USRE19747E - Method of cooling composition tile - Google Patents

Description

4 A.Sheets-Shoe?. 2

G. P. HEPPr-:s

METHOD: 0F COOLING COMPOSITION TILE original Filed .July 5. 19:52

Nov.' 5, 1935.

` ''Trvrz for eoe fttorney.

- Heppes,

` Re, 19,747 I' 4 Sheets-Sheet 3 J5? Z/n for. V Geofye .T Hennes.

G'. P. HEPPEs original Filed .July s. 1932 In) i METHOD 0F COGLING COIPUSITION 'IILBl I5 l5. lum

Nqv. 5, Y19,735.

lNov. 5, 1935. G. P. HEPPEs METHOD oF COOLING coMPosITIoN TILE original Filed July 5, 19:52 4 Smets-sheet 4 #www er Reuma Nov. s, 193s 19.141 Y .l Mn'rnon or cooLiNo coivrrosrnon ma y George P. Heppes, Upper Montclair, N. J., as-

elgnor to The Tile-Tex Company, Chicago Heights, Ill., a corporation of Illinois Original No. 1,942,060, dated January 2, 1934, Serial No. 620,842, July 5, 1932. Application for reissue September 28, 1934, Serial No. 745,930.

18 Claims. -(Cl. (i2-170) This invention relates to Improvements in a.

method and means for making composition tile and refers particularly to a method and means for cooling' the heated pliable slabs, from which the o tile is to' be cut, to the desired temperature for cutting.`

The utility, objects and advantages of my invention will be apparent from the accompanying drawings and following detail description.

In the drawings, Fig. 1 is a top plan view of a machine suitable for carrying out my invention.

Fig. 2 is a side elevational view illustrating particularly the drive.

Fig. 3 is an opposite side elevational view to that shown in Fig: 2.

Fig. 4 is a sectional viewV taken on the line 4 4- of Fig. 1.

Fig. 6 is a longitudinal sectional view takenV on I the line 6 6 of Fig. 1.

Fig. 7 is a detailed sectional view'illustrating particularly the reversing mechanism of the cooling unit. v

Fig. 8 is a sectional view taken on the line 8 9 of Fig. 1.

Fig. 9 is a detailed perspective view of a slab of material previous to its insertion in the irstk calendar unit. y

Fig. 10 is a cross sectional view of a finished block of tile.

Referring in detail to the drawings, I indicates a motor which may be adapted to serve as the driving medium for my machine. It is to be understood, of course, that any prime mover may be utilized such as steam engine, internal combuston engine or the like. The motor shaft 2 may be coupled to a speed reducing unit 3 by means of coupling 4. Shaft 5 which is the low speed shaft of the speed reducer 3 may be coupled to shaft 8 by means of coupling l, the shaft 6 being the drive shaft for the ilrst mixing 4unit 8.

The mixing unit 8 may comprise a'pair of coacting rolls 9 and I0 being disposed adjacent each other. their axes being parallel. A pinion II may be mounted upon the drive shaft E and may be adapted to mesh with gear I2 which, in turn,

may be'rnounted upon the shaft I3 of the roll I0. A gear Il may be mounted upon shaftv I6, the same shaft which lcarries the co-acting roll 9.

The gear I4 may be of larger diameter than the the ratio of the angular velocity of the rollsv I0.

and 9 may be approximately '3 to 2. However, I

do not'wish to be limited to this particular differential in angular velocityy inasmuch as the same may be changed to meet various conditions of operation and variations in the material worked upon. 'I'he purpose of the differential in angular 5 velocity will be hereinafter more fully described. Both of the rolls 9 and I 0`may be o f hollow construction as shown best at Il and I 8 in Fig. 4, said rolls being adapted to be heated by steam introduced therein by means (not shown). This l0 typeof mixing unit wherein rolls are heated is well known to the art and lt is believed that the showing of steam connections thereto is unnecessary. The rolls 9 and |0 may be supported respectively upon shafts I0 and I3 which may be 15 journalledin the bearing blocks I9 and 20. The

blocks I 9 and 20 may be slidably positioned within the frames 2| mounted upon supports 22. Screws 23 may be threadedly mounted at the ends of frames 2| and may be connected to the bearing 20- blocks 20, the arrangement being such that by rotation of the screws 23 the blocks 20 may be moved towards or away from the blocks I9. In this manner the clearance between the peripheries of the rollsA 9 and I0`may be controlled. 25

The product of my invention, namely a ooring or wall composition tile may -comprise a binder such as asphalt or Gilsonlte, a filler and a pig- Iment. A representative mix may comprise approximate1y 26% of binder, 74% nner and a suit- 30 able quantity of pigment to obtain the desired color of the final product. Manyv types of llers may be used such as asbestos or other materials having like characteristics. It is to be understood, of course, that the above proportions are a given merely for purposes of illustration and are not. intended to serve as a Vlimitation upon my invention.

For purposes of illustration assume that Gilsonite is used as the binder and that asbestos is o used las the ller and .that the materials areV used in tl-e approximate proportions suggested above. Lugs 24 may beV mounted upon the frames 2| and may be adapted to support a hopper 2l which may be pivotally mounted upon said lugs. The asbestos and ground Gilsonite maybe introduced into the hopper 25 as shown at 28 in Fig. 4, the construction of the hopper being 'such as to direct the asbestos and Gilsonlte between the rolls 9 and I0. 'Ihe temperature of 50 the rolls 9 and I0 may be maintained at approximately 260 to 300 F;, by means of the steam introduced therein. However, the fastest moving roll, namely roll .I0 may be maintained at a lower temperature, relative to the temperature 55 of roll l. The Gilsonite upon contacting the hot rolls softens and the materials are formed into a more or less doughy mass which adheres to the surface of the more rapidly moving coolest roll III. The' doughy mass may be stripped from the roll I by means of the knife I1 which may be constructed of brass or other material havinghigh heat conducting' properties. 4'Iii'ie mass maybe stripped yfrom the roll III. may be reinserted between the rolls l and i0 and may be Aworked again and this procedure may be repeat'-` 4 Fig. 4 and as has been hereinbefore mentioned said stripping knife may be constructed of brass or other material having high heat conducting properties. Q I have found that if a material is -used for the knife 21 which does not readily lose its heat, the doughy material being mixed between the rolls will adhere-to the -blade of the f knife which will necessitate frequent cleaning of the knife.A However, if a brass knife or a knife of the material having heat conducting properties similar to those of brass is used, the douhy mass will not adhere to the blade of the knife.

'I'he second mixing unit may comprise rolls l0 and 3l mounted respectively upon shafts 32 and I3. 'I'he shafts I! and Il may be journalled respectively in bearing blocks I4 and 3l --whiclril may be adjustable towards or away from each other by means of screws It. The frames for the support of the blocks 34 and le may be similar-to the frames 2l of the mixing unit l. Shaft $1 of the speed reducing mechanism I may be connected to shaft Il supported by bearings 3l and 40, said connection' being accomplished through the coupling 4|. A pinion 42 may be mounted upon the shaft Il and may beadapted to mesh with the gear 43 which, in turn, may be mounted upon shaft 33 and may be adapted to drive. roll #i directly. Gears 44 and 45 may be respectively mounted upon the shafts I2 and I3, thegears being of such dimensions as to ro .roll I0.

The doughy mass is removed from the nrst mixing unit s in the form of a slab or sheet of relatively pliable material. Said material may then be inserted between the rolls lili Iand .3l which are also of hollow construction and may be steam heated, roll 3l being maintainedy at a lower temperature than roll Il. As in the case of the rolls 9 and III, the mass will adhere to the roll'li as shown best at 4I in Fig. 5, which is revolving'at a greater angular velocity and is cooler than the roll 3l. Upon milling the material in the second mixing unit 2B the material may be further worked and the color may be brought to a more uniform state as will.be hereinafter more fully described',r trimmings from'the press, which cuts the tile into the particular desired shapes. may be mixed with the ldoughy mass 4I during its working in the mixing unit 2l. In this manner the waste may be utilized.

After working the material 4B in the mixing unit- 28 until said material possesses' uniform characteristics as to texture and color, the same may be stripped from the roll 3i by means of the knife 41 which maybe pivotally mounted `upon the frames 2l of the second mixing unit. i The knife 41 is constructed of a to -the knife 21. namely, one possessing relatively l high heat lconducting properties. v

The strip of material taken from the roll 3| of the vsecond mixing unit may be folded in the 6 bearing blocks il and B4, the blocks I4 being. 1

adjustable toward or away from the blocks I3 by means of screws It. The blocks il and I4 may be slidably mounted within the frame il which, in turn, may be supported by the member 51,15 frame il and member 51 being similar in construction to the frames 2i and supports I2 oi the mixing units 8 and Il.

A pinion Il may be mounted upon the shaft Il and is adapted to mesh with gear l mounted 20 roll ill by passing steam into the hollow interior 80 l thereof, said roll may be heated to a temperature of approximately 80 to 100 F., the roll 49 may be maintained as cold as possible by circulating water through the hollow interior thereof. .At this stage the material adheres to the surface 35 having the highest temperature and. consequently the mixed dough-like strip taken from the mixer Il when inserted between the calender rolls 4l and l0 adheres to the surface of the roll Il.

'I'he axes of the rolls 49 and III may be so ad- 40 justed with respect toeach other as to provide a clearance space between their respective adjacent surfaces equal to approximately a thickness greater than the thickness of the final product, that is, the thickness of the tile. Of course, it is to be understood that the thickness of the strip 62 which adheres to the heated roll i0 will depend 'ipon the characteristics of the material worked and consequently I do not wish to be limited to the above mentioned'illustrative 50 example.l

A shaft 63 .may be rotatably mounted between the frame 5I and may carry a eut-ofi' knife 6 4 which may be of a length substantially equal to the length of the rolls. and 50. The shaft 63 5.5 may be rotated by means of sprocket chain 65 which may pass around sprocket wheel 66, said sprocket chain being in turn Edriven by the sprocket wheel 61 mounted upon shaft 68 of the variable speed reducing mechanism 89, which 60' merely necessary to decrease the angular velocity of the shaft 63 while maintaining the rotation of the roll 50 constant. f

In carrying out my invention the material may b e passed through the machine proper in what may be termed a series-batch operation, that is,

ply suilicient material to produce a plurality of unit slabs 12. As will be hereinafter more fully described, the remaining operations performed upon said slabs' are in the nature of continuous y operations, each slab being operated upon in series.

` Subsequent to the severing ofthe material 92 upon the roll 99, the unit slabs12 formed by said 'cutting operation may be stripped 'from the surface of the roll 99 by means of the stripping knife 19 which may be of similar material and similar construction to the knives 21 and 41 upon the mixing units 9 and 29, respectively. After being stripped from the roll 59 the slabs may be carried forwardly and upwardly upon conveyor belt 14 which may be carried around `pulleys 19 and 19. l

The arrangement is such that the rate of travel of the conveyor belt 14is materially greater than the peripheral speedof the roll 99 which results in the unit slabs 12. being positioned lupon the conveyor 14r in spaced relationship asshown best in Fig. 1. As will be hereinafter more fully. de

scribed,fthe unit slabs 12 are subsequently operated upon Aby a second calender unit in which operation the material is calendered and pressed substantially 20%. Consequently, when the slabs are subsequently pressed to the final thickness of the product, said slabs expand laterally and if the spacing upon the belt was not sufficiently great. to compensate for this expanding action, said slabs would enter the subsequent mechanism too close together. Consequently, in order to maintain desirable spacing of the unit slabs, the belt 14 may travel at a rate of speed in excess of the peripheral speed of the roll 99. .As an example of this increased rate of speed the follow'- ing. may be suggested: for a 20% excess of thickness the belt 14 may be caused to travel at a rate vof speed 50% greater than the peripheral speed of the roll 99. However, I do not wish to be limited to the above cited example in that the `rate of speed offthe belt in excess of the periphpass over pulleys 19 and 19, the pulleys 19 being rotated by means ofsprocket chain99 which may pass around sprocket wheel 9| mounted upon the shaftwhich carries the pulleys 19. The sprocket chain 99 is, in turn, driven by the sprocket wheel V92 mounted upon shaft 93. A second sprocket wheel 94 may be mounted upon shaft 99 and may be driven by sprocket chain 99 which, in turn,

may be driven by the motor 99. In this manner the unit slabs delivered from the'belt 14 are carried by the belts v11 to a point immediately above the rolls 91 and 99 of the second calender unit T'he rolls 91 and99 may be respectively mount-- ed upon shafts 99 and 99 which may be journalled respectively in the bearing blocks 9| and 92,.

slidabiy mounted within the frame u whiehare supported by members 94. The blocks 92 may be adjusted towards or away from the blocks 9| by means of the screws 99. A gear 99 may be mounted upon the shaft 99 and may be driven by 5 a pinion, not shown, which may be mounted upon shaft 91 .lournalled in bearings 99. A'bevelledgear 9'9 may also be mounted upon the shaft 91 and may be adapted to mesh with bevelled gear |99 mounted upon shaft |9| which may be sup` 1,0

`ported-by bearings |92. The opposite end of upon the shaft 99. The gears |99 and |99 may be .of equal diameters and 'consequently rolls 49 and 99 may be driven at equal angular velocity. 20

Similar to the first calender unit 49, one of the rolls, namely roll 91, may be cooled by the passage of water therethrough, whereas the other roll 99 may be heated by passing steam therethrough and the unit Siebe 12, carried by the belt 11 and 25 delivered between the rolls 91 and 99, will adhere to the warmer roll 99. In passing between the rolls 91 and 99 as has been hereinbefore described, the slabs 12 are'reduced in thickness and consequently all pook-marks and blemishes will 30 be removed from thesurfaces of the slabs. 'Ihe slabs adhering to the surface of the roll 99 are stripped therefrom by means of knife |91 which may be of similar construction to the knife 19, said slabs being deposited upon the conveyor belt 35 |99 which passes around pulley |99.

'The unit slabs calendered in the second calender unit 99 and stripped from the roll 99 by the knife |91 are deposited upon the belt |99 and are carried forwardly by said beu, the subs being dis- 0 posed therein in spaced relationship with respect to each other and with respect to the direction of travel of the belt. The belt |99 may travel over guide roller |I9 which may be mounted upon support I I and after passage thereover said belt 45 may becarried around a substantial portion of the area of the surface of cooling drum H2. The drum I2 may be of hollow construction and may be supplied with water or other cooling medium through the pipe ||9 which may connect intothe 5 interior of said drum. Said drum-may be mounted upon shaft |I4 which Imay be journalled in bearings H9 mounted upon, frame I9. 'I'he slabs carried by the belt 99 are confined between the belt and the surface of the cooling drum ||2 55 during the passage of the belt over the surface of the drum. In this manner a. substantial portion of the heat is removed from the slabs. In addition, by thus cooling one surface of each` of the slabs, namely the surface in contact with the 60 drum II2, the volatile matter or gases contained within the slab are driven away from the cooled surface toward the warmer surface whichis in contact with the belt. Due to the Vcooling of one surface the materialwhich comprises the slabs is 05 densii'led adjacent that surface. In addition, the cooled -surface is simultaneously brought into concave form which further tends to dens'fy the material adjacent that surface. lIn this manner volume material contained within the sieb is 11t- 70 erally pressed or forced from the material adjacent the concave surface of the slab or the cooled surface thereof.

The warmer surface of the slab is adjacent the belt and said-warmer surface also comprises the may be journalled infbearing |2| slidabiy posi.

The belt |22 upon leaving the surface of the drum I|2 is carried around pulleys ||1, ||2 and ||2 `and returns over pulley |22. 'Ihe pulley |22 may be mounted upon shaft |22 which, in turn,

tioned between guides |22 and |22. The bearing |2| may be longitudinally moved betweenA the guides' |22 and |22 by means of the screw |24 which may be actuated by means of nut |22.y By this arrangement the tension of the belt |22 may be adjusted and when the desirable adjustment has been made, the screw |24 may be locked by means of nut |22.

The slabscarried between the surface of the roll of the drum ||2 on belt |22 are carried upon the surface of said drum after the belt |22 leaves the drumand passes `around pulley ||1. At a subsequent period of travel of the slabs upon the vsurface of the drum ||2, said slabs are stripped from the surface of 'the drum by means of the stripping knife |21 mounted upon the frame ||2. The slabs thus removed from the surface of the drumk 2 are deposited upon the belt |22 which passes around pulley |22 immediately beneath the position of the stripping knife |21. The slabs 12 are so deposited upon the belt |22 that the cooled surface thereof is disposed adiacent the belt |22 and the warmer surface thereof faces upwardly. Upon forward motion of the belt `|22 the same is carried around cooling drum |22 which may be' 'constructedsimilarlytothedrum ||2, thedrum |22 also having a hollowinterior and being supplied with a cooling medium through the pipe |2I. 'lhe drum |22 may be mounted upon shaft |22 which may be journalled in bearings |22 mounted upon the frame ||2. The belt |22 is-carried around the drum |22 and covers a substantial portion of the area of said drum. In over the surface of said drum the slabs 12 are confined between the belt and the drum. However, at this period, the cooled surfaces of the yslabs are disposed adjacent the belt', whereas the uncooled surfaces are maintained adjacent the cooling surface of the drum. v In this manner the heat is removed from the warmer surface' of the slab and the material adjacent thereto.

The belt|22 upon leaving the surface of the drum |22 is carried around pulleys |24 and v|22 and returned over the pulley |22. The pulley |22 may be mounted upon shaft |22 which may be journalled in bearing |21, siidably positioned between the guides |22 and |22. The bearing |21 may be longitudinally moved between the guides |22 and |22 by means 'of screw |42, which may ybe actuated'by nut |4| and locked by nut |42. lBy this arrangement the tension of the'belt |22- may be adjusted.

At the point of travel where the belt 22 breaks contact with the surface of the drum |22, the slabs -12 carried between the belt and the drum 'are stripped from the surface of the drum'by means of the stripping knife |42 which may be of similar construction to the knife |21. The slabs thus stripped from the surface of the drum |22 are carried forwardly tothe conveyor belts |44 which travel around pulleys |42 and |42.

The pulley |42 may be mounted upon shaft |41,

saidshaftalsobeingadaptedtocarryasprocket wheel (not shown) over which sprocket chain |42 travels, said sprocket chain also passing around a sprocket wheel (not shown) mounted upontheshaftofmotor|42. Inthismannerv then be removed manually or mechanicalLv to a lo suitable punch press (not shown) equipped with dies for'cutting tiles of desired shapes and dimensions. A sectional view of one of the tiles is shown at |12 in Fig. l0.

If the slabs 12 are not brought to a suitable` ll cutting temperature, difllculty will be encountered in cutting said slabs. If, for instance, lthe slabs are too warmfimperfect cuts will be made by the dies, whereas if the slabs are too cold the cutting will result in chipped edges of the tiles so and the lives of the cutting knives `or dies of the-press will be materially shortened. To bring the slabs to a desired cutting temperature, of course, will depend -upon the thickness of the slabsand therate of passage of the slabs through 22 the cooling portion of the machine. For a given rate of passage through the machine and a predetermined temperature of the surfaces of the cooling drums which may be controlled within certain llimits by controlling the pe of water 2o or other cooling medium therethrough, a slab of thickness of approximately one-eighth inch may be suiliciently cooled by one passage through the cooling portion of the machine. However,-

with other lfactors remaining constant, if the22 slabs are of greater thickness, one passage of the slabs through the cooling portion of the machine may not suilice to lower the temperature lof the slabsto the desired degree for cutting.

Consequently, I have provided a means and a 4,0

method of returning the slabs, after their passage through the cooling portion yf the machine. to the belt |02 whereby the slabs may beagain carried through thecooling unit. l

dTo accomplish this end I have provided a 42 switching mechanism |22 which may comprise a member |52 which may be loosely journalled upon shaft |24, the same shaft which carries pulley |24. The member |22 may carry arcuate plate |54' provided with handle |55. The mem- 20 ber- |22 may also carry an extension |22 which, in turn, may support a counterwelght |21 which may normally maintain the arcuate plate |24 in the position shown in Fig. 6. An arm |22 may be carried by the weight |21 and a roller |22 2 5 ymay be rotatably mounted upon the end of said arm, said roller being adapted to vride upon the surfaceof the belt |22 during its passage over the pulley |24.

To pass the slabs 12 through the cooling meeh- 00 anlsm comprising they drums ||2 and |22 but once, the switching mechanism |22 will be positioned as shown best in Fig. 6. If a greater dethe slabs 12 are stripped from the surface of .my w

the roll |22, the forward edges of said slabs contact the concave face of the arcuate member |24 and are directed upwardly. Said forward edges in passing upwardly are inserted between the surface of the beit |22 andthe roller |22 and are 1s flili upon frame ||6 when the belt |22 over the pulley |36. The chute |6| directs the slabs to the upper surface of the belt |08 previous to its passage around the first cooling drum ||2. In this manner each of the slabs stripped from the drum |30 are carried aroundthe pulley |34 upon the belt |26 and are deposited in series upon the belt |68 whereby said slabs may again be.

passed through the cooling unit. As has been hereinbefore described the slabs, depending upon their thickness, may be passed through the cooling unit once or any number of times sufficient to properly cool the material to a desired cutting temperature. n

The size of unit batches which are made up or mixed in the mixing units 8 and 26, are so proportioned as to comprise a desired number of slabs which, if passed through the cooling unit more than once, will not be overlapped by the` slabs being returned from the chute |6|. That is, the I'lrst recycled slab delivered to the belt |68 from the chute |6| will be delivered to said belt following the passage of the last slab initially entering the cooling unit. If the slabs are to be delivered-through the cooling unit but once, the batches mixed in the'units `8 and 28 may be substantially larger. f course, it is. to be understood that if the slabs are to be passed through the cooling unit `but once, the calendering and` cooling units of the machine may be run continuously, that is, properly mixed material may be continuously forwarded to the first calendar unit 48.

The driving mechanism for the cooling drums ||2 and |36 may comprise a sprocket wheel |62 mounted upon shaft 89. Sprocket chain |63 may pass over the wheel |62 and may connect said wheel with sprocketA wheel |64 mounted `upon shaft |32. A pulley |65 may be mounted upon shaft |32 and may beoperatively connected to pulley wheel |66 mounted upon shaft ||l by means of belt |61. 'I'he belt |61 may be crossed in order to'` impart reversed directions of rotation to the drums |33 and H2.

If desired, conventional'circular slitting knives (not shown) may be mounted adjacent and operate in lconjunction with calender roll 88 of the second calender unit 89. 'I'he knives may be adjusted to trim the edges ofthe slabs 12 or to sever each slab into two or more units. 0f course, it is to be understood that the slitting knives maybe eliminated since they comprise no part of my broad invention. f'

The making of slabs of composition material from which unit tiles may subsequently be cut has hereinbefore been described, the slabs being of one color. However, my invention broadly contemplates the making of slabs which may be subsequently cut lnto'tile of desired dimensions with' faces resembling marble, that is, in regard to the swirls or configurations which are characteristic of marble.

I- claim as my invention: 1

1. In a process wherein binder, ller andpigment are mixed under the influence of heat to form a coherent mass which is calendered and cut into unit slabs for the manufacture of composition tile, the improvement which comprises feeding said slabs through a cooling zone wherein opposite faces of said slabs are caused to progressively contact cooling surfaces, removing said slabs after through said cooling zone and again feeding them through the cooling zone in contact with the cooling surfaces whereby the temperature of the slabs is reduced to a suitable cutting tem- 2. In a process wherein binder, filler and pigment are mixed under the influence of heat to form a coherent mass which is calendered and cut into unit slabs for the manufacture of composition tile, the improvement which comprises causlng the opposite faces of each of said slabs to progressively contact a plurality of successive cooling surfaces, and repeating the operation by causingthe opposite faces of each slab to again progressively contact ysaid cooling surfaces until the temperature of said slabs is reduced to a. suitable cutting temperature.

3. In a process wherein binder, filler and pigment are mixed under the influence of heat to form a coherent mass which is calendered and cut into unit slabs for the manufacture of composition tile, the improvement which comprises feeding each slab through a cooling zone wherein one face of each slab is brought into contact with a cooling surface, transferring said slabs to a second cooling surface in such a manner that the opposite face of each slab contacts said second cooling surface, removing said slabs from said 'second cooling surface 'and again feeding `the slabs through the cooling zone in contact with Asaic'l 30 cooling surfaces.

4. In a process wherein binder, filler and pig-k ment are mixed under the influence of heat to form a coherent mass which is calendered and cut into unitl slabs for the manufacture of compoa5 sition tile, the improvement which comprises` causing one face of each of said slabs to contact a moving cooling surface, thereafter causing the opposite face of each slab to contact a second moving cooling surface, removing the slabs from contactvwith-said second moving cooling surface and recycling them into contact with said first s mentioned cooling surface.

5. In a process wherein binder, filler and pigment are mixed under the influence of heat t0 45 form a coherent mass which is calendered and cut into unit slabs for the manufacture of composition tile, thel improvement which comprises feeding unit slabs through a cooling zone wherein opposite faces of each slab are progressively brought into contact with rotating cylindrical surfaces, periodically removing the slabs from a. succeeding surface and returning same to a preceding surface whereby the temperature of the slabs after being eventually removed from the cooling zone has been reduced to a desirable cutting temperature.

6. In a process wherein binder, filler and pigment are mixed under the influence of heat to form a coherent mass which is calendered and cut into unit slabs for the manufacture of composition tile, in `whichprocess the unit slabs are fed into contact with a plurality of cooling surfaces wherein opposite faces of said slabs progressively contact said cooling surfaces the improvement which comprises, periodically removing slabs from a succeeding cooling surface and recycling and again feeding saidslabs into contactwith a preceding cooling surface whereby to reduce the temperature of said slabs to a suitable cutting temperature.

7. In a process wherein binder, filler and pigment are mixed under the influence of heat to form a coherent mass which is calendered and cut into unit slabs for the manufacture of com- 15 position tile, the improvement which comprises bringing one face of said slabs in series into contact with a rotating cooling surface. thereafter bringing the opposite face of saidslabs in seriatim into contact with the secondrotating coolinto contact with a cooling surface, densifying and cooling the material adjacent said face while subjecting the material adjacent the opposite face to tension, thereafter passing said slabs in seriatim into contact with a second cooling surface to cool and densify the material adjacent that fa'ce initially subjected to tension while subjecting the opposite face to. tension, returning said slabs in series into contact with said cooling surfaces, and repeating said recycling operation until the slabs reach a temperature suitable for cutting into composition tile. f

9. `In a process wherein a batch consisting of binder, filler and pigment are mixed under the influence of heat to form a coherent mass which is calendered and cut intounit slabs from which composition tile may be cut the improvement which comprises, bringing one face of each of said slabscomprising a batch in seriatim into contact with a moving cooling surface; thereafter bringing the opposite face of each of said slabs compsingabatchinseriatimintocontact witha second moving cooling' surface, returning said slabs in series and again causing them to lcontact said rst mentioned cooling surface and during passage in contact with said cooling surfaces -maintaining-the distan between the first slab of said batch and another slab in said batch less than the length of the path of travel in contact with said cooling surfaccs.

10. In a process wherein a plurality of batches comprising a binder, a filler and a pigment are .mixed under the influence of heat to form coherent masses, the or batches being calendered and cut into unit slabs, and the unit slabs of each batch passed in series through a cooling zone, the improvement which comprises returning the unit slabs leaving the cooling zone in series for repassage throughsaid cooling zone and maintaining the distance between the rear edge of a slab of one batch and the front edge of the slab in a succeeding batch greater than the length of a lbatch times the number of recycling operations performed upon each batch.

l1. In` a process wherein a binder, a filler and a pigment are mixed under. the influence of heat to form a coherent mass which is calendered and cut ini/o unit slabs from which composition tile may be cut, the improvement which comprises the following successive steps: bringing one face ofeachof saidslabsinseriesintocontactwitha relatively cold moving surface, thereafter' bringing the opposite face of each ofsaid slabs in series intoeontwt with s wond relatively com moving surface, returning said slabs in series, and again causing said slabs to contact said first and second cooling surface and repeating said 'recycling op'eration until the temperature of the slabs has been reduced to a suitable cutting temperature.

12. In a process wherein binder, lier and pig-V ment are mixed under the influence of heat to form a coherent mass which is calendered into a slab for the manufacture of composition tile, the

improvement which comprises feeding said slab vl5 through a cooling sone wherein opposite faces of said slab are caused to progressively contact cooling surfaces. l y n 13. In a process wherein binder, filler and pigment are mixedunder vthe influence of h eat to 10 form a coherentmass which is calendered into a slab for the manufacture of composition tilethe improvement which comprises feeding such slab through a )cooling zone wherein one face of such slab is brought into contactwith a cooling surl5 face, transferring said slab to a second cooling surface in such a manner that the opposite face of such slab contacts said second cooling surface, and removing said slab from said second cooling surface.

14. In a process wherein binder, filler and pigment are mixed under the influence of heat to form a coherent mass which is calendered into a slab for the manufactureof composition tile, the improvement which comprises bringing one face 25 of said slab in series into contact with a cooling surface, densifying and cooling the material adjacenty said 'face while subjecting the material adjacent the opposite face to tension, thereafter passing said slab into contact with a second cool- 30 ing surface to cool and densify the material adjacent that face initially subjected to tension while subjecting the opposite face to tension, and removing said slab from said second cooling surface.

15. In a process wherein binderfilller and pigment are mixed under the influence of heat to form a coherent mass which is calendered into a slab for the manufacture of composition tile the improvement which comprises. bringing said 40 calendered slab without previous fiexure thereof into contact with a rotating, cooling surface to set and densify the surface of the slab in contact Y with said cooling surface, removing the slab from contact with said cooling surface and bringing the opposite face of the slab without substantial intervening ilexure of the slab into contact with a second rotating cooling surface to set and densify said opposite face of the slab. y

16. In a process wherein binder, filler and pigment are mixed under the influence of heat to form a coherent mass which is calendered into a slab for the manufacture of composition tile the limprovement which comprises, bringing said..

calendered slab into contact with a rotating cooling surface, of sufiiciently large radius to prevent permanent distortion of its thickness caliper. to

vset and densify the surface of the slab in contact 'slab for the manufacture of composition tile, the 70 improvement which comprises, bringing one face of the calendered slab into direct contact with a rotating, cooling surface to chill said face of the slab and prevent formation of blisterson said face and to iiex the opposite face of the slab, and con- 'lo `lli ning the entire area of the opposite face of the slab to maintain said contact, removing said' slab from contact with said rotating, cooling surface, bringing the opposite face Aof the slab into direct contact with a second rotating cooling surface whereby to chillvsaid opposite face,` conning the entire area of said cooled face of the slab to said contact, removing said slab from contact with said second cooling surface and recovering the cooled slab. y

18. A process of making composition tile consisting of a binder, ller and pigment which are previously mixed under the inuence of heat to form a, coherent mass which comprises, calenderingsaidmasstoformaslabhavingadesired wearing surface finish. bringing said wearing surface into contact with a rotating, cooling drum whereby to chill and set said wearing surface and reduce the temperature thereof below the yield point of the binder, removing said slabvfrom contact with said rotating, cooling drum and thereafter bringing the Aopposite face or non wearing face into contact with a second rotating. cooling drum whereby to chill and set -the plastic binder of said non wearing face below the yield point 10 thereof, while maintaining throughout the cooling operation the wearing surface finish imparted to the slab during the calendering operation.

GEORGE P. g' is

Images