The Manufacture of an Improved Artificial Stone, and the Manufacture of Various Articles therefrom.
Year: 1895

page_text: Date of Application, 10th May, 1895
Complete Specification Left, 1st Feb., 1896-Accepted, 7th Mar., 1896
PROVISIONAL SPECIFICATION.
The Manufacture of an Improved Artificial Stone, and the
Manufacture of Various Articles therefrom.
We, WILLIAM HENRY METCALFE, of No. 19 Caistor Park Road, Plaistow,
in the County of Essex, Plasterer, and FRANK BARBER WRIGHTSON, of
No. 73, Basinghall Street, in the City of London, Solicitor, do hereby declare
the nature of this invention to be as follows
This invention relates to the manufacture of an improved artificial stone, and is
designed to utilize, for this purpose, the waste or debris termed in the Staffordshire
district "Schraff," and resulting from the breakage of or damage to articles in
baking or firing pottery ware.
We have found that such material, when mixed with Portland or other cement,
as hereinafter mentioned, is very suitable, by reason of its great durability,
appearance, and non-slipperiness, for paving purposes, and for the manufacture of
slabs or tiles for flooring and walls. Also, that it can be laid or applied in situ,
and be employed for manufacturing window heads, sills, and mantel pieces, and all
other articles which admit of being moulded or formed of artificial stone.
In carrying out our invention, we first crush or otherwise break the waste
material or debris, and then subject it to a suitable number of sifting operations to
bring it to the required size, and, at the same time, to free it from unnecessary dust.
We then mix the crushed material with Portland or other cement, in any
suitable proportions, and add thereto a sufficient quantity of water to bring the
mixture into a proper consistency for moulding, or for use in situ. We find it
advantageous to leave a small quantity of the dust with the sifted material, so as
to assist in effectively binding the material and cement together.
The mixture of crushed schraft and cement, while in its moist or plastic
condition, may be placed in moulds, and may, if desired, be subjected to hydraulic
or other pressure to consolidate it.
After it has set, it is removed from the moulds and allowed to dry. In its
finished state, its exterior presents a uniform surface; but, if desired, the surface
may be rubbed with any stable substance and the material will then present a
mosaic like effect, and can be polished.
Colouring matter may be added to the mixture to impart to the finished product
any desired colour.
It is obvious that, in place of the schraff, the debris resulting from broken
saggeis, and the refuse pottery from dust shoots, can be also employed.
Dated this 10th day of May 1895.
ERNEST DE PASS,
Chartered Patent Agent,
78, Fleet Street, Loudon, E C., and 5* Market Street, Nottingham,
Agent for the Applicants.

page_text: The Manufacture of an Improved Artificial Stone, and the
Manufacture of Various Articles therefrom.
We, WILLIAM HENRY METCALFE, formerly of No. 19, Caiston Park Road,
Plaistow, but at present residing at No. 8, Addington Road, Star Lane, Canning
Town (case of Mi Field), both in the County of Essex, Plasteres, and FRANK
BARBER WRICHTSON, of No. 73, Basinghall Street, in the City of London,
Solicitor, do hereby declare the nature of this invention and in what manuer
the same is to be performed to be particularly descubed and ascertained in and
by the following statement
-
Om sand invention relates to the manufacture of an improved artificial stone and
to the manufacture of various articles therefiom and is designed to utilise for this
purpose the waste of débits resulting from the breakage of or injury to articles of
pottery or earthenware in the baking or fiting operation and which waste or débris
in the Staffordshire potteries is technically known as "Schiaff" but the invention is
also intended to utilise other descriptions of waste earthenware, such, for example,
as broken "baggers," bioken or damaged tiles, and the refuse cai theuw are from dust
sboot-
We have discovered that broken pottery or earthenware combined with Portland
o other cement in suitable proportions as hereinafter described is by reason of its
durability very suitable for paving purposes, whilst, in addition to the characteristics
above referred to, its ornamental appearance tenders it especially suitable for the
manufacture of slabs or tiles for the flooring and walls of buildings or for the
marulacture of window heads, window sills, mantelpieces and other miticles which
adout of being moulded or formed of artificial stone, whilst it can, if occasion
requites, be laid in situ.
In carrying our invention into effect, we take waste earthenware or débus which
has been hied or baked and first crush or otherwise break the same into pieces of a
suitable size, and this broken material we submit to a number of sifting operations
in order to separate o Eize the pieces and at the same time to fiee them from
munecessary dust.
A quantity of this crushed material of the desued size has then added thereto a
quantity of Portlaud or other suitably cement in proper proportions, say, for
example, from about 60 to about 75 per cent. of crushed material to from about 40
to about 25 per cent of a suitable cement
The mixture in these proportions has been found to answer well for most pui poses
but it will be evident that the proportions will vary according to the more or less
binding nature of the crushed miterial and the use to which the material is intended
to be put.
These materials are then thoroughly mixed and during the mixing a sufficient
quantity of water 18 added to bring the mixture to the proper consistency for
inoulding into the required form or for use in situ.
We hud it advantageous to add a small quantity of the siftings, that is to say,
the dust to the mixture in order to assist in effectually binding the materials
together.
The mixture of crushed earthenware and cement whilst in a moist or plastic
condition may, when it 18 desued to form it into paving blocks or various other
articles, be placed in moulds of the required shape, and, if necessary, therein
subjected to a pressure obtained by the aid of hydraulic or other machinery in
order to consolidate it.
After the material has become set, it is removed from the moulds and dried by
exposure to the ordinary atmosphere or heated air or artificial heat otherwise

page_text: In its finished state the material presents a uniform appearance and a generally
even sui face but for some purposes the surface of the article may be rubbed down
with any suitable substance in order to give the surface a finer finish.
By a judicious selection of the colours of the "schiaff" or other earthenware
waste, highly artistic and decorative effects may be obtained, whilst in order to
give the finished articles a more ornamental appearance in imitation of coloured
maible or the like any suitable colouring matter may be added to the mixture
during the mixing operation.
Having now particularly described and ascertained the nature of our said
invention and in what manner the same is to be performed we declare that what
we claim 18:-
1. An artificial stono composed of waste pottery or earthenware broken into
pieces of convenient size sifted and combined in suitable proportions with a cement
or binding material and water and if necessary submitted to pressure, substantially
as herein described.
2. The manufacture from artificial stone of various articles such for example as
slabs or tiles, window sills, mantelpieces and other articles by breaking waste
pottery of earthenware into pieces of convenient size aud sifting and combining the
same in suitable proportions with a cement or binding material and water and if
necessary submitting the same to pressure, substantially as heroin described.
Dated this 1st day of February 1896.
VAUGHAN & SON,
Agents for the Applicants.