Improvements in the Manufacture of Plain and Ornamental or Decorated Ceramic Ware and Moulded Articles, Panels, Cor- nices, and the like.
Year: 1899

page_text: Date of Application, 19th Oct., 1899 -Accepted, 30th Dec., 1899
COMPLETE SPECIFICATION.'
Improvements in the Manufacture of Plain and Ornamental or
Decorated Ceramic Ware and Moulded Articles, Panels, Cor-
nices, and the like.
I, ARTHUR METZ, of 21, Rue de Rocroy, Paris, France, Manufacturer of
Ceramic Ware, do hereby declare the nature of this invention 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 the manufacture of plain and ornamental or decorated
ceramic ware and moulded articles, in one or more colours, such as panels,
cornices and the like, with or without various incrustations and incorporations
of metals, ornamental stones, luminous devices or designs &c., and it has for
its main object to obviate the considerable waste caused by the drying and firing
of said ware as practised at present and to allow of the production of current
articles or decorative articles of faultless manufacture without limitation as to
the dimensions of such articles.
This invention has also for its object to combine the effects produced by
metals, ornamental stones, and luminous devices or designs with the effects pro-
duced by the ceramic ware alone for the purpose of increasing its decorative
effects.
These objects are achieved according to this invention by the process herein-
after described.
Such
The first operation in the ordinary processes of manufacture of ceramic ware
is the preparation of the pastes which are to constitute said ceramic ware.
pastes are generally composed of clays, marls or potter's clays in the natural
state employed alone or mixed together, with the addition of water. These
materials are baked and pulverized or simply pulverised and are employed alone
or mixed with other substances in the natural state. Fluxes are sometimes
added thereto. When fine sandstones are employed, they are moistened slightly
and are moulded in a hydraulic press or by other known means.
After these various pastes have been moulded, they have to be carefully dried
before being placed in the oven, and it is during this drying operation that many
articles crack or become deformed thereby causing great waste which is the more
considerable the greater the dimensions of the articles.
The firing of the articles that follows on the drying operation causes also much
waste and often deforms the articles by reason of the high temperature (from
1200° to 1800° according to the purpose or nature of the articles) to which said
firing must be carried in order to impart the requisite strength to the ceramic
ware.
Now according to this invention I dispense with the slow and careful drying
and the firing at a high temperature which are at present absolutely necessary in
order to impart strength to the ware and with this object. I substitute for the
pastes employed hitherto "setting pastes" that is to say, pastes which set rapidly
without becoming deformed and do not require to be fired at a high temperature.

page_text: The following is an example of the composition of a setting paste suitable for
the purposes of this invention,-
4 parts of calcined pulverised Mandoudi stone (stone found in quarries situated
in the district of Mandoudi, a town in the island of Euboea, Greece; it consists
mainly of protoxide of barium Ba0).
4 parts of powdered baryta,
2 parts of baked and pulverised clay,
1 part of crushed sandstone, are mixed together in a solution of sodium silicate
of 15° Baumé or in a solution of any other suitable agglomerant.
The paste having been made, the remaining processes of the manufacture vary
according to the products which it is desired to produce. This paste can be
turned or it can be moulded.
When it is desired to produce articles in manifold colours, as many pastes are
made as there are colours, and the workman or the artist executes the moulding
by arranging the several pastes in the moulds in such a manner as to produce
the desired article.
By this means statuettes, friezes, or other architectural ornaments may be
produced.
Another means of manufacturing coloured articles of setting pastes consists
in moulding the statue, the frieze, or other article, in a setting paste of one
colour white for instance, and then in decorating this statue, frieze, &c. with
coloured setting paste by proceeding in the following manner:-After the article
has been removed from the mould, the article is moistened with a solution of
silicate of sodium of 15° Beaumé which enables the decoration applied to the
moulded article or to the wet panel to become embodied therewith.
Another way of making decorated articles of setting paste, consists in
decorating in the following manner the surface which is visible before the
article is removed from the mould. In this case the mould consists only of a
bottom part, usually flat and smooth, and of a surrounding part or border which
is intended to limit the contour of the ceramic article to be produced. For
instance a flat planed board may be employed, provided with a border or frame
of plaster, wood, iron or steel, &c. This frame is adapted to be removed when
required and its depth is made equal to the thickness of the panel, frieze &c.,
which it is desired to produce.
The setting paste prepared as herein before described is then poured into the
mould constructed as just described. As soon as this paste has been poured
in but before it has quite set, the decoration of its visible surface is taken in
hand, that is to say, that surface which is visible whilst the article is in the
mould. This decoration consists in applying with the aid of brushes or other
means to the surface which has not yet set, devices or designs of more or less
artistic nature in coloured setting paste. These devices, designs, or subjects
which may be formed more especially in relief on the surface to be decorated,
may be of any varied colours, contrasting or combining more or less har-
moniously with the colours of the ground. In this manner really artistic work
may be executed, thus producing a kind of painting in plaster capable of harden-
ing at the same time as the main body or mass constituting the panel. The
coloured designs in setting plaster become embodied with the ground or backing
which is thus provided with reliefs of greater or less prominence and the whole
forming a solid body which sets and hardens at the same time in such a manner
that these ceramic articles can be said to be really actual monoliths of homo-
geneous composition and of uniform strength and solidity, whilst producing the
very finest decorative effect.
The coloured reliefs made in this manner in setting plaster, may be as pro-
minent as desired, they may even be so prominent as to lead the observer to
suppose that those articles have been produced by moulding and have hardened
in the mould. This decoration is suited to the most varied styles of art. The
most ingenious and artistic articles can be produced in this manner by means

page_text: of landscapes, flowers, fruits, still life of all kinds, and even portraits.
It will
be readily understood that this kind of painting in relief allows of a better
imitation of nature and other objects, because these appear not only in their
natural colours, tones and shades, but also with the whole or part of their peculiar
conformation.
Before my decorative articles have become quite set they may be ornamented
by means of various applications, such as applications of the fillings or powders
of metals (gold, silver bronze &c.) or applications of glass in pieces, grains or
powder, white or coloured in various shades.
After these articles have been made as described, their effects may obviously
also be heightened by having recourse to gilding, or to painting or varnishing
with gold, silver, bronze. In a word, all known decorative processes may be
employed which will have the result of heightening the more particularly decora-
tive effect of my ceramic panels.
I may apply these processes to the manufacture of panels and decorative
articles, cornices, &c. comprising various incrustations with metals, ornamental
stones, or others, with polished or dull portions (these latter may be gilded)
or with parts having recesses or reliefs relatively to the general arrangement
of the panel, cornice, or other decorative surface, or being provided locally with
openings or parts for concentrating the light whose effects will harmonize with
the design of the panel or moulded article. For the purpose of producing these
decorations, I may employ metals in the rough, or worked, polished, or even
cut in facets or chased, or with reliefs produced by moulding or other means.
may utilise the most various metals such as copper, steel, wrought iron, cast-iron,
silver, &c., said metals being either in the natural state or ornamented by
nickelling, enamelling, gilding, silvering or other means, or I may utilise stones
and ornamental stones of all shapes and sizes, and any other ornamentations, and
all devices rendered luminous either by electricity or other means.
I
For the purpose of producing these incrustations, recourse may be had to
various methods of making panels or moulded articles; one method consists in
introducing (see Figure 1 of the accompanying drawings) together with the pastes
on the bottom A of the mould, blocks or plugs C of wood, cork, papier-maché, cr
other material, or hollow blocks or plugs C of metal of suitable shapes. These
plugs CC are put at the places in the design where the applications of metals,
ornamental stones &c. are to be subsequently made. Then the paste D for
forming the panel is poured in. This paste surrounds the plugs CC. When
the mass has become set, it is removed from the mould and there is thereby
cbtained a panel having in its surface at suitable points blocks or plugs Cof
wood, cork or other suitable materials which may be utilized in various ways as
hereinafter described. These plugs (see Figure 2 which is drawn on a larger
scale) may be covered by the applied devices M which are fixed by means of
adhesive agents, or screws e, or in other ways.
The applied device M of metal, stone or other material may be provided with
a screw-threaded stem which extends through the plug Cand is held at the
rear by means of a nut c (Figure 3).
When the applied device is to be incrusted in the panel so as to be embedded
therein either partially, or wholly as shown in Figure 4, flush with the surface
of the panel, the plug of wood or cork is removed with the aid of a cutting
instrument, and the ornament O is inserted into the recess formed thereby.
When the plug C, which is placed temporarily into position, extends through
the entire thickness of the panel, the cavity formed by the removal of the plug,
extends from one face to the other of the panel as shown in Figure 5, and the
incrusted device may be fixed by means of adhesive agents. To render the con-
nection stronger, it may be desirable to form the plug with a slight inward taper
or dovetail (Figure 5) in order that the incrusted device M shall not be liable
to slip out after the setting or the hardening of the adhesive agent.
The same system of holes having tapered or dovetailed sidės may be adopted

page_text: (Figure 6) when the holes extend through only a part of the thickness of the
panel. The wooden plug C might also be formed with a groover in its two
sides (Figure 7); it will thus hold more firmly in the paste if it is left therein,
and the decoration can be applied to the outside. By making the plug with
beads s (Figure 8) the cavity formed by its removal will be grooved so as to hold
the device more firmly.
When the plug C extends only through a part of the thickness of the panel,
there remains on the removal of the said plug a bottom or backing which may
serve to hold a means of attachment of the embedded device, for instance a
screw-threaded stem d (Figure 9) which is inserted in a hole formed by the
removal of a small wooden peg e projecting from the rear surface of the large
plug C which is of relatively slight thickness (Figure 10).
These plugs embedded in the mass of the panel will also allow of applying
thereto luminous devices, such as for instance, electrical devices in the form of
luminous vases, bulbs or globes or rings with lens-like glass of suitable colours,
representing ornaments, fruits, flowers, leaves, &c. In this manner moon-light
or sun-light effects or a sky studded with stars may be imitated. The luminous
devices may be mounted on the aforesaid plugs, or suitable vases or lamps may
be fitted in the cavities formed by the removal of the plugs (Figure 11). The
conducting wires f are preferably situated behind the panel.
Figure 11 shows small beads or imitation precious stones mounted by being
embedded in cavities formed by the removal of small plugs or pegs.
I may produce in the same way decorated cornices, friezes or other moulded
parts, with or without designs; also borders for the panels in one or more
pieces also frames for the said panels in one or more pieces. Plugs of wood,
cork or other soft material are inserted at suitable points of the surface of the
article being moulded so as to allow on the removal of the said articles from the
mould, of applying designs or devices upon the said plugs, or by removing the
said plugs, of forming cavities for the reception of the devices that may be
embedded either wholly or partially therein, or of lamps or other decorative
objects as indicated in Figure 12. These plugs embedded in the panels, cornices,
friezes or other pieces may also serve for the purpose of fixing these decorative
pieces between the parts of the building or framework to which they are to be
applied, or for the purpose of fastening or fixing together the several parts of a
bordering, and of connecting the said bordering to the panel, or if the frame is
in one piece, of connecting said frame to the panel which it is intended to sur-
round; all such connections being effected by means of metallic or other attach-
ing devices which may be fixed from one plug to the other.
The baking of the various articles hereinbefore described is effected about 48
hours after the herein before described moulding of said articles, and as the
articles manufactured in accordance with my methods are firm, it will not be
necessary to bake them at a temperature exceeding that which is necessary to
fuse their outer surface. A temperature of from 300 to 500 degrees Celsius is
generally sufficient.
In the case of articles having metals, ornamental stones &c. applied to them,
the baking is effected before said applications, and in cases where the wooden
plugs are to remain in the articles, suitable wood must be employed and the
plugs are rendered incombustible by known processes.
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:
:-
1. The process for the manufacture of ceramic articles which consists in
moulding or otherwise forming said articles of setting pastes which harden
rapidly, only a slight baking being required, substantially as and for the pur-
poses herein before described.
2. The manufacture of panels, cornices, ornamental articles and designs of all

page_text: kinds moulded or otherwise formed of setting pastes in one or more colours, or
representing objects of any kind, decorated with incrustations of metals, stones,
ornamental stones, &c., in intaglio or in relief, with or without luminous devices
or designs, substantially as herein before described.
3. In the manufacture of panels or other ceramic ware decorated with incrus-
tations and applications, the moulding of the ground or main body of the ware
after having previously arranged on the bottom of the mould, solid or hollow
blocks or plugs of comparatively soft material or hollow plugs of metal, said
plugs becoming embedded and fixed in the mass of the ware and serving for the
fixing of the external devices by screwing or other means, or forming by their
removal cavities or hollows suitable for the reception of incrustations, devices,
lamps, &c. or serving to fix said ware to the parts of the building or framework
to which they are to be applied, substantially as herein before described and
shown.
4. The manufacture of ceramic ware, panels, friezes &c. of setting pastes,
by pouring into a mould having a smooth bottom, setting paste whose visible
surface receives, before removal from the mould, and before the paste has become
set, decorations in relief made of setting pastes of more or less varied colours
which set and harden at the same time as the paste that is intended to form the
ground or main body or support of the panel, frieze, or ceramic article to be
produced, substantially as herein before described.
5. In the manufacture of ornamental articles as specified in the preceding
claims, the application of metals, glass and any other various decorations to
said articles, substantially as herein before described.
Dated this 10th Joy of Ostalo 1800
J. C. MEWBURN & ELLIS,
55 and 56, Chancery Lane, London, Chartered Patent Agents.