US2907129A - Method and apparatus for making mosaic tiles or the like - Google Patents

Description

Oct. '6, 1.959 E. J; BEDELL 2,907,129

METHOD AND APPARATUS FOR MAKING MOSAIC TILES OR THE LIKE 3 Sheets-Sheet 1 Filed May 20, 1958 lNV ENT OR.

Eugene J. Bedell BY "wmh km ATTY 2,907,129 METHOD AND APPARATUS FOR MAKING MOSAIC TILES OR THE LIKE Filed m 20, 1958 E. J. BEDELL Oct. 6, 1959 3 Sheets-Sheet 2 INVENTOR. Eugene J. Bedell MM, max.

ATTY- Oct. 6, 1959 E. J. BEDELL 2,907,129

' METHOD AND APPARATUS FOR MAKING MOSAIC 'IQ'ILES 0R .THE LIKE Filed May 20, 1958 i v s Sheets-Sheet 3 FIG.II

m mm

ATTY

United States Patent METHOD AND APPARATUS FOR MAKING MGSAIC TILES OR THE LIKE Eugene J. Bedell, Massapequa, N.Y.

Application May 20, 1958, Serial No. 736,590

2 Claims. (Cl. 41-1) The present invention relates to a new and novel method and apparatus for making mosaic tiles or the like, and more particularly to such a method and apparatus whereby mosaic tiles and the like may be efficiently mass produced.

The present invention provides a new method and apparatus for producing designs, pictures or patterns upon mosaic tiles or in concrete and similar pliable materials, and is especially adapted for producing mosaic tiles; and accordingly the invention will be particularly described in connection with the mosaic tile art, although it is apparent that it is equally applicable to similar pliable materials other than clay from which mosaic tiles are ordinarily produced.

The art of producing mosaic tiles is an old one, and for many years mosaic tiles have been produced in an extremely tedious and time consuming manner. In recent years attempts have been made to design methods and apparatus for producing mosaic tiles in a more rapid and expeditious manner, but such methods and apparatus have not proved to be commercially satisfactory, and have not provided sufliciently improved rates of production in combination with adequate quality in the finished products. The present invention is especially designed to provide a means whereby mosaic tiles and the like can be mass produced in a rapid manner, and yet the method and apparatus provides reliable and consistent results of good quality.

The apparatus according to the present invention is a very compact arrangement whereby with a single operation the mosaic tiles may be cut, provided with an indented pattern and colored. When utilizing the novel structure according to the present invention, even a relatively unskilled laborer can rapidly produce quality tiles, and the possibility of obtaining poor results due to human error is reduced to a minimum. The apparatus according to the present invention comprises an arrangement wherein a rigid frame supports a plurality of cutting wires at the lower portion thereof such that upon downward movement of the frame, the pliable clay or the like is automatically cut into a plurality of desired shaped tiles.

The frame also supports a relatively rigid pattern indenting means comprising downwardly projecting walls which define the desired pattern. These walls are cut partially through the surface of the clay, and in one modification a poroussheet of material is supported tautly between the walls of the pattern indenting means. This porous sheet supports a suitable coloring substance in the pocket defined between the walls and the sheet whereby as the frame is moved downwardly the lower surface of the sheets engages the upper surface of the clay and transfers the coloring substance to the surface of the clay which, due to its inherent absorbent qualities, will pick up the coloring substance. The novel apparatus according to the present invention also includes a cooperating support slab upon which the clay is disposed and which has a plurality of grooves therein corresponding to the cutting wires supported on the frame. In a second modification, sheets of material are connected between the pattern indenting means and extend upwardly in a more or less cone shape. Each of the cones is provided with an opening for introducing coloring substance which is directed by the sheets to predetermined arcas of the clay or the like.

When employing the apparatus according to the present invention, an operator merely needs to align the frame with the supporting slab and then move the frame downwardly whereupon the operation is performed automatically.

According to the novel method of the present invention, the pliable material is first formed in a suitable manner of a predetermined thickness and then placed on a suitable supporting surface. The pliable material is cut into a plurality of separate pieces by passing a cutting member completely through the material, and the desired pattern is indented into the upper surface of the pliable material by cutting partially through the thickness of the material. Predetermined areas of the upper indented surface of the material are colored in accordance with the design which is impressed in the surface. The cut, indented and colored individual pieces are then heated or fired in a suitable kiln or the like so as to harden the pliable material and provide a finished colored surface thereon. A sheet of material, preferably flexible in nature, is then secured, in a suitable manner as by employing adhesive, to the upper surface of the individual pieces whereupon the entire mosaic assembly can be lifted off of the supporting surface. The applied sheet may then be cut into pieces of predetermined size and configuration to facilitate handling and shipment of the finished article.

An object of the present invention is to provide a new and novel method and apparatus for making mosaic tiles or the like whereby the articles may be mass produced in an expeditious manner.

Another object of the pcsent invention is to provide a method of producing a mosaic article and separating it into sections for ease in shipment and installation.

A further object of the present invention is to provide a method and apparatus for making mosaic tiles and the like whereby the mosaic tiles may be produced by an operator in such a manner as to require a minimum amount of skill and training.

Yet another object of the present invention is to provide an apparatus for producing mosaic tiles and the like which is extremely compact, simple and inexpensive in construction, and yet which provides reliable and consistent results.

Other objects and many attendant advantages of the present invention will become more apparent when considered in connection with the accompanying specification and drawings wherein:

Fig. 1 illustrates a top view of improved apparatus for producing mosaic tiles or the like according to the present invention;

Fig. 2 is a sectional view taken along line 2-2 of Fig. 1 looking in the direction of the arrows;

Fig. 3 is a view illustrating the manner of interconnection of the cutting members of the apparatus;

Fig. 4 is an enlarged view illustrating the manner of interconnection between the pattern indenting means and the coloring means of the present invention;

Figs. 5-9 illustrate various steps in the method according to the present invention;

Fig. 10 illustrates a support member employed in a modified method according to the present invention;

Fig. 11 illustrates the manner of rolling a body of pliable material;

Fig. l2 illustrates a modified pattern indenting and coloring means according to the invention, with certain portions thereof removed;

Fig. 13 illustrates an enlarged section of the pattern indenting andcoloring means of Fig. 12 with the color directing means secured in place; and

.Fig. 14 illustrates a modified cutting means according to the present invention.

Referring now to the drawings wherein like reference characters designate corresponding parts throughout the several views, there is shown in Figs. 1 and 2 the novel apparatus of the present invention including a rigid outer substantially rectangular frame indicated generally by reference numeral and comprising two oppositely disposed side members 11 and 12 connected at the end portions thereof by end members 13 and 14. The frame may be of any suitable rigid material such as wood or the like. As seen most clearly in Fig. 1, a pattern in the shape of a fleur-de-lis is supported in position with in the frame by means of a plurality of wires extending laterally across the inner open portion of the frame and secured at opposite ends by means of wood screws or nails 21 to the side members 11 and 12. A longitudinally extending wire 22 extends from one end member 13 to the opposite end member 14 and is attached to the respective members by means of wood screws or nails 23. It is apparent that intersecting wires 20 and 22 provide a supporting means for supporting the fleur-de-lis pattern in position adjacent the top portion of the frame. The fleur-de-lis pattern is composed of a plurality of downwardly projecting thin walls 25 formed of a suitable flexible material such as plastic or metal which may be easily deformed into the proper configuration. The various walls 25 are connected to one another as by welding or the like to provide a unitary rigid structure defining the outlines of the desired pattern. The upper edges of walls 25 are suitably secured to the lower surface of wires 20 and 22 where the wires intersect the walls by means of soldering or the like, and in this manner the fleur-de-lis pattern is supported in fixed position beneath the lower surface of wires 20 and 22. It is apparent that a pattern of any desired configuration may be formed of a plurality of wall members which are secured to one another and supported beneath wires 20 and 22.

Referring now more particularly to Figs. 2 and 4, a

sheet of porous material formed of a suitable material such as nylon or silk is suspended tautly between and connected to the adjacent wall portions of the pattern. Each of these sheets of porous material has a central flattened rather taut portion which bridges the space between adjacent walls 25 of the pattern, the opposite edges 31 and 32 of each of sheets 30 being bent upwardly and secured to the side surfaces of walls 25 in a suitable manner such as by means of an adhesive or the like. In this manner, it is seen that a small pocket is defined between adjacent walls 25 and the upper surface of sheets 30 extending between adjacent wall portions. These pockets are adapted to receive a body of suitable coloring material indicated generally by reference numeral 35 in Fig. 2. This coloring material may be conventional liquid color glaze as employed in the tile making art. v The material or sheets 30 is of a porous character such that the liquid glaze supported within the pockets defined between the sheets and the walls 25 will permeate the sheets and cling to the bottom thereof due to the capillary action of the sheet in combination with the heavy color glaze. In this manner, the coloring substance is continuously provided to the lower surface of sheets 30 such that the coloring substance is always in proper position to be transferred to an associated tile or the like.

Secured to the lower surface of frame 10 is a cutting means in the form of a plural ty Ofi i iQ l lstretche between the opposite side frame members and end frame members 1114 and having the opposite ends of each wire fixed by means of wood screws or nails 41. As seen most clearly in Fig. 3, the wires intersect one another so as to provide a plurality of spaces of substantially similar configuration, in this case squares, and the wires are interlocking with one another in a conventional basket weave. As seen in Fig. 1, cutting wires 40 form a grid network which will cut out a plurality of substantially square mosaic tiles or the like when the frame is lowered onto a piece of pliable material. The apparatus shown in Figs. 1 and 2 is adapted to cooperate with a suitable work supporting surface in the form of a slab as indicated by reference numeral 45, in Fig. 5 of the drawings. Slab 45 is preferably formed of stone or a similar hard material, and is provided with a plurality of intersecting longitudinally and transversely extending slots 46 and 47 respectively which extend partially through the thickness of the slab. Slots 46 and 47 are spaced apart the same distance as cutting wires 40 of the apparatus, and are adapted to register with the cutting wires whereby the cutting wires may be forced downwardly into the slots in the slab 45.

In practice, a piece of untreated clay or similar pliable material is initially formed into a flattened piece of substantially uniform thickness by suitable means such as by passing it between a pair of mechanical rollers, or placing it on a flat surface and passing a roller thereover. This slab may, of course, be performed either mechanically or by hand in an obvious manner. The piece of flattened clay is then placed upon the upper surface of slab 45, and the apparatus as shown in Figs. 1 and 2 is then lowered down upon the upper surface of the pliable material, and the inner side walls 42 of the frame members 11-14 are adapted to slide over side surfaces 43 of slab 45 whereby the-apparatus is guided in its downward movement.

As seen by reference to Fig. 2, cutting wires 40 will initially engage the upper surface of the flattened piece of pliable material indicated by reference numeral 50 and upon downward movement of the apparatus, wires 40 will pass completely through the thickness of the piece of pliable material, and will pass downwardly into slots 46 and 47 of slab 45. The apparatus is shown with cutting wires seated upon the lower surface of slots 46 and 47 in Fig. 2, whereby the downward movement'of the apparatus is checked. In this position, it is apparent that the lower edges of walls 25 have cut into the upper surface 51 of the clay or the like 50, thereby indenting the desired pattern into the upper surface of the individual pieces which have been separated from one another.

In the position shown in Fig. 2, the lower surfaces of sheets 30 have also come into contact with the upper surface of the pliable material such that the coloring substance suspended upon the lower surface of the sheets is transferred directly to the upper surface of the pliable material, and since such material, as clay, is quite absorbent, the coloring substance will be readily absorbed thereby.

The apparatus may then be completely removed from the slab and the pliable material with the cutting wires passing upwardly through the slots which have been cut through the pliable substance. From the foregoing description, the manner of construction and operation of the apparatus according to the present invention is clearly evident, and it is apparent that a very compact structure is provided for performing a plurality of operations in a simple and expeditious manner.

The method of the present invention may be more clearly understood with reference to Figs. 5-9 of the drawings. 'As stated previously, the pliable material is first formed into a piece of substantially uniform predetermined thickness as. by rolling or the like. The piece of pliable material is then preferably placed on the top ofslab 45 as illustrated in Fig. 6., The material is then cut into a plurality of separate pieces by a suitable cutting means. It is apparent that this may be accomplished in a number of different manners. For example, a knife may be passed completely through the thickness of the material and drawn longitudinally along the piece of material and subsequently laterally across the piece of material for separating the individual pieces. Also, a separate cutting means comprising a plurality of cutting members formed of a suitable relatively rigid material may be fixedly secured to one another to provide a rigid frame which need merely be depressed through the thickness of the material for separating out the various individual pieces. It is also apparent that the apparatus as disclosed herein may also be employed for this purpose, and it is particularly suited for cooperation with a slab having slots therein as disclosed in Fig. 5 of the drawings. After cutting out the separate pieces, the desired pattern is then indented partially through the thickness of the material. This pattern may be formed either as a separate unitary structure, or may be combined with cutting means as disclosed in the drawings. After the pattern has been indented in the material, and preferably while the indenting Walls are still in indenting position relative to the surface of the material, the upper surface of the individual pieces is colored. This coloring may be applied with the pattern indenting means in place without the utilization of a sheet extending between the walls of the indenting means, or it may be applied by means of a sheet of porous material as disclosed in the invention apparatus.

Fig. 7 illustrates the piece of pliable material after the individual pieces have been separated from one another. The pattern has been indented in the upper surface of the pieces and the upper surface of the pieces has been suitably colored in predetermined areas according to the pattern indented therein. The entire assembly including slab 4S and the individual pieces 55 is then inserted into a suitable heating oven such as a conventional kiln where the clay is fired in the usual manner to harden the pliable material and provide a finished colored surface thereon.

The entire assembly including the individual pieces and the slab is then removed from the oven, and a sheet of material is secured to the upper surface of the individual pieces as indicated in Fig. 8 by reference numeral 56. Sheet 56 is preferably of a flexible material such as heavy paper or the like, and is secured to the individual pieces as by adhesive or similar means. Sheet 56 also has the mosaic design of the individual pieces imprinted thereon such that the design and coloring of the mosaic may be easily determined merely by glancing at the sheet 56. Sheet 56 retains the individual pieces in proper operative relationship to one another, and eliminates the possibility of their becoming displaced due to jarring or rough handling. In addition, sheet 56 provides a means whereby the entire mosaic may be lifted off of the slab intact.

The sheet may also be numbered in order to identify the various tiles thereunder and to aid in assembly, and furthermore, the sheet may be divided into a number of different sections of desired size and configuration to facilitate handling and shipping of the article. When it is desired to lay the mosaic in place, a worker need merely to remove the sheet 56 from the upper surface of the tiles by tearing it away from the individual pieces as illustrated in Fig. 9. The pieces are then in proper relative relationship, and assembly thereof is a simple matter.

Referring now to Figs. 10-14, a modified method according to the present invention is disclosed. As seen in Fig. 10, a sheet metal support member 60 is provided with a plurality of longitudinally and transversely extending aligned rows of openings which are spaced from one another the same distance as the slots 62 provided in slab 63, this slab being similar to slab 45 previously described. It is apparent that sheet metal support 60 may be placed on the top surface of slab 63 such that the rows of openings in member 60 will be aligned with the slots in the slab. By moving member 60 longitudinally and transversely with respect to slab 63, the rows of openings in member 60 may be misaligned with the slots in slab 63 such that only a minimum number of the openings in member 60 are disposed over an open slot 62.

After misalignment member 60 with member 62, a

surface of guide members 65 until the body 64 of pliable material becomes a thin, flattened sheet of desired uniform thickness. 66 are then removed, and support member 60 is again moved relative to slab 63 such that the rows of openings in member 60 are aligned with the slots of the slab.

A pattern depressor and coloring member 70' shown as being substantially hexagonal in shape is provided with a plurality of cross members 71 which support a suitable design composed of a plurality of interconnected wall members 72 in a manner similar to that in which the pattern is formed in the apparatus shown in Fig. 1. The pattern depressor and coloring member are then lowered onto the upper surface of the pliable material'as seen in Fig. 12. In this figure, the color directing means formed of a suitable material such as nylon or the like, has been removed for the purpose of illustration. As seen in Fig. 13, a plurality of sheets 75 each has the lower ends thereof secured to the side walls 72. of the pattern means in) a suitable manner such as by adhesive or the like. The sheets 75 shown as being secured between each pair of adjacent walls 72 may be either connected at opposite ends thereof so as to provide an enclosed space therebetween, or a single sheet of material may be employed within each of the spaces defined within the pattern means, thereby providing an enclosed color directing means within each of the enclosed areas of the pattern. In this manner, each of the spaces within the pattern means which it is desired to color is provided with an enclosed substantially cone-shaped upwardly extending color directing means. The upper end of each of the cone-shaped means is provided with an opening 76. The adjacent portions 76 of sheets 75 are maintained in position by a. substantially cylindrical rigid collar 77 which maintains the upper ends of sheets 75 in the desired shape.

It is apparent that when the pattern depressor and coloring means shown in Fig. 12 are depressed into the upper surface of the pliable material, the color directing means defined by sheets 75 permit color to be inserted through the openings 76 and directed downwardly into certain restricted areas of the pattern. The coloring substance inserted through openings 76 may be either in a liquid form, or preferably in a powder form which may be blown through openings 76 into the space defined by sheets 75.

Subsequent to depressing of the pattern and coloring of the upper surface of the pliable material, a cutter member Sil shown in Fig. 14 is employed. Member 80 comprises a substantially rectangular rigid frame having a plurality of longitudinal and transverse strips 81 formed of a fairly rigid material, such as plastic or metal. The cutter member is lowered upon the pliable material and forced therethrough, thereby cutting the pliable material and separating it into a plurality of individual pieces. The pliable material displaced during the cutting operation passes through the rows of openings provided in support member 6%). Cutter member 80 is subsequently removed from the pliable material, and the sheet metal sup- Guide members 65 and roller member" ings therein are moved out of register with the slots in slab 63, thereby cutting off any pliable material which may be hanging from the bottom of the sheet metal support, and accordingly providing a substantially smooth lower surface to the sheet of pliable material.

The individual pieces of pliable material are then ready to be fired as described previously, and the remaining steps of the method are substantially identical with those described in connection with Figs. -9 of the drawings.

It is apparent that the method disclosed in F igs. 14 provides a slightly modified manner of producing mosaic tiles or the like, but the general principles of the method are the same as those of the method described previously.

It is apparent from the foregoing that there is provided a new and novel method and apparatus for making mosaic tiles and the like, whereby the articles may be mass produced in a simple and expeditious manner. The tiles may be produced by an operator in a manner such that a minimum amount of skill is required. The apparatus according to the present invention is very compact and sturdy, yet is quite simple and inexpensive in construction and provides reliable and consistent results in operation. The completed mosaic may also be divided into a plurality of sections according to the present invention to facilitate shipping and installation. The mosaic may be easily installed merely by removing the sheet attached to the upper surface of the tiles, and thereby assembly of the completed mosaic is a very simple matter.

As this invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, and since the scope of the invention is defined by the appended claims, all changes that fall within the metes and bounds of the claims or that form their functional as well as conjointly cooperativeequivalents are therefore intended to be embraced. by

those claims. 7

I claim:

1. Apparatus for making mosaic .tiles which comprises a rigd frame means, cutting means supported by said frame means and comprising a plurality of elongated cutting members extending from one side portion to the opposite side portion of said frame means, pattern indenting means supported by said frame means and including downwardly projecting wall members having lower edges adapted to form indentations partially through the thickness of a piece of pliable material, said wall members defining a predetermined pattern, and a sheet of porous material suspended between said wall members and adapted to support a coloring substance.

2. Apparatus as defined in claim 1 wherein said cutting means is supported adjacent the lower portion of said frame, and said indenting and coloring means are supported adjacent the upper surface of said frame whereby upon downward operative movement of the frame, the cutting means will initially engage the surface of the material to be treated, and the pattern indenting means and coloring means will subsequently engage the treated surface.

References Cited in the file of this patent UNITED STATES PATENTS 178,308 Leathers et a1 June 6, 1876 259,724 Sims June 20, 1882 538,311 Alcan Apr. 30, 1895 1,580,519 Meyer Apr. 13, 1926 2,230,778 Flores Feb. 4, 1941 2,591,941 Innerfield Apr. 8, 1952

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