CERTAIN IMPROVEMENTS IN CASTING AND FINISHING COCKS FOR GENERAL PURPOSES
Year: 1856

page_text: LETTERS PATENT to William James Payne, Brassfounder, of 119, Waterloo
Road, Lambeth, in the County of Surrey, for the Invention of "CERTAIN
IMPROVEMENTS IN CASTING AND FINISHING COCKS FOR GENERAL PURPOSES."
Scaled the 9th June 1857, and dated tho 22nd December 1856.
PROVISIONAL SPECIFICATION left by tho said William James Payne at
tho Office of the Commissioners of Patents, with his Petition, on the
22nd December 1856.
I, WILLIAM JAMES PAYNE, Brassfounder, 119, Waterloo Road, Lambeth,
in the County of Surrey, do hereby declare the nature of the said Invention
for "CERTAIN IMPROVEMENTS IN CASTING & FINISHING COCKS FOR GENERAL
PURPOSES," to be as follows:-
These improvements consists in having previously prepared conical matrix's
or moulds of metal or other suitablo material made true to each other, so that
by casting the external cock or shell part on the male conical matrix or mould
& the plug or key in the female conical matrix or mould of any suitable
metal or mixture of metals, the two castings will be true, or nearly so, to each
other in the conical part; or by leaving an internal cavity in the casting of
the external cock or shell (which may be of brass or any other suitable
material) & inserting therin the male conical matrix or mould & pouring

page_text: in any suitable metal to fill the space between the said conical male matrix or
mould & the external cock or shell part a true or nearly true conical cavity
is thereby obtained, & by having room or space on the external part of tho
plug or key (which may be of brass or any other suitable material), & by
inserting such plug or key into the female conical matrix or mould before
mentioned, & pouring in any suitable metal to fill the space or room between
such plug or key & the female conical matrix or mould, a casting will bo
produced, which will fit or nearly fit the conical part of the before-mentioned
external cock or shell casting.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said William James Payne in the Great Seal Patent Office on
the 19th June 1857.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, WILLIAM
JAMES PAYNE, Brassfounder, of 119, Waterloo Road, in the Parish of
Lambeth, in the County of Surrey, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Twenty-second day of December, in the year of our
Lord One thousand eight hundred and fifty-six, in the twentieth year of Her
reign, did, for Herself, Her heirs and successors, give and grant unto me, the said
William James Payne, Her special license that I, the said William James
Payne, my executors, administrators, and assigns, or such others as I, tho
said William James Payne, my executors, administrators, and assigns, should
at any time agree with, and no others, from time to time and at all times
thereafter during the term therein expressed, should and lawfully might make,
use, exercise, and vend, within the United Kingdom of Great Britain and
Ireland, the Channel Islands, and Isle of Mau, an Invention for "CERTAIN
IMPROVEMENTS IN CASTING AND FINISHING COCKS FOR GENERAL PURPOSES," upon the
condition (amongst others) that I, the said William James Payne, by an
instrument in writing under my hand and seal, should particularly describe
and ascertain the nature of the said Invention, and in what manner the same
was to be performed, and cause the same to be filed in the Great Seal
Patent Office within six calendar months next and immediately after the date
of the said Letters Patent.
NOW KNOW YE, that I, the said William James Payue, do hereby
declare the nature of my said Invention, and in what manner the same is to
be performed, to be particularly described and ascertained in and by tho

page_text: following statement, reference being had to the Drawing hereunto annexed,
and to the letters and figures marked thereon (that is to say):-
In the manufacture of cocks or taps for drawing off liquids and fluids it is
desirable that the materials employed for effectually closing the passage or
aperture through which the liquids and fluids pass should be such as to with-
stand the chemical and mechanical action of such liquids and fluids. Now,
my Invention consists in lining the barrels and coating the plugs of ordinary
or other cocks or taps with molten zinc, or any other molten metal or metallic
alloy possessing sufficient fluidity in its molten state and sufficient hardness
and lubricity when set to resist abrasion when the cocks or taps are in use,
whereby I am enabled to make ordinary or other cocks of iron, coated or
galvanised with zinc or tin, or of any suitable material not readily corrodible
by the action of the atmosphere, or by the action of the liquids and fluids, for
which such cocks may be used; I thus ensure great economy, and the
necessity for turning and grinding the barrels and plugs of cocks is to a great
degree obviated.
.
And in order that my Invention may be more fully understood, I have
shewn the modes I prefer for carrying out my Invention in the Drawing
hereunto annexed, in which Fig. 1 represents a longitudinal section of the
shell of a cock made of cast or malleable iron (with the plug removed)
shewing the apparatus applied thereto for lining with molten metal the inner
surface of the barrel of the cock; and Fig. 2 is a plan view of the same.
The metal which I prefer for this purpose is a mixture composed of fifteen
parts of zinc to one part of tin, but any metal or metallic alloy possessing
sufficient fluidity in its molten state and sufficient hardness and lubricity,
when set to resist abrasion, may be employed. a, a, is the cock; b, b, is a coro
or dic (which may be of steel or any suitable material), turned very smooth
and true, which is placed in the centre of the barrel, and leaves a space of about
one-eighth of an inch between the core or die b, b, and the barrel at all parts
except at the passage way or duct through the cock, where a small dovetailed
cavity on each side of the barrel c, c, (Fig. 1) is included in the space left,
which space is to be filled with the molten lining metal (colored blue), the
small dovetailed cavities being for the purpose of giving the lining metal
firmer hold to the barrel.
The cock is held in position by hinged jaws d, d, (Figures 1 and 2,) which
jaws also grip an arm or handle fixed to the core or die b, b, to keep the die in its
proper place for passing an arm or core e, e, through an opening or slot made
in the centre of the core or die b, b, the arm or core e, e, being for the purpose
of continuing the passage way or duct through the lined portion of the barrel

page_text: when the molten metal is poured in. The cock before pouring the lining
metal therein is to be washed on the inner surface of the barrel with a saturated
solution of salammoniac in water, to cause the lining metal to adhere closely
to such inner surface. The cock is to be heated to about six or seven hundred
degrees Fahrenheit, and such is also to be the case in respect to the cores or
dies; and in order to prevent the molten metal adhering to the cores or dies,
the exterior surfaces thereof are to be held over a flame to receive a coating of
smoke. The cock with the cores or dies is then placed in position, the hinged
jaws d, d, closed, and the molten metal is poured into the barrel of the cock
through a tube f (Fig. 1) about six inches long, which fits into the upper part
of the hinged jaws, which upper part serves as a gate or runner to contain a
sufficiency of the lining metal above the cock, so as to ensure a sound casting.
When the lining metal is sufficiently set, the cock is removed from the hinged
jaws, the coro or die c, e, is withdrawn, the core or die b, b, is removed, the
overplus or runner of the lining motal is then divided from the cock by a saw
or other cutting instrument, and the interior of the barrel of the cock will
be found to have a smooth and true surface, corresponding to the core or
die b, b.
The second part of the Invention relates to the modes of coating the plugs
of cocks (which plugs may be of iron coated or galvanised with zinc or tin, or
of any suitable material), and is shown in sectional clevation at Fig. 3. g, g, is
a cylinder (which may be of steel or any suitable material), the interior
surface of which is made true to that part of the core or die b, b, in Fig. 1, on
which the barrel of the cock is cast, as previously described. The cylinder
stands in a step on the foundation or base plate h. In the centre of the
cylinder g is placed the galvanised iron plug i to be coated with the molten
metal, the collar of which plug rests in a shoulder formed in the top of the
cylinder g, and is thereby held central in the upper part of the cylinder. In
the bottom of the base or foundation plate is formed a hole, into which is
inserted a steel piece j, on the top of which, and forming part of the same
piece, is a threaded male screw, which serves as a core or die for forming a
female screw on the lower part of the plug, when the molten coating metal is
poured in. The top of the above-mentioned threaded male screw is left in a
conical form to fit into a corresponding conical cavity left in the lower part of
the iron plug to be coated, whereby it is held central in the lower part of the
cylinder. The lower parts of the iron plug terminate in two horns or
projections, which pass on each side of the threaded male screw, and prevent
the contraction of the coating metal when cooling, causing a fracture in thic
female screw cast or formed by the coating metal in the lower part of the plug.

page_text: Immediately between the bottom of the cylinder and the steel piece j, and
fitting into a shoulder in the base or foundation plate h, is a washer-shaped
picce k, with a D-shaped aperture through the centre, which forms a
corresponding D-shaped projection at the bottom of the cone of the plug
when coated, adapted to receive a washer of that formed aperture when tho
plug is finally fitted to the cock. is a metal core, which passes through
the iron plug, and comes in contact with the sides of the cylinder at that part
corresponding with the duct or passage way through tho barrel of the cock,
and which is driven out after the plug is coated, forming the duct or passage
way through the plug; the iron plug being kept by these means in tho
centre of the cylinder g, leaving a space of about one-eighth of an inch
between the plug and the cylinder, which space is to be filled with the molten
coating metal; previous to which the cylinder and plug are heated to about six
or seven hundred degrees Fahrenheit, and the cylinder is to be smoked to.
prevent the adherence of the coating metal thereto. The fluid metal is then
poured in through a funnel m (shewn by dotted lines in Fig. 3), and enters a
bole in the collar of the plug; it then passes through two ducts or ways n, n,
which are formed at right angles to each other through the centre of the plug,
and flows out between the cylinder and plug and forms a coating thereto,
which coating is left until sufficiently set; the steel piece j is then pushed
up, which forces it out of the foundation plate; the piece j is then unscrewed
from the bottom of the plug, and the washer-shaped piece k removed. The
plug is then detached from the cylinder, when a true and smoothly-coated cast
will be produced, corresponding to the barrel of the cock, and requiring but
little adjusting or fitting thereto. The bottom of the barrel of the cock
where the washer acts against it, is then turned true, and the washer and a
male screw applied to the bottom of the plug in the ordinary manner of screw-
bottomed cocks. By the above-described arrangements the barrels of cocks
may be lined and the plugs coated with great facility, and when they have
been worn away by use the metal lining and coating may be re-cast on tho
same barrels and plugs.
I would here observe, that instead of coating the iron plugs in a steel
cylinder, as above described, I may coat them with molten brass, gun metal, or
other analogous metal in a mould of sand or other suitable material, in which
case the iron plug to be coated is not continued below the top of the aperture
or duct through the plug (which is formed by a core of sand), the remainder
of the plug being composed wholly of the coating metal, as will be readily
understood by reference to Fig. 4, which is a side view, partly in section, of the
two portions. The coating metal in this case is admitted through a gate or

page_text: duct left in the sand mould, in the ordinary manner of metal castings; the
plug is then turned or ground, and is then ready to be fitted into the lined
barrel of the cock, and may be either rivetted to the bottom of the barrel, or
attached by a screwed nut and washer, in the ordinary manner.
Having now described my Invention of "Certain Improvements in Casting
and Finishing Cocks for General Purposes," and the manner of carrying the
same into effect, I wish it to be understood that I do not mean or intend to
confine myself to the precise arrangements for lining the barrels and coating
the plugs of cocks as herein described, as they may doubtless be varied
without departing from the nature and object of my Invention. In conclusion
I claim the manufacture of cocks as herein explained; I claim particularly
the mode herein described of lining the interior surfaces of the barrels of
cocks; I also claim the modes of coating the plugs of cocks as herein
described.
In witness whereof, I, the said William James Payne, have hereunto
set iny hand and seal, the Seventeenth day of June, in the year of our
Lord One thousand eight hundred and fifty-seven.
Witness,
WILLIAM JAMES PAYNE. (L.S.)
AUGUSTUS FREDERICK EFFLAND,
120, Waterloo Road, Lambeth.