THE MANUFACTURE OF A NEW COMPOUND RESEMBLING, WOOD, AND THE PRO- DUCTION OF MOULDED ORNAMENTS AND OTHER OBJECTS THEREFROM
Year: 1881

page_text: LETTERS PATENT to Charles Denton Abel, of No. 28, Southampton Buildings,
.
Chancery Lane, in the County of Middlesex, for an Invention of "THE
MANUFACTURE OF A NEW COMPOUND RESEMBLING, WOOD, AND THE PRO-
DUCTION OF MOULDED ORNAMENTS AND OTHER OBJECTS THEREFROM." A
communication from abroad by Bruno Harrass, of Bohlen, in the German
Empire.
PROVISIONAL SPECIFICATION left by the said Charles Denton Abel at the
Office of the Commissioners of Patents on the 4th July 1881.
CHARLES DENTON ABEL, of No. 28, Southampton Buildings, Chancery Lane,
in the County of Middlesex. "THE MANUFACTURE OF A NEW COMPOUND
RESEMBLING WOOD, AND THE PRODUCTION OF MOULDED ORNAMENTS AND OTHER.
OBJECTS THEREFROM." [A communication from abroad by Bruno Harrass, of
Bohlen, in the German Empire.]
The present Invention has for its object the manufacture of various articles, such
as ornaments for building, furniture, picture frames, &c., of an artificial compound
resembling wood, capable of being moulded, and consisting mainly in the admixture
of cellulose or paper material reduced to pulp with starch and flour.
For this purpose about 3 parts by weight of cellulose or paper material are mixed
with one part of starch from wheat, rye, or other grain, or potatoes, and two parts
of flour of wheat or other grain containing gluten; this mixture is then boiled in a
water bath for about one hour and is afterwards left to cool, resulting in the
production of a tough fibrous glutinous mass, which is then mixed with an equal
quantity of sawdust or finely ground wood. This compound is then rolled in sheets
in a rolling mill, which sheets after drying are suitable for use by being pressed into
metal moulds of the desired configuration, for which purpose the moulds and
presses have to be heated to a considerable degree, such as about 280° Fahr., and
require a considerable pressure, such as about 8,000 lbs. per square inch, flat objects
requiring however less pressure than other forms. The moulded mass is removed
hot from the mould and allowed to cool, when it becoines hard and clastic, similar to
wood, increasing in hardness with age.

page_text: Articles manufactured of this material can be treated like wood, that is to say,
they can be sawn, planed, filed, coloured, glued, and polished. They may also be
coated with veneer, for which purpose the veneer coated with cement is laid in
strips in the pressing mould and is covered with a layer of the above compound in
a dry pulverised state, which is then subjected to pressure.
In operating with moulds having strong reliefs and depressions, after having
introduced the veneer and pulverised material, and upon this a layer of the material
in the solid condition, the mould is first subjected to a moderate pressure, after
which the partly moulded mass is taken out and any imperfections in the veneer
coating are made good. A fresh entire sheet of veneer having been laid in the
mould the mass is replaced therein and subjected to further pressure.
To prevent the warping of the moulded objects kaolin is added to the cellulose,
which is thereby rendered more plastic and better capable of penetrating into the
recesses of the mould.
The veneer can also be applied to the mass after this has been moulded into
shape, and without the use of the pulverised layer. The veneer is in this case
coated with cement, and after applying it to the moulded object this is again placed
in the mould and subjected to pressure.
In order to increase the binding properties of the compound, dextrine, albumen,
blood, resin, or other binding material may be added. If blood be used this must
be dried and ground fine for admixture with the other materials.
A good pulverised compound for the above purpose is produced by the following
proportions
2 to 10 parts pure wood fibre or cellulose.
6
1
1
دو
33
30
"
5
>>
5
"
"
sawdust.
dry powder of dextrine or blood, albumen, and the like.
flour.
1/8 " 2 dry kaolin or chalk, gypsum, and the like.
»
To this compound may be added any desired colouring material in powder forin.
In some cases the compound may be economised by forming an ordinary wood
block approximately to the shape of the mould; and after introducing a comparatively
thin layer of the pulverised compound, introducing the said block as backing, or
blocks of metal may be used for this purpose.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said Charles Denton Abel in the Great Seal Patent Office on the
3rd January 1882.
CHARLES DENTON ABEL, of No. 28, Southampton Buildings, Chancery Lane,
in the County of Middlesex. "THE MANUFACTURE OF A NEW COMPOUND
RESEMBLING WOOD, AND THE PRODUCTION OF MOULDED ORNAMENTS AND OTHER
OBJECTS THEREFROM." A communication from abroad by Bruno Harrass, of
Bohlen, in the German Empire.
The present Invention has for its object the manufacture of various articles, such
as ornaments for building, furniture, picture frames, &c., which may serve as a
substitute for art-wood carvings, from an artificial compound capable of being
moulded, and consisting mainly in the admixture of cellulose or paper material
reduced to pulp, including all vegetable materials, such as cotton, or grass, or wood,
or other fibres, with starch, flour, and sawdust.
The substances may be compounded in various proportions. I find however that
a suitable material is produced in the following manner :-The ordinary cellulose of
commerce is reduced to pulp by the addition of water, and is then strained in a
fine sieve so as to leave the pure cellulose. I take of this cellulose about 3 parts by
weight and mix the same with about one part of starch and about two parts of flour
of wheat or other grain containing gluten. I then boil this mixture in a water
bath for about one hour. The boiling is preferably effected in thin sheet metal
tubular vessels, in which the material is afterwards allowed to cool.
A tough
fibrous glutinous mass is thus produced, which is then mixed with about an equal
bulk of sawdust or finely ground wood. The compound is then rolled in sheets
from an eighth to half an inch thick or thereabouts. These sheets are then allowed
to dry by exposure to the air or by the aid of a gentle heat, and are then ready for.
being manufactured into the articles desired to be produced. This is effected by
means of metal moulds and presses, which have both to be heated to a considerable
degree, such as about 280° Fahr. The moulds I prefer to employ are constructed
of iron, bronze, or other metal of sufficient strength to resist the heat and pressure
applied during the manufacture. Such moulds consist. of two parts, the matrix or
female mould in which is sunk or engraved the pattern, shape, or configuration of
the article to be produced, and the male covering part, on which are the requisite
rough projections to fit the deeper cavities of the matrix, so as to assist in securing
the requisite pressure over all parts of the article in preparation. When the
moulds and presses are heated to about the degree before mentioned, the compound
is fed into the mould. This is preferably effected by covering the matrix with one;
or more layers of the rolled compound sufficient to make up the thickness of the
article to be produced. The mould is then subjected to a considerable pressure,
such as 9,000 to 10,000 lbs. per square inch, flat objects requiring however less
pressure than other forms. The moulded mass which takes the configuration of the
mould very quickly is removed hot from the mould and allowed to cool until it
becomes hard. Articles manufactured of this material resemble wood in many.
respects and can be treated like wood, that is to say, they may be sawn, planed,
filed, coloured, glued, and polished.
When manufacturing moulded ornaments or ornamental work it is advisable in
some cases to apply to the surface veneers of wood of an ornamental or otherwise
valuable character, so that a perfect resemblance to wood may be given to the
moulded ornaments or ornamental work. When applying the veneer covering I
take veneers of suitable thickness, say of about 80 to an inch, covered on one side
with cement. The veneers are laid in strips of convenient size, so as to cover the

page_text: inside surface of the matrix in some places in two or more layers, the object being
to insure a sufficient covering of veneer over the whole surface. The cement which
I apply to the veneer to insure an intimate union between it and the other part of
the compound consists of a solution of glue or like substance or other gelatinous
cement applied to the vencer by a brush. Other cements may be used, but gelatinous
cements are so easily applied and obtained, and they are now manufactured of such
superior quality, and their colouring properties under the action of heat interfere so
little if at all with the colour of the veneer to be fixed, that they will generally be
found to answer well and on the whole better than resinous or mineral cements.
The veneer having been placed on the matrix mould I apply to it a layer which
may be from an eighth to half an inch thick of pulverised material, hereinafter
described, to which may be added colouring material in a powdered form, suitable
to or resembling the colour of the wood intended to be imitated, and upon this I
place the sheets of compound. The mould thus charged is then covered and
subjected to heat and pressure, after which the moulded and ornamented mass is
taken out. If on inspection of the same it should be found. that imperfections
in the vencered coating exist, these should be made good in the following manner:-
Sheets or strips of veneer of the requisite size coated as before described are laid in
the mould, the moulded mass is replaced in the mould and is subjected to further
heat and pressure, after which the moulded article is removed from the mould while
still hot. For flat objects, such as lock scutcheons, buttons, and the like, a single
pressing operation is generally sufficient.
The pulverised material above referred to is composed of cellulose or wood in
a finely ground state, and in order to increase the binding properties, dextrine,
albumen, blood, resin, or other materials which act in a similarly binding manner
may be added in small proportions. If blood is used it must before admixture be
dried or baked and reduced to a fine powder. To prevent the warping of the
moulded objects a refractory substance, such as for example, kaolin, may be
advantageously added in a powdered state to the before mentioned pulverised
material, which is thereby also rendered somewhat more plastic and better capable
of penetrating into the recesses of the matrix. The veneered ornamental surfaces
may in some cases be applied to the mass after it has been moulded into shape and
without the use of a pulverised layer. In this application of the veneer it is coated
with gelatinous cement as before described, it is then laid on to the moulded object
which is again placed in the mould and subjected to heat and pressure as aforesaid.
Of the two methods of forming the ornamental work I prefer applying the veneer
in the manner first described. It is obvious that if desired the back as well as the
front surface of the ornamental article may be veneered as described..
A useful pulverised compound suitable for the purpose above mentioned is
produced by the use of the substances before referred to in about the following
proportions by measure:-About 2 parts of cellulose or other equivalent paper
material, or materials of which paper is made, such as wood or other vegetable pulp;
about 1 part of dry pulverised dextrine or other binding material; about 1 part of
wheat flour; about 1/4 part of kaolin or of chalk, gypsum, or other refractory
substance; about 6 parts of sawdust in fine powder. To this compound may be
added any desired colouring material in a powdered form; when requisite, the
ingredients after being well mixed are finally well pulverised. In some cases where
it is desired to give greater substance or weight to the moulded article, a backing
or core of wood or of metal may be used and attached to the moulded article by
means of another intermediate layer of the pulverised material as before described.
Having thus described the nature of the said Invention, and in what manner
the same is to be performed, as communicated to me by my foreign correspondent,
I claim,―
First. The manufacture of a compound resembling wood or analogous material,
substantially as herein described.
Second. The production of moulded ornaments or articles of ornamental work,
substantially as herein described,

page_text: Third. The manufacture of moulded ornaments or articles by applying veneered
surfaces to the compound, substantially as herein described.
Fourth. The use of wood or metal for the cores or foundations of articles
manufactured of the compound, as herein described.
In witness whereof, I, the said Charles Denton Abel, have hereunto set my
hand and seal, this Third day of January, in the year of our Lord One
thousand eight hundred and eighty two.
CHAD. D. ABEL. (L.S.)