of re 30 silient material such as cork, etc. are dispersed. which about 50% or more of the cork is not ?ner gravity in rubber of about 1 and is not very com 25 laid pieces during cure to produce a perfectly v pressible. Ground cork between 14-20 mesh has 25 a gravity of about 0.30 in rubber and is quite even surface and the intended design is not de formed by any unintentional lateral ?ow of the compressible. It is not necessary to use cork of The defects mentioned above are thus avoided because when the ?ooring is subjected to pres sure for curing, the cork or other resilient mate ‘ rial under the heavy gauge blocks is compressed 35 and the low gauge blocks are brought into con tact with the heated platen, plate or pan of the press and there is no a$preciablelateral distor tion of the heavy gauge pieces. The light gauge blocks are vulcanized in pressure contact with 40 the smooth platen of the press and each block has a perfectly smooth surface. The rubber of the matrix is .cured with the cork under com any particular particle size. A ground cork in than 20 mesh will in general be found satisfactory. 30 Instead of cork other volumetrically compressible materials such as ground sponge (sponge rub ber), rubber scrap, ground or shredded Balsa wood, corn stalk pith and like porous materials may be used. 35 The invention is particularly valuable in pre paring ?ooring from blocks of different colors which are prepared at diil'erent times vand are therefore commonly of somewhat different thick ness. The matrix may be made from any suit- 40 able rubber composition compatible in rate of vulcanization with the inlaid blocks and which pression so that when the pressure is released the will adhere to these blocks or to any intermediate inlaid blocks form‘ a smooth surface. layer of material such as the fabric shown in The invention will be further illustrated in' Fig. 3. The following formula for the rubber in 45 45 connection with the accompanying drawing in a matrix comprising ground cork has been found which Fig. 1 shows rubber blocks of different to give satisfactory results: thickness placed on a’ rubber matrix before vul Parts canization. Fig. 2 shows the same pieces of ma 50 terial after vulcanization. Fig. 3 shows a modi ?ed product. In making the ?ooring the individual pieces of inlay l are ?tted together on the matrix 2. In the preferred form of the invention this matrix is 55 composed of rubber in which particles of cork 3 Rubber _____ __ 100 Mercaptobenzothiazyl disul?de ___________ __ 1 50 Sulfur ___ 3 ' Sublimed litharge _______________________ __ 5 Ground cork (14-20 mesh) ______________ __ 100 ' I claim: 1, Flooringmaterial with a smooth upper‘ sur- ‘5 2 2,129,622 face composed of rubber blocks of different thick ness on a matrix composed of vulcanized rubber and a subdivided cushioning material, the cush ioning material under thick blocks being com pressed to a greater extent than cushioning ma terial under thinner blocks. cushioning material, by bringing the exposed sur faces of the blocks into pressure contact with a flat surface thereby compressing to different ex ground cork, characterized by the upper surface .tents the cushioning material under blocks of different thickness, and vulcanizing the rubber of the matrix while thus holding the cushioning'ma terial under compression. 9. The method of making ?ooring which com 10 of the flooring material having a smooth surface prises pressing unvulcanized rubber blocks of dif produced by vulcanization in pressure contact ferent thickness onto a matrix of unvulcanized rubber and ground cork to bring the upper sur face of each block into the same plane and into pressure contact with the smooth surface of the 15 press used for vulcanization, and vulcanizing the upper surface of said blocks in pressure contact 2. Flooring material composed of adjoining rubber blocks of di?erent thickness backed up with a matrix composed of vulcanized rubber and 10 matrix of.’ substantially uniform thickness com posed of unvulcanized rubber and a subdivided with a smooth surface while the blocks are backed up by said matrix and further characterized by 15 the fact that cork under the thicker blocks is compressed to a greater extent than cork under the thinner blocks. 3. Rubber ?ooring which comprises rubber blocks of different thickness on a matrix composed 20 of vulcanized rubber and a subdivided cushioning with said surface while vulcanizing the rubber of the matrix. 10. The method of making rubber ?ooring material, characterized by (1) said rubber ?ooring which comprises placing blocks of unvulcanized having a perfectly smooth upper surface produced rubber of different thickness onto a matrix of by vulcanization in pressure contact with a ' uniform thickness composed of vulcanized rubber smooth surface and (2) cushioning material and subdivided cushioning material, bringing the exposed surfaces of the blocks into pressure con 25 under/blocks of different thickness being com pressed to a different extent. tact with a ?at plate of a vulcanization press, 4. Rubber ?ooring comprising rubber flooring thereby compressing portions of the cushioning blocks of different thickness backed up with a material under the thicker blocks to a greater matrix composed of vulcanized rubber and sub extent than the portions under the thinner blocks and vulcanizing both the rubber blocks and the 30 30 divided cushioning material, the cushioning ma terial under blocks of different thickness being matrix while maintaining the cushioning material compressed different amounts to compensate for under pressure. the difference in thickness in said blocks and be , 11. The method of making rubber flooring ing held in said compressedcondition by the sur which comprises placing blocks of rubber of dif 35 rounding rubber in the matrix, said ?ooring being ferent thickness onto a matrix of rubber and a characterized by absence of lateral flow of the subdivided cushioning material, the upper sur material composing the individual rubber blocks. faces of said blocks being in different planes, sub. 5. Rubber ?ooring material comprising rubber jecting this assembly to sufficient vertical pressure flooring blocks of different thickness backed up to bring the surface of each rubber block into with a matrix composed of vulcanized rubber and pressure contact with a ?at plate of a vulcaniza a sub-divided cushioning material, the cushioning tion press without causing substantial lateral flow material under blocks of different thickness being of any rubber block thereby compressing portions compressed to a different extent and being held of the cushioning material to a greater extent in this state by the surrounding vulcanized rubber, than other portions and vulcanizing the exposed said flooring being characterized by the absence surface of the rubber blocks while in such pres 45 45 of lateral flow of the material composing the in sure contact. _ I dividual blocks and by a smooth upper surface 12. In the method of making rubber ?ooring produced by vulcanization in pressure contact from (1) blocks of rubber of different thicknesses, with a smooth surface. each block having a smooth upper surface and 6. Rubber ?ooring which comprises adjoining (2) a matrix composed of unvulcanized rubber 50 50 rubber blocks of different thickness vulcanized to and subdivided cushioning material, which blocks a matrix composed of rubber and ground cork, the arranged on the matrix do not present a smooth upper surface of the ?ooring being a smooth sur ?ooring surface, the steps which comprise sub face, the matrix under blocks of different thick— , jecting this assembly to suilicient vertical pressure in a vulcanization press to bring the surface of 55 55 ness being compressed to a different extent. '7. Rubber ?ooring which comprises blocks of each rubber block into pressure contact with a rubber of di?erent thickness backed up by a ?at plate of the vulcanization press thereby sub matrix composed of rubber and ground cork, said rubber ?ooring having a smooth upper surface jecting cushioning material under blocks of differ ent thicknesses to di?erent degrees of compres 60 produced by vulcanization in pressure contact , sion whereby the surface of each rubber block is 60 with a smooth surface and being characterized by absence of lateral fiow of the rubber blocks and by the cork under blocks of different thickness being compressed to a different extent. 8. The method of making ?ooring having a 65 smooth upper surface which comprises forcing blocks of inlay of different thickness against a brought into pressure contact with said flat plate of the vulcanization press without causing sub stantial lateral ?ow of any block, and vulcanizing the blocks and matrix while in such pressure contact. FRANK H. MANCHESTER.