IMPROVEMENTS IN AND RELATING TO MOSAIC AND SIMILAR WORK
Year: 1884

page_text: I, WILLIAM ROBERT LAKE, of the firm of Haseltine Lake & Co, Patent Agents
Southampton Buildings in the County of Middlesex do hereby declare the nature
of my invention for "IMPROVEMENTS IN AND RELATING TO MOSAIC AND SIMILAR
WORK " to be as follows:-
This invention relates to that class of mosaics formed by casting a metallic frame
work around mineral pieces previously prepared and arranged in position to
produce the required design.
The object of the said invention is to reduce the cost of producing such mosaics
to ensure a more perfect finish and artistic effect to gain greater firmness or rigidity:
in the finished product, and to facilitate the manufacture thereof.
The said invention consists in the improved mosaic and in the process of pro-
ducing the same, all substantially as hereinafter set forth.
In carrying the said invention into practice I arrange several or many pieces or
portions of glass or other mineral plates which go to make up the desired design
and which may be of any size or shape, between sheets, plates or moulds of suitable
material and construction, in such a manner that each individual piece or portion
shall be detached from those laterally adjacent, a passage or passages being formed
around the said pieces or portions communicating with a supply opening lying
between the said plates, close to the edges thereof.
Through the said supply opening is poured the liquid metal which passing
through passages and finally filling the same, hardens or solidifies and forms a
metallic frame work the parts of which are integral with one another.
The sheets or plates pressing against the opposite faces of the glass or mineral
parts, prevent the metal from covering the same so that when the sheets or plates
are removed the colors of the glass or mineral parts are exposed to view.
The preferred method of casting the frame work around the portions of glass
and the peculiar description of mosaics resulting from such methods, I shall now
more particularly describe.
I arrange the glass or mineral parts or fragments (glass being used when the
mosaic is intended for windows or to be used in other situations where it is

page_text: desirable that the passage of light shall be permitted) upon a table or surface upon
which may be marked or laid out the pattern of the desired design to facilitate the
adjustment of the said mineral parts or fragments.
These parts or fragments are set at distances apart equal to the desired width of
the frame.
Upon the fragments or pieces thus arranged and over the passages or interstices
between them is pressed a sheet of asbestos or other flexible material which, having
been gummed or covered with an adhesive substance, adheres to the said pieces so
that when the said sheet is raised, as it subsequently is, and turned over, the glass
portions are brought to the top of the sheet without being changed in their
relations to one another.
.
A second sheet similarly gummed is then caused to adhere to the other side of
the glass portions and the whole laid aside to dry, a warm drying chamber being
employed.
After this, the sheets with the mineral parts between are placed in suitable
frames or moulds and tilted so that the metal can be poured between the edges of
the sheets. This being done and the passages filled, the metal hardens and forms a
frame-work around the glass or mineral parts, which frame-work holds the said
parts in fixed relation to one another.
I prefer to heat the glass and asbestos sheets to a high degree of temperature so
that the metal will not harden or solidify before it has completely filled the
passages.
To accomplish this result I may employ various methods, two of which I will
describe, but I do not wish to limit myself to either.
One method consists in employing a double mould or one composed of duplicate
parts placed back to back with a chamber between into which the molten metal,
which might be called back metal, is poured before the metal intended to form the
frame of the mosaic is run into the prepared mould. This back metal raises the
temperature of the different parts of the mould and the enclosed glass to a uniform
heat preventing any injury to the glass by reason of its coming in contact with the
hot metallic fluid, and also exerts a uniform pressure upon the felt coverings and
the glass keeping their adjacent surfaces in contact and preventing the overflow of
the metal upon the surface of the glass.
The moulds are in duplicate, the back metal chamber being surrounded, except
at the mouth thereof, by a lining of felt or other non-combustible material of any
desired thickness, each duplicate part of the said mould having a feeding channel
and passages around the glass through which the metal flows, and outlets through
which the gases and superfluous metal escape the said channels, passages, and
outlets being formed and separated by sheets of felt.
Before casting I place a sheet of felt on each side of the prepared mould and
arrange outside thereof two boards one on each side and clamp or bind the whole
securely together and then raise the whole on one edge and pour in the back
metal and finally pour in molten metal for the frame into the feeding channel.
The other process above referred to is one in which no back metal is employed,
only one half of the double mould being used; this method consists in providing a
perforation through the felt covering communicating with two passages and
inserting therein a tube of suitable length, the feeding channel in this instance
being dispensed with. The mould thus constructed is placed on a bed of warm
sand and also covered on the top with the same, and weights are placed thereon to
keep the adjacent surfaces of the felt and glass together; the entire apparatus is
then slightly raised at the end thereof opposite to the tube perforation and the
frame metal poured into the mould through the said tube. The heat of the sand
in this case serves the same purpose as the back metal in raising the glass and
mould to the desired temperature.
I prefer to use as a binding metal one, (such as an alloy of lead, antimony and
bismuth) that will expand in cooling and having a low point of fusion.

page_text: The expansibility of the metal in cooling causes the same to hold the glass
portions with great firmness and prevents the looseness and consequent rattle
resulting from the use of contractile metal such as pure lead.
I do not wish to limit myself to the use of flexible sheets of material or to
gummed sheets in the process of casting a framework around mineral pieces, as
any device may be substituted therefor which is adapted to hold the said pieces
in a fixed position between two surfaces so that they may be subsequently cast to
form a mosaic.
But I prefer to employ asbestos in the process as it cannot be destroyed by
contact with molten metal, is porous and thus allows the exit of air to a certain
extent as the passages fill with metal moreover it is pliable and plastic when damp
and thus is easily made to conform to uneven surfaces and is otherwise peculiarly
adapted for the purpose.
In preparing the sheets having the mineral parts between them to receive the
metal, I prefer to employ a suitable press. By means of this device the side plates
or sheets are brought into perfect contact with the sides of the portions of glass so
that the metal will be more effectually prevented from covering the side surfaces
of the said glass portions.
Under certain circumstances it is found advantageous to use a heavier frame
than that lying flush with the side faces of the glass and to produce such a frame,
I form in the side plate or sheet a groove or grooves corresponding with the
passage between the glass portions or some of the said passages. By these means
one or more transverse ribs integral with the cast framework are formed, which
add greatly to the stiffness of the mosaic as will be evident. The grooves may be
formed in the sheet material before it is applied to the surface of the mineral
portions by making corresponding grooves in an appropriate bed, then laying the
damp sheet thereon and pressing the said sheet into the said grooves, after which
the damp material is allowed to dry. After this the said material is gummed and
placed in position on the surface of the mineral portions.
If it is desired to give greater strength to the mosaic than the ribs afford,
I enlarge the grooves and arrange therein suitable bars or wires, around which is
cast the binding metal, the wires being enclosed with the softer metal forming cores
which add greatly to the tenacity of the framework.
Under other circumstances it is desirable not only to give firmness or rigidity to
the mosaic as a whole by forming the transverse strengthening ribs, but it is also
desirable to give greater security to the individual pieces of glass. To this end
I form the cast framework with projecting and overlapping flanges which overlie
the mineral pieces holding the same with such firmness as to prevent the same
from being easily detached by the force of impact.
This result I attain by first securing upon the surface or surfaces of the glass
portions, sheets of material of a size smaller than the glass or mineral portions so
that when the glass and sheet secured thereon are in position the former will
project from the latter the passages thus formed being T or I shaped and thus
adapted to cause the metal to form the overlapping flanges.
It will thus be observed that the strengthening ribs, broadly considered, may
be formed either by grooving the plate or by building the same up by applying
sheets of material the said grooves lying between the same.
When the asbestos or flexible sheets or plates of material provided with adhesive
substance are applied to the portions of glass and the casting process is completed
the said sheets may be removed by simply wetting them and dissolving the
adhesive substance after which the said sheets may be removed for subsequent use.
I have found it desirable under some circumstances to form the mosaic hollow
or concave by this construction certain peculiar effects of illumination are produced
when employed in windows or as roundels for windows, or when employed in
larger or more varied forms, as lamp shades or globes, the integrality of the frame
work allowing of adequate strength to such frame work without requiring such a

page_text: large proportion of opaque surface as has been heretofore necessary when the
frames of the said shades or globes were made of metallic portions soldered together
to form the frame work, as will be understood.
The hollow or concave forms of mosaic with integral framework may be provided
with strengthening ribs, and with projecting jewels.
As an article adapted to be inserted in windows, a roundel, may be made that
possesses properties which make it peculiarly effective for purposes of illumination,
the said roundel having projecting jewels which concentrate the light and throw it
into the room with peculiar brilliancy while the cast frame work being opaque and
allowing of a much wider surface than can be obtained by the ordinary processes
of lead glazing, brings the colors of the projecting jewels into strong prominence
producing effects which are new in window ornamentation.
100
HASELTINE, LAKE & Co.,
For the Applicant.

page_text: COMPLETE SPECIFICATION.
I, WILLIAM ROBERT LAKE of the firm of Haseltine Lake & Co Patent Agents
Southampton Buildings, in the County of Middlesex do hereby declare the nature
of my invention for "IMPROVEMENTS IN AND RELATING TO MOSAIC AND SIMILAR
WORK and in what manner the same is to be performed, to be particularly
described and ascertained in and by the following statement:―
"
This invention relates to that class of mosaics formed by casting a metallic
framework around mineral pieces previously prepared and arranged in position to
produce the required design.
The objects of the said invention, are to reduce the cost of producing such
mosaics, to secure a more perfect finish and artistic effect, to gain greater firmness
or rigidity in the finished product, and to facilitate the manufacture thereof.
The said invention comprises the improved mosaic and the process of producing
the same all substantially as hereinafter set forth.
In the accompanying drawing,
Figure 1 is a plan of a mosaic having projecting jewels with a cast framework
around, and holding said jewels rigidly and securely together.
Figure 2 is a sectional view of the same.
Figures 3 and 4 are respectively a plan and section of a hollow or concave
mosaic showing a projecting jewel which may be secured therein.
Figures 5 and 6 are respectively a plan and section of a flat roundel with a
projecting jewel arranged in connection with pieces placed flush with the frame,
and
Figure 7 illustrates a roundel or a mosaic provided with strengthening ribs
formed on the framework.
Figures 8 and 9 illustrate the arrangement of mineral pieces in moulds and
Figures 10, 11 and 12 illustrate certain processes in the manufacture.
Figures 13, 14 and 15 show peculiar constructions in the mould and illustrate
modifications in the process of casting.
Figure 16 shows a section of a mosaic having strengthening ribs with wires cast
therein.
Figure 17 illustrates a mould press for clamping sections of a mould together.
Figures 18 and 19 illustrate certain strengthening ribs overlapping the glass or
mineral parts.
Figures 20 and 21 are respectively a plan and end view of a mould board and
Figure 22 is a sectional view illustrative of certain features of the process.
In carrying the said invention into practice I arrange several or many pieces or
portions a of glass or other mineral plates (which make up the desired design, and
which may be of any size or shape) between sheets plates, or moulds d, Figures 8,
10, 11, and 12, of suitable material and construction, in such a manner that each
individual piece or portion shall be detached from those laterally adjacent, a
passage or passages 6 being formed around said pieces or portions communicating
with a supply opening c lying between the said plates, close to the edges thereof.
b
Through the said supply opening is poured the liquid metal which, passing
through the passages b, and finally filling the same, hardens or solidifies and forms
p.metallic frameworkr the parts of which are integral with one another.

page_text: The sheets or plates d pressing against the opposite faces of the glass or mineral
parts, prevent the metal from covering the same, so that when the sheets or plates
are removed the colors of the glass or mineral parts are exposed to view.
The preferred method of casting the framework around the portions of glass and
the peculiar description of mosaics resulting from such methods, I shall now more
particularly describe.
I arrange the glass or mineral parts or fragments a (glass being used when the
mosaic is intended for windows or to be used in other situations where it is
desirable that the passage of light should be permitted) upon a table or surface m,
Figure 10, upon which may be marked or laid out the pattern of the desired
design to facilitate the adjustment of the said mineral parts or fragments.
These parts or fragments are set at distances apart equal to the desired width of
the frame. Upon the fragments or pieces thus arranged, and over the passages or
interstices between them, is pressed a sheet of asbestos or other flexible material,
which, having been gummed or covered with an adhesive substance, adheres to the
said pieces, so that when the said sheet is raised as it subsequently is, and turned
over, the glass portions are brought to the top of the sheet without being changed
in their relation to one another. A second sheet similarly gummed is then caused
to adhere to the other side of the glass portions and the whole laid aside to dry, a
warm drying chamber being employed.
After this, the sheets with the mineral parts between, are placed in suitable
frames or moulds and tilted, as shewn in Figure 12, so that the metal can be
poured between the edges of the sheets. This being done and the passages filled,
the metal hardens and forms a framework around the glass or mineral parts, in
fixed relation to one another.
I prefer to heat the glass and asbestos sheets to a high degree of temperature so
that the metal will not harden or solidify before it has completely filled the
passages.
To accomplish this result I may employ various methods, two of which I will
describe, but I do not wish to limit myself to either.
One method consists in employing a double mould or one composed of duplicate
parts placed back to back with a chamber between, into which the molten metal,
which might be called back-metal is poured before the metal intended to form the
frame of the mosaic is run into the prepared mould. This back metal raises the
temperature of the different parts of the mould and the enclosed glass to a uniform
heat, preventing any injury to the glass, by reason of its, coming in contact with
the hot metallic fluid, and also exerts a uniform pressure upon the felt coverings
and the glass keeping their adjacent surfaces in contact and preventing the over-
flow of the metal upon the surface of the glass.
The moulds as shown in Figures 13, 14 and 15 and as stated above, are in
duplicate, s being the back metal chamber, surrounded except at the mouth thereof
by a lining of felt or other non-combustible material 81, 8¹¹, of any desired thickness,
each duplicate part of the said mould having a feeding channel t and passages t
around the glass V, through which the metal flows, and outlets through which
the gases and superfluous metal escape, the said channels, passages and outlets
being formed and separated by sheets of felt u u¹ are the gummed sheets on the
upper and lower surfaces of the glass.
Before casting I place a sheet of felt u on each side of the prepared mould
and arrange outside thereof two boards, one on each side, clamping or binding the
whole securely together; I then raise the whole on one edge, and pour in the back-
metal and finally pour in molten metal for the frame into the feeding channel t.
The other process above referred to is one in which no back-metal is employed,
only one half of the double mould being used; this method consists in providing a
perforation through the felt covering u³ communicating with the passage t¹ at t³,
and inserting therein a tube of suitable length, the feeding channel t in this instance
being dispensed with. The mould thus constructed is placed on a bed of warm
sand and also covered on the top with the same, and weights placed thereon to

page_text: keep the adjacent surfaces of the felt and glass together; the entire apparatus is
then slightly raised at the end thereof opposite to the tube perforation and the
frame metal poured into the mould through the said tube. The heat of the sand
in this case serves the same purpose as the back metal in raising the glass and
mould to the desired temperature.
I prefer to use as a binding metal one, (such as an alloy of lead, antimony and
bismuth) that will expand in cooling and one having a low point of fusion.
The expansibility of the metal in cooling causes the same to hold the glass
portions with great firmness, and prevents the looseness and consequent rattle
resulting from the use of contractile metal such as pure lead.
I do not wish to limit myself to the use of flexible sheets of material or to
gummed sheets in the process of casting a framework around mineral pieces, as any
device may be substituted therefor which is adapted to hold the said pieces in a
fixed position between two surfaces, so that they may be subsequently cast to form
a mosaic. But I prefer to employ asbestos in the process as it cannot be destroyed
by contact with molten metal, and is porous thus allowing the exit of air to a
certain extent as the passages fill with metal, moreover it is pliable and plastic
when damp, and thus is easily made to conform to uneven surfaces, and is other-
wise peculiarly adapted for the purpose.
In preparing the sheets having the mineral parts between them to receive the
metal, I prefer to employ a suitable press such for example as is illustrated in
Figure 17.
By means of this device the side plates or sheets are brought into perfect contact
with the sides of the portions of glass, so that the metal will be more effectually
prevented from covering the side surfaces of the said glass portions.
Under certain circumstances it is found advantageous to use a heavier frame
than that lying flush with the side faces of the glass and to produce such a frame,
I form in the side plate or sheet a groove or grooves e figure 22, corresponding with
the passage between the glass portions a, or some of the said passages. By these
means one or more transverse ribs f, figure 16, integral with the cast framework
are formed, which add greatly to the stiffness of the mosaic as will be evident.
The grooves may be formed in the sheet material before it is applied to the
surface of the mineral portions by marking corresponding grooves in an appropriate
bed, then laying the damp sheet thereon and pressing the said sheet into the said
grooves, after which the damp material is allowed to dry.
After this, the said material is gummed and placed in position on the surface of
the mineral portions.
If it is desired to give greater strength to the mosaic than the ribs f, afford,
I enlarge the grooves e and arrange therein suitable bars or wires, around which
is cast the binding metal; the wires being enclosed within the softer metal form
cores g figure 16 which add greatly to the tenacity of the framework.
Under other circumstances it is desirable not only to give firmness or rigidity to
the mosaic as a whole, by forming the transverse strengthening ribs, but it is also
desirable to give greater security to the individual pieces of glass. To this end I
form the cast framework as illustrated by figures 18, 19, in which cases the cast
framework has projecting and overlapping flanges, which overlie the mineral pieces,
holding the same with such firmness as to prevent the same from being easily
detached by the force of impact.
This result I attain by first securing upon the surface or surfaces of the glass
portions, sheets of material of a size smaller than the glass or mineral portions, so
that when the glass and sheet secured thereon are in position the former will
project from the latter, as shown in figure 19, the passage thus formed being T or I
shaped and thus adapted to cause the metal to form the overlapping flanges.
It will thus be observed that the strengthening ribs, broadly considered, may
be formed either by grooving the plate d, or by building the same up by applying
sheets of material, the said groove lying between the same,

page_text: When the asbestos or flexible sheets or plates of material provided with
adhesive substance are applied to the portions of glass and the casting process is
completed, the said sheets may be removed by simply wetting them and dissolving
the adhesive substance, after which the said sheets may be removed for subsequent
use.
I have found it desirable under some circumstances to form the mosaic hollow or
concave as shown in figures 1, 3 and 4, by this construction certain peculiar effects
of illumination are produced when employed in windows or as roundels for
windows, or when employed in larger or more varied forms, as lamp shades or
globes, the integrality of the frame work allowing of adequate strength to such
frame work without requiring such a large proportion of opaque surface as has
been heretofore necessary when the frames of the said shades or globes were
made of metallic portions soldered together to form the frame work, as will be
understood.
The hollow or concave forms of mosaic with integral framework may be provided
with strengthening ribs, and with projecting jewels.
As an article adapted to be inserted in windows, the roundel illustrated in
figures 1 and 2, possesses properties which make it peculiarly effective for purposes
of illumination said roundel having the projecting jewels a¹ which concentrate the
light and throw it into the room with peculiar brilliancy, while the cast frame
work being opaque, and allowing of a much wider surface than can be obtained by
the ordinary processes of lead glazing, brings the colors of the projecting jewels
into strong prominence producing effects which are new in window ornamentation.
Having now particularly described and ascertained the nature of my said
invention, and in what manner the same is to be performed, I declare that what
I claim is
First The process of forming mosaics consisting in arranging mineral portions in
separated relation to one another between clamping surfaces, and filling the inter-
stices or passages between said mineral portions with a solidifyable liquid material,
substantially as set forth.
Second The process herein set forth for producing mosaics, consisting in
arranging mineral portions in separated relation to one another between holding
surfaces, of bringing said mineral portions to an abnormally high degree of tempera-
ture, and filling the passages between the mineral parts with liquid metal, sub-
stantially as set forth and shown.
Third The process of manufacturing mosaics consisting in arranging mineral
portions on a suitable table or surface, causing said portions to adhere to a gummed
sheet or surface; reversing or turning said sheet and causing a second sheet or
Burface to adhere to the opposite side of said portions; and combining said
portions by casting molten metal around them, substantially as set forth and
shown.
Fourth The process of forming mosaics consisting in securing mineral portions
between sheets or plates, said portions being arranged at suitable distances apart
to form passages; arranging said sheets with the mineral portions between in
suitable presses, and tilting the said parts upon their edges to allow the metal to
be poured between the sheets or plates, all substantially as herein set forth.
Fifth The process of forming mosaics, consisting in securing mineral portions
between damped and gummed sheets of asbestos, and subsequently casting molten
metal around said portions to form an integral frame work, as set forth.
Sixth A mosaic formed of mineral parts having a metallic framework cast around
them, and provided with strengthening ribs cast integral with said framework,
substantially as set forth and shown.
Seventh A mosaic having the portions a secured together with a cast framework,
said framework having the projecting ribs and overlapping flanges h, substantially
as set forth and shown.
Eighth A concaved or hollow mosaic, the portions a of which are secured
together by a cast metal framework, substantially as set forth and shown,

page_text: Ninth A cast metallic framework provided with projecting jewels, said jewels
being secured therein in the casting process, the whole forming a mosaic as set forth
and shown.
Tenth The process of forming glass or mineral mosaics consisting in casting
around the mineral portions a framework of expansible metal or one that will
expand in cooling, substantially as set forth.
Eleventh A mosaic having strengthening ribs provided with a core wire or rod,
substantially as set forth.
Twelfth The process of forming mosaics consisting in arranging the mineral
parts in separated relation to one another upon a table, surface, or ground work ;
transferring said parts without changing or disturbing their relative positions to
one another to a press or mould; and casting a framework around said mineral
parts, substantially as set forth.
HASELTINE, LAKE & Co.,
For the Applicant.