An Improved Manufacture of an Artificial Solid Material and Apparatus therefor.
Year: 1890

page_text: Date of Application, 21st Jan., 1890-Accepted, 17th May, 1890
[Communicated from abroad by JOHN F. GESNER, of the City and State of New York,
United States of America.]
An Improved Manufacture of an Artificial Solid Material
and Apparatus therefor.
I, HENRY HARRIS LAKE of the firm of Haseltine Lake & Co.,, Patent Agents,
Southampton Buildings in the County of Middlesex, 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 :-
In order to convey a clear idea of the nature of my product and the process of
production, I will first state some of the chemical and physical characteristics which
I have ascertained by experiment are possessed by certain of the materials employed
by me.
When the soluble alkaline silicates of soda and potash ordinarily known as soluble
glass, are left exposed to the air for some time, they gradually lose a portion of their
contained water from evaporation dry to a certain extent and acquire a considerable
degree of hardness.
Especially is this the case if they have been previously mixed with a portion of
earthy mineral matter, not capable of decomposing them, such as clay, chalk; silica;.
natural stone and the like. At the same time such mixtures shrink and warp
considerably in drying, under ordinary circumstances and are consequently liable to
get out of shape if moulded in the ordinary way into any particular form or pattern:
Mixtures of this kind sometimes become very hard, resembling stone, and may be
used as such, or for cements where water is not liable to come in contact with thěni,
but rapidly deteriorate when exposed to moisture, and are practically useless to with-
stand the climatic influences of the weather as artificial stone; on account of the
solubility of the alkaline silicates contained in them.
The soluble alkaline silicates moreover, in the said mixtures, under ordinary
atmospheric temperatures and conditions, and unless exposed to a temperature
of 212° Fahrenheit or above, always retain a large proportion of combined water or .
water of cystallization.
It is mixtures of this kind that it has hitherto been sought to decomposé or render
waterproof for use as artificial stone. For this purpose the mixture of soluble glass
and earthy mineral matter, such as chalk, clay and the like has been sprinkled while.
still wet, or after ordinary drying in the air, with chloride of calcium, or other
decomposing substance, or immersed in a solution of the same, for the purpose of
decomposing the soluble silicate in the mixture and precipitating an insoluble silicate
in its place.
On account however of the want of thorough dryness and lack of porosity of the
material sought to be decomposed in this way, for the formation of another insoluble
material, any decomposition that takes place under these circumstances is slight, and
merely superficial, and leaves the interior portion of the mass entirely untouched by
the decomposing solution.
To remedy this want of porosity, sand has been used to mix with the soluble glass,
with or without the addition of other mineral matter, and various devices have been
employed to cause the solution of chloride of calcium or other decomposing solution
to effect a more thorough decomposition of the material under treatment, such as
attempting to force the decomposing solution into the mass by an air pump; or
immersion of the material in a heated decomposing solution, but all to little avail.
By the use of the sand, moreover a coarse grained stone only can in any case be
formed, whereas by my process, on the contrary; I can make stone of the most
pulverulent substances, and consequently of the finest grain. Mixtures of soluble

page_text: glass and mineral matter have also been cast or moulded first, without the simultaneous
application of heat or pressure and then removed from the mould and dried in the air
or by artificial means, without being calcined; and the said mixtures have been
vitrified at a baking heat in kilns thereby rendering them both impervious to and
undecomposable by, the chemical agents I employ.
I have found by experiment, that if soluble glass after ordinary drying in the air,
be submitted to a temperature above the vaporizing temperature of the solvent but
below the vitrifying temperature, for the purpose of driving off the combined water
(if the solvent be water) or water of crystallization, without vitrifaction, the material
does not become friable, dry into a powder, or lose its cohesive power, as many salts
do under similar conditions, but swells, puffs up greatly into a shapeless mass as the
heat is increased, and finally dries into a very hard, light, porous material. This
treatment I refer to as "calcining."
If the material, under these conditions of heat, be at the same time closely confined
or submitted to pressure, while attaining perfect dryness and a high degree of
porosity and hardness, during this process of calcination, it can be made to retain
any shape into which, while in a hydrous, soft and plastic condition, it may originally
have been moulded.
The confinement or pressure during calcination is for the purpose of causing the
material to retain the shape to which it has been cast or moulded, and to preserve a
certain degree of density in it, without impairing its porosity but I can and do employ.
in certain applications the product made with the omission of the confinement
or pressure.
I have found that the porous material thus formed, being deprived of its moisture,
is also deprived of its liability to shrinkage or warping, and furthermore, by reason
of being porous and anhydrous throughout, it is peculiarly adapted to be impreg-
nated and decomposed by any chemical agent by which it is to be converted from a
soluble into an insoluble body. It also bas a peculiarly hard character, which it did
not heretofore possess nor attain by ordinary drying; retaining this hardness to a
great extent after the soluble glass in it has been decomposed and replaced by other
chemical substances.
I may stop the process at this point and apply the product thereof to the arts;
which product may be varied by the use of soluble glass alone or in admixture with
other materials. The product however at this point still contains the silicate in a
soluble state and I prefer to continue the process as follows to convert it into an
insoluble body.
I immerse the material already produced into a saturated cold or hot solution of a
chemical body having the property of converting the soluble glass into an insoluble
body. On account of the porosity of the calcined material and its dryness, the
converting solution is rapidly absorbed into its pores and a thorough conversion of its
contained soluble glass is insured.
The material still retains its porosity after the last treatment and a thorough and
rapid removal of the soluble salts resulting from the treatment can be readily affected
by washing.
When taken from the bath of the decomposing solution, a change is found to
have taken place in the chemical and physical constitution of the material. The
soluble silicates have been replaced by silica or a silicate of another base, according
to the character of the converting solution used. The excessive hardness and brittleness
of the calcined material have disappeared and it has become considerably softer. It
still retains however, to a remarkable degree the peculiarly hard and compact
character which it possessed when first taken from the calcining press, if pressure bad
been employed in the calcining operation. The material resulting from the last
operation may be applied to various uses, but I prefer to subject it to the following
additional treatment in order to expel from it the superfluous moisture it contains.
For this purpose I submit it again to heat and pressure. After which, to prevent its
again taking up water, I may fill its pores with a water resisting substance or glaze
or enamel it by the aid of heat.

page_text: 1
Having thus outlined the process for producing my product, I will proceed to
describe more particularly each step and its variations.
For the production of material which I call Hyalohyaloid, I apply my process to
soluble glass alone being the ordinary commercial article of from 35° to 40° Beaumé.
This I do by first allowing a solution of it to dry in the air until sufficiently hardened
to be readily handled. It is then calcined under pressure as more particularly
described hereafter.
Generally however, the same character of soluble glass will be treated in admixture
with some solid substance or substances in a divided state, with which it is mixed in
a pug mill or mixer until by evaporation or otherwise it has acquired the consistency
of a stiff paste or of dough, the proportions of the ingredients varying, according to
the character of the material I desire to produce.
I do not wish to limit myself in this application either to the product produced
by the treatment of the soluble glass alone or by its treatment in admixture with other
substances since the object of this application is to cover the product broadly and
to leave claims for the more specific products resulting from various mixtures to
subsequent applications.
To submit the soluble glass prepared as above whether alone or in admixture to
calcination, I spread or place it between two opposite and parallel hot metallic moulds
or forms, which corresponding in shape and pattern, and fitting upon, or into each
other, can be brought together in contact or separated at pleasure, by proper
mechanical means.
The simplest form of press I may use consists merely of two metallic plates, which
are first heated to the required temperature by any exterior source of heat, and then
placed horizontally, one above and one below and in contact with the material to be
calcined, which I thus confine and calcine between and in contact with hot surfaces;
the edges of the material being also preferably confined.
The interior of these plates may be made hollow, and capable of being filled with
steam or of having heat communicated to them in place, by any other appropriate
means, in any other convenient manner, such as by the circulation through them of
hot air or bot liquids, or by the contact of naked flames, so as to avoid the necessity
of removing them, for the purpose of reheating them when they become cold.
The most approved form of apparatus is shown in the accompanying drawings in
which
Figure 1 is a vertical section of the press through the line 1, 1, of Figure 2.
Figure 2 is a sectional plan view through the line 5, 5, of Figure 1.
Figure 3 is an end view.
Figure 4 is a detail showing the heating pipes.
The
a is a vertical frame. 6 61 62 are the press plates of which there may be any
required number. These press plates may be provided with any suitable means of
heating, but I prefer to employ a series of pipes like that shown in Figure
pipes c c¹² are in the same horizontal plane and extend through a corresponding
series of holes in the plate h. d is the supply and e the escape pipe for the heating
agent connected by flexible tubes so as not to interfere with the movements of the
press plates.
In lieu of the series of pipes passing through the plate, I can employ a series of
burners as shown within the plate 61 (Fig. 1) one row extending through each hole in
the plate and each row supplied with gas or burning fluid by any suitable means. By
either of the arrangements shown or any other suitable means, I heat each of the
plates as hot as required.
Each plate is provided with four arms f f f f arranged at each corner and one
pair projecting toward one end of the machine and the other pair toward the other
end. Secured across the ends of each pair of these arms, is a cross-piece
cross piece being forked at the end as shown.
each
gggg are links which cross each other in pairs at h and h¹ and are there pivotally
connected together. One extremity of gis pivote to one extremity of 9 and the
saume is true of g' and g². Each of the pivots at the extremities of these links has a

page_text: bearing in the forkel end of one of the cross pieces and 2. By means of these
arms, cross pieces and links, the press plates are compelled to move uniformly and
parallel to one another, so that motion communicated to one must be transmitted to
the others equally and they will all move in parallel planes. Of course, the plates
may be connected with the links gggg in any other suitable manner, but I prefer
the arrangement above described."
It is desirable that a yielding pressure should be exerted upon the press plates,
and to this end I suspend the cross piece j below the top cross piece of the frame by
the bolts k k¹ so that the cross piece is free to rise or fall on the bolts.
I insert
spiral springs between the top cross piece of the frame and the cross piece j, which
springs tend to press the cross piece j down against the heads of the bolts & and k'.
m is a screw which is threaded into a nut on the cross piece j and the end of which
screw is swiveled to the top of press plate b. By this arrangement, it is obvious that
when the screw is advanced the pressure of the springs is brought to bear on the
top press plate and by the connecting links transmitted to each of the other press
plates, also arranged horizontally.
The opposing faces of the press plates may be channeled as shown.
I will next describe the apparatus or case within which the plastic material is to be
placed and rolled out and held while being pressed. It is shown in plan view in
Figure 2 and in cross section in Figure 1. n is a square frame rabbeted as shown,
so as to receive an inside frame o. The frame o is also rabbeted as shown. The
central openings of these frames are of the size to admit the passage of the press plates.
In the rabbets of the frames n and o are two perforated sheet metal plates p and pl.
Between these plates are two thicknesses of cloth (preferably asbestos cloth) and the
plastic material is place and rolled out between the two layers of asbestos cloth.
99 Figure 1, are the two layers of asbestos cloth.
are eyes connected with
the inner frame and extend out so as to be secured to the outer frame each by a
bolt & s². I may use any other convenient means to secure the two parts of the
frame together.
8
In order that the weight of the press plates may be compensated for, I providė
projections t t¹ on each of the upper plates in the path of each of which as it descends
is a spring u u', properly secured on a supporting frame.
In operating the machine, the frame n and parts enclosed therein are removed from
the press plates. Then the frame o is removed from the frame n. Also the perforated
plates and asbestos cloth. The perforated plate p is then placed over the opening in
the frame n in the position shown. Then a layer of asbestos cloth is placed over the
perforated plate. Then the asbestos cloth is sprinkled with a powdered absorbent
material such as chalk, clay, silica or the like. Then a layer of plastic material which
is rolled out with a roller and sprinkled with absorbent powdered material. Then the
second layer of asbestos cloth is laid over the plastic material. Then the second
perforated plate p¹. Then the frame o which is secured to the frame n by the
bolts Now the case may be handled as much as desired without disturbing
its contents. The perforated metallic plates keep the material stiff, and the asbestos
cloth keeps it smooth and prevents its sinking into the holes of the perforated metal,
and the frame binds the whole together. Next, it is placed in the press so that the
press plates will act upon the opposite perforated plates within the frame openings.
Next, the press plates are screwed together so as to bring the yielding pressure of the
springs and to bear upon the plastic material. The plates are now heated to a
gradually increasing temperature and the moisture is expelled from the plastic material
through the asbestos cloth, the perforated plates and the channels on the surface of
the press plates. If the material at first has a tendency to swell under the heat, the
springs will admit of its doing so to any desired extent but as the operation
continues if the material shrinks, the springs will cause the plates to follow it up and
preserve a substantially uniform pressure until the extent of motion permitted by the
bolts is reached when the operator will know the operation is complete. By
having nuts on the bolts kk' as shown, the extent of this motion may be adjusted
at will!

page_text: I have described the case composed of the frames n and o and the perforated plate
and asbestos cloth as used in combination with the press. In treating comparatively
thin layers of material however, I contemplate employing this case without any press.
Thus, the material is placed within it, rolled out thin and confined as already
described; then the case is laid away preferably in a drying room until the material
within has suitably hardened; or Τ may raise the beat under these conditions
sufficiently high to calcine it the case meantime acting to preserve the form and
surface thereof. Especially where this case is to be used without the press, I prefer
to insert four springs vv between the frame o and the perforated plate next to it, one
at each side of the frame. When the frames n and o are fastened together with the
material within, these springs are compressed and during the operation of hardening
the material will exert a constant pressure so that the perforated plates will move to
or from each other as the material shrinks or expands.
I have shown the plates p and p¹ as both being perforated, but I contemplate some-
times using perforations only in one of them, depending upon driving the moisture off
from one side only of the material.
In
In some cases, in order to hasten the process, I may affect a partial drying in the
air, of the soluble glass in admixture or otherwise, after moulding or pressing it into
any given form or shape I may require it to take, before submitting it to the joint
action of heat and pressure, since when first exposed to a heat above 212° F., as the
soluble glass begins to lose its water of crystallization, the partially dry and hard
material becomes soft again, and readily takes the required shape of the mould.
order to facilitate this preliminary drying, I may remove the material entirely from
the mould, or the mould partially or entirely from the material, after casting, and
expose the material to the air, or to artificial beat until it has set, or hardened, or
acquired some degree of hardness, from the evaporation of a portion of its contained
water, when I return it to my moulding press to undergo my process of drying and
calcination by the direct application of heat and pressure.
I take care however, not to allow the material so drying in the air, unless under
pressure, to set, or get so hard as not to become soft or somewhat plastic again, when
I place it in my moulding press, as it may warp and shrink so much, get so much out
of shape, and lose so much moisture, if too long exposed to the air after mixing, as.to
become incapable of softening again sufficiently in the moulding press, to flatten out
again or to take the required shape of the mould. The proper and gradual drying
and subsequent calcination of the material, while preserving at the same time the
original form or pattern that may have been given to it, require some degree of skill,
which can be readily acquired by a little practice and experience.
"
Having placed my mixtures of soluble glass then in what I will hereafter denominate,
my" calcining press," I first apply to the plates of said press and keep up, a tempera-
ture a little below or about 212° F., until I have expelled superfluous mechanically
contained moisture from the material, or until I have brought about the solidification
of the soluble glass contained therein; if this has not already sufficiently hardened, by
having been previously air-dried or reduced to the ordinary state of dryness, which, it
gradually attains after a few days' exposure to a dry atmosphere of average
temperature.
To prevent the material adhering to the plates of the case or press, during the
process of drying, and subsequent calcination, I sprinkle plentifully, both the plates of
the press with which the material may be brought in contact and the material itself,
with fine, dry, powdered, chalk, clay, silica or other fine, dry, absorbtive mineral
matter; or whitewash the sides of my press with the same and allow it to dry; or I
may interpose cloth, well dusted over with the said dry mineral matter, between the
material to be dried and calcined, and the plates of the press, and which may afterwards
be readily stripped from the material.
I then keep gradually increasing the heat above the temperature of 212° F.,.until all
the combined water or water of crystallization of the soluble glass under treatment,
has been expelled in the state of vapour, and it has attained a very porous and perfectly
anhydrous condition. This gradual increase of heat can be conveniently, effected by

page_text: +
י
:
carefully regulating, by means of a stop cock, the amount and pressure of the steam
admitted to the hollow plates of the calcining press. In some cases I may use super-
heated steam in my press when a high temperature is required.
During the process of gradually expelling the combined water from the soluble glass
in the mixture; by a gradually increasing temperature, from 212° F. upwards, under
pressure, an infinite number of vapour vesicles are formed, and owing to the nature of
the material, these are caught and imprisoned in its substance as it gradually acquires
Tan increasing degree of hardness from the expulsion of water. These vapor vesicles
constitute a multitude of extremely fine pores which finely coalescing and communi-
cating with one another to a greater or less extent, throughout the mass of the material
during the process, afford a means of escape to the exterior, for all interiorly contained
moisture. The material thus attains a state of porosity similar to that, which well
leavened bread acquires in the processes of raising and baking. The pressure or confine-
ment to which it is subjected in the meantime, prevents the soluble glass from
I attaining the formless, spongy condition, which it would otherwise do, and stamps and
leaves upon it, the original impression or pattern of the calcining press.
The object of gradually raising the heat, is to give time for the moisture near the
surface to escape first, through the porous substance of the material thus formed, and
by degrees in this way, to work toward and into the interior of the material.
Some skill and judgement are required here, to avoid forcing the process or
raising the heat too rapidly and too high, as in this case the material may become
so spongy and porous as to lose proper solidity and tenacity. On the other hand, if
the applied heat be not high enough, or not maintained a sufficient length of time,
the material will not be thoroughly calcined, and therefore, not susceptible of
subsequent thorough decomposition. No harm to the material can result from an
unnecessarily long exposure to heat, so long as the temperature be not raised so high
as to produce decomposition or vitrifaction.
The pressure and heat must be so adapted to each other and the duration of their
application so adjusted that the material may not lose density and firmness, while
retaining at the same time a high degree of porosity.
Care must be taken to avoid the sudden application at first, of a high temperature
to the material under confinement, as this would cause the rapid evolution of a
large volume of steam, defeating the object of the process and possibly acting with
destructive effect.
The degree or intensity of heat to which 1 may ultimately raise the plates of my
case or calcining press, and the time required for its application, will depend
entirely upon the kind, and the thickness, of the material to be treated between
them.
To treat a mixture of one inch or thereabouts in thickness, I may employ a
gradual increase of heat after ordinary drying or setting, from 212° F. to between
400° and 500° or higher, for 12 hours. In this case I may use superheated steam
for the heating medium in my calcining press. If the higher temperatures above
given would be destructive of the ingredients mixed with soluble glass, the temperature
would be confined to the lower degrees.
I continue the heat applied to my case or calcining press at its maximum for a
considerable time after there is no longer any apparent evidence of escaping steam or
moisture from the mixture, when the process is finished.
The amount of pressure required to be exerted on the material by the plates of the
case or calcining press, will depend upon the kind of material to be treated, and the
sort of product desired. Simple, close confinement, may sometimes be sufficient if
the material be thin, of small superficial dimensions, and not to be impressed with
any pattern, but made plain or flat, or if the object of the applied pressure or con-
finement be merely to keep the material in shape, and to prevent its puffing up too
. much. If a pattern is to be stamped upon it however, some pressure will be
required and this will vary somewhat according to the thickness and bulk of the
material; the greater the thickness and superficial dimensions of the mixture, the
· greater will be the pressure required, and vice versa.

page_text: The pressure applied, must be sufficient to off-set at first, the expansion of the
material, and as it afterwards shrinks, the pressure must be maintained upon it, to
cause it to take and retain a sharp impression of the mould.
If a material of greater density be required, hydraulic or similar pressure may be
applied during the process of calcination, care being taken in this case to increase
the temperature gradually, so as to allow the vapour generated to escape slowly,
regularly and by degrees, in small portions at a time. The greater the applied
pressure, the longer time it will require to calcine the material, and the denser twillna
be the resulting product.
But the pressure or confinement, must never be so great as not readily to allow
of the free escape of vapour from between the material and the plates of the
caleining case or press or from the material itself. The pressure upon the plates of
said case or calcining press, should be elastic enough to yield somewhat against the..
expansion of the material, as it begins at first to part with its combined water, and
while strong enough to follow up and maintain a pressure upon the said material, as
it afterwards contracts from the expulsion and loss of said water, not so strong as
to confine the escaping steam too much.
A little experience in practical working of the intelligent workınan, will soon enable
him to judge correctly of the intensity of the heat and the time and pressure required,...
for the particular kind and thickness of material he may be treating.
nd
"
When I take the material from my calcining press, 1 find that it has undergone a
great physical change. It has become much harder than before, and of an entirely...
different character from ordinary dry mixtures of soluble glass, which have hitherto
been known and obtained by drying the same in the air.
1.
There has been set up in it a highly porous, and absorbent condition, similar to that
of earthenware or porcelain in the state of biscuit" preparatory to glazing.
Although very porous, the material has become very solid, harsh and gritty, so as
to quickly wear away any edge tool that may be employed to cut or saw it.
Having thus applied the first step of my process, I will now describe particularly.
the application of the step which converts the substance into insoluble matter.
In order to render the material essentially waterproof in itself, the soluble alkaline i
silicates in it must be replaced by other compounds which are insoluble, and this is:
effected by bringing it in contact with solutions of chemical agents capable of.
decomposing soluble glass.
Hitherto, chloride of calcium has been chiefly recommended or used for this
although a few other salts have also been suggested.
もい上
purpose...
4.
I have found by careful experiment that besides these, a large number of other
chemical compounds in solution are capable of effecting this decomposition. Such.
are the ordinary soluble free acids, and the soluble oxides and salts of the metals;.
other than those generally of the alkaline metals, except some of these in double salts,
as in some of the so-called "alums."
Among the most important and available of these are:-
SOLUBLE FREE Acids.

page_text: To Surpypusurpureo, supato, c
phosphite, hypo-phosphite, tungstate.
Zinc, chloride, sulphate, acetate, sulphite, nitrate, hypo-phosphite, chlorate.
Lead; nitrate, acetate.
Copper, chloride, sulphate, nitrate, acetate.
Mercury, bi-chloride.
Aluminium, sulphate, acetate, chloride, nitrate, hyposulphite, hypo-chlorite,
sulphite.
Manganese, chloride, sulphate, acetate.
Iron, chloride, sulphate, nitrate, acetate, sulphite.
Nickel, chloride, sulphate, nitrate, acetate.
Chromium, sulphate, potassium and chromium sulphate, ammonium and chromium
sulphate, potassium bichromate, sodium bichromate.
Tin, proto-chloride, sulphate, hyposulphite.
Antimony, antimony and potassium tartrate.
Besides these, there are some chemical compounds and mixtures which can best be
described by their ordinary commercial names, such as, superphosphate of lime,
bisulphite of lime, chloride of lime, or bleaching powder, pyrolignite of lime, the
alums, aluminous cake. Other decomposing compounds may be found cheaper and
more available in the future.
I do not confine myself to decomposing compounds that are soluble in water
only, or to aqueous solutions of the same merely, but I may sometimes use as
solvents for my decomposing agents, other menstrua, such as acids, alkalies,
alcohol.
I therefore in the dry, calcined and pressed condition of my material which I
have described, immerse it into a saturated cold or hot solution of the kind of
chemical bodies I have indicated.
On account of the great porosity of the calcining material thus prepared, and its
perfect dryness, the decomposing solution is rapidly absorbed into its pores, and a
thorough decomposition of its contained soluble glass insured. Moreover, the
material still retaining its porosity after decomposition, thorough and rapid
removal of the soluble salts resulting from the said decomposition can be readily
effected by washing.
The time necessary for its thorough decomposition will depend upon the kind and
thickness of material to be treated, but generally from six hours to twenty four
hours will be sufficient.
The character of the decomposition which takes place will depend upon the kind
of decomposing solution used. If a dilute acid be employed, it abstracts soda or
potash from the alkaline silicate in the mixture, forming a soluble salt, and precipitates
free insoluble silica. If a simple metallic oxide not of an acid character be used,
it abstracts the silica or silicic acid from the alkaline silicate forming an insoluble
metallic silicate which is precipitated, while soluble soda or potash is set free.
If again, a metallic salt be the decomposing agent a double decomposition takes
place, the silica in the soluble glass abstracting the base of the metallic salt,
forming an insoluble metallic silicate which precipitates, while the acid of the
metallic salt thus set free, combines with the freed base of the alkaline silicate,
forming a soluble salt.
The choice of these and other similar decomposing soluble substances, will depend
upon their cheapness and availability. Care must be taken in their selection, not
to employ one which is apt to exert a decomposing action upon any one of the
ingredients in the mixture under treatment.
I prefer for general use, an aqueous solution of a metallic salt with an acid
re-action, such as, ferrous sulphate, aluminum sulphate, the alums and the like. A
stronger and better product seems to result from the use of this kind of decom-
posing agent, from the consequent precipitation of an insoluble metallic silicate,
than from that resulting from the use of dilute acids, where merely insoluble silica
is precipitated.

page_text: It is now desirable to wash out the soluble oxides or salts contained in it, and
compress and dry it, although in some cases where the retention of the soluble salts
would not interfere with its appearance or application, it may be compressed and dried
at once for use without further treatment.
Heretofore, washing has been effected by immersion of the material for a time in
still or running water or exposure to the action of steam, and this for ordinary
purposes may be sufficient, but when a fine product is to be produced that will not
effloresce I have found that spraying water in fine jets on the material is more
effective, besides resulting in a great saving of water, which is sometimes an item of
expense. For this purpose I hang up the material to be washed in a chamber where
fine jets of water are arranged to play in a spray upon it, for from six to twenty four
hours, according to the thickness of material or until it is sufficiently free from
soluble substances.
The decomposed material, when first taken from the decomposing bath, or after
washing to remove the soluble salts in it, is so thoroughly saturated with moisture
that it may be somewhat spongy and fragile, and liable also to lose somewhat on this
acount its original form or shape, especially if it has been moulded to any fine pattern.
To make it retain its original shape or form to which it may have been moulded, to
increase its density, and to expel from it all superfluous moisture, I may again submit
it to pressure and heat in the same press, or in a similar one which I have already
used for calcining it, and which I have described above as my "calcining press." In
this part of my process I may also use hydraulic pressure, in a hydraulic or other
press, with or without the aid of heat so as materially to increase the density and
harshness of the material thus treated.
As the material after this treatment, still remains very porous, unless it has been
previously submitted to hydraulic pressure referred to above, I may in some cases;
in order to render it impervious to water, especially when it is to be exposed to the
weather, cover it, or fill its pores with a water resisting substance. This I accomplish
conveniently, either by painting, japanning, varnishing or lacquering it, or, by
immersing it in a water proof substance which has been melted, fused or brought
into a state of solution or liquid suspension, until it is covered, or its pores are filled
with the same, when I take it out and allow it to dry or cool.
Convenient substances for the latter purpose named are melted or dissolved
paraffine, wax, drying oils, melted or dissolved asphaltum, sulphur, india rubber and
gutta percha, tar, fused or dissolved insoluble metallic soaps or insoluble metallic
oleates or stearates, alcoholic alkaline, or other solutions of the resins, gums and
the like.
The substance when complete in its framework or structure by which the whole is
knit together, consists of an insoluble compound of silicon (silica or silicate of lime
and the like) in a porous or cellular condition. With this framework may be com-
bined some water resisting material injected into the pores, and there may also be
combined foreign solid substances, between the particles of which the insoluble
compound of silicon occupies the relationship of a skeleton or framework uniting or
cementing the whole together.
Coloring matter may be added by simply incorporating with the soluble glass,
before treatment any pigment which will not act chemically in the subsequent
mean that
operations; depending upon the color desired to be produced. By this I
the pigments should not be combustible, fusible or decomposable under the temperatures
employed and not capable of decomposing the soluble glass with which they are
¡mixed.
Having now particularly described and ascertained the nature of my said inven-
tion, and in what manner the same is to be performed, I declare that what I
claim is :-
1. An artificial product the tissue or contexture of which consists of a compound of
silicon substantially free from water of crystallization in the form of a solid cellular

page_text: 2. An artificial product the tissue or contexture of which consists of an insoluble
compound of silicon in the form of a cellular mass, substantially as described.
3. An artificial product consisting of particles of a solid knit together by a tissue
or contexture consisting of a compound of silicon substantially free from water of
crystallization in the form of a solid cellular mass, substantially as described.
4. An artificial product consisting of particles of a solid knit together by a tissue
or contexture consisting of an insoluble compound of silicon in the form of a cellular
mass, substantially as described.
5. An artificial product the tissue or contexture of which consists of an insoluble
compound of silicon in the form of a solid cellular mass, the cells of the same.being
filled with a water excluding substance, substantially as described.
6. An artificial product the tissue or contexture of which consists of an unvitrified
non alkaline compound of silicon in the form of a cellular mass, substantially as
described.
7. A moulded article of manufacture the tissue or contexture of which consists
of an insoluble compound of silicon in the form of a cellular mass, substantially as
described.
8. An artificial product the tissue or contexture of which consists of an insoluble
compound of silicon in the form of a compressed cellular mass, substantially as
described.
9. In the art of treating the soluble alkaline silicates both separately and in
admixture with other matter, heating the same to a temperature between the
volatilizing temperature of the solvent and the heat of vitrification, until the solvent
is expelled, substantially as described.
10. In the art of treating the soluble silicates both separately and in admixture
with the other matter, heating the same under confinement, substantially as
described.
11. In the art of treating the soluble silicates both separately and in admixture
with other matter, first drying a solution of the same and then heating while
under confinement, substantially as described.
12. In the art of treating the soluble silicates both separately and in admixture
with other matter, heating the same while under a continuous pressure which follows
up the shrinkage of the material, substantially as described.
13. In the art of treating the soluble silicates both separately and in admixture
with other matter, first drying a solution of the same and then applying a gradually
increasing heat ranging from the volatilizing temperature of the solvent upwards
while under confinement, substantially as described.
14. In the art of treating the soluble alkaline silicates both separately and in
admixture with other matter, heating the same until the solvent is expelled without
vitrification and then treating the same to render it insoluble, substantially as
described.
15. In the art of treating the soluble alkaline silicates, both separately and in
admixture with other matter, expelling the solvent whereby the alkaline silicate is
left porous and then rendering the same insoluble by the introduction of a converting
agent into the pores thereof, substantially as described.
16. In the art of treating the soluble alkaline silicates, both separately and in
admixture with other matter expelling the solvent by the application of heat and
pressure whereby the alkaline silicate is left porous and then rendering the same
insoluble by the introduction of a converting agent into the pores thereof, substantially
as described.
17. In the art of treating the soluble alkaline silicates both separately and in
admixture with other matter, expelling the solvent whereby the alkaline silicate is left
porous, then rendering the same insoluble by the introduction of a converting agent
into the pores and then drying the same under pressure, substantially as described.
18. In the art of treating the soluble alkaline silicates both separately and in
admixture with other matter, expelling the solvent whereby the alkaline silicate is left
porous, then rendering the same insoluble by the introduction of a converting agent
i.

page_text: into the pores, then removing the soluble salts from the pores by washing, sub-
stantially as described.
19. In the art of treating the soluble alkaline silicates both separately and in
admixture with other matter, expelling the solvent whereby the alkaline silicate is left
porous, then rendering the same insoluble by the introduction of a converting agent
into the pores, then filling the pores with a water resisting substance, substantially as
described.
20. In the art of treating the soluble alkaline silicates both separately and in
admixture with other matter, incorporating with the same while in solution, a coloring
matter, then subjecting the same to heat and pressure for expelling the solvent, sub-
stantially as described.
21. The combination with each two adjacent members of a series of press plates, of
four links, each link being pivoted at its one end to one of said press plates and at its
opposite end to the other, whereby the uniformity of motion of all the press plates in
the series is preserved, substantially as described.
22. In combination, the press plates provided with means for being heated, a
stationary frame, and spring mechanism interposed between the stationary frame
and the press plates, and a screw whereby pressure is applied, substantially as
described.
23. In combination, the stationary frame, the series of press plates, the pivoted
links connecting each one of the series with another, whereby the uniformity of the
motion of each is maintained, the screw, whereby the pressure is exerted, and the
spring interposed between the screw and the stationary fraine, whereby the pressure is
made yielding, substantially as described.
24. In combination, the press plates provided with means for being heated, a
perforated plate covering the face of the material being pressed and a frame sur-
rounding the edges of the material whereby the material is prevented from spreading
laterally, substantially as described.
25. In combination. the press plates provided with grooved surfaces and with
means for being heated, a perforated plate covering the face of the material being
pressed and a frame surrounding the edges of the material whereby the material is
prevented from spreading laterally, substantially as described.
26. In combination with the press plates provided with means for being heated, a
removable holder for the material being pressed, consisting of two plates and the
telescoping frames n and o whereby the edges of the material are enclosed and the
plates are held to the faces thereof, substantially as described.
27. In combination with the press plates, the screw, the spring interposed between
the screw and the main frame to exert a yielding pressure, a removable frame enclosing
the edges of the material and of the proper size to admit of the passage of the press
plates through it, and the plates arranged above and below the material being pressed
within the removable frame, substantially as described.
28. In combination, the press plates, the plates for holding the material being
pressed, the frames n and o between which said perforated plates are held and
devices substantially as described whereby said frames are fastened together, as set
forth.
29. A case for holding plastic material while hardening which consists of the
frames n and o and the perforated plates inclosed and held by the same, substantially
as described.
30. A case for holding plastic material while hardening which consists of a
perforated plate p, a plate p', and a frame enclosing the edges of the same but
admitting of play for the said plates to move to and from each other, substantially
as described.
31. A case for holding plastic material while hardening, which consists of two plates,
a frame enclosing the edges of the plates and springs arranged in said frame to press
said plates toward each other, substantially as described.
32. The removable case for holding plastic material while hardening having two

page_text: plates and a frame to enclose the material on its faces and edges and a 'cloth
interposed between the plates and the material combined with and arranged to be
held by and withdrawn from the supporting frame and when used as and for the
purposes set forth.
33. In combination two plates adapted to compress a plastic material between
them, one of said plates being provided with ducts for the escape of moisture
from the plastic material while being subjected to pressure, substantially as
described.
34. In combination with two plates adapted to press a plastic material between
them, a porous fabric interposed between the plastic material and one of said plates,'
substantially as described.
35. In combination, two plates adapted to press a plastic material between them
and a porous fabric interposed between each of said plates and the plastic material,
substantially as described.
36. In combination, two plates adapted to press a plastic material between them;
each of said plates being provided with ducts for the escape of moisture from the
plastic material, and a porous fabric interposed between each of said plates and the
plastic material, substantially as described.
37. In combination, two plates adapted to compress a plastic material between
them one of said plates being provided with ducts for the escape of moisture from
the plastic material while being subjected to pressure, and means whereby said plastic
material is subjected to heat while under confinement between said plates, substan-
tially as described.
38. In combination with two plates adapted to press a plastic material between
them, a porous fabric interposed between the plastic material and one of said plates,
and means whereby said plastic material is subjected to heat while under confinement
between said plates, substantially as described.
39. In combination, two plates adapted to press a plastic material between them, a
porous fabric interposed between each of said plates and the plastic material, and
means whereby said plastic material is subjected to heat while under confinement
between said plates, substantially as described.
40. In combination, two plates adapted to press a plastic material between them,
each of said plates being provided with ducts for the escape of moisture from the
plastic material, a porous fabric interposed between each of said plates and the plastic,
inaterial, and means whereby said plastic material is subjected to heat while confine-
ment between said plates, substantially as described.
41. In combination, two plates adapted to compress a plastic material between
them, one of said plates being provided with ducts for the escape of moisture from
the plastic material while being subjected to pressure, means whereby said plastic
material is subjected to heat while under confinement between said plates, and means
whereby a yielding pressure is produced by said plates upon said plastic material as
the same is being subjected to heat.
42. In combination with two plates adapted to press a plastic material between
them, a porous fabric interposed between the plastic material and one of said plates,
means whereby said plastic material is subjected to heat while under confinement
between said plates, and means whereby a yielding pressure is produced by said
"plates upon said plastic material as the same is being subjected to heat, substantially
as described.
+
48. In combination, two plates adapted to press plastic material between them
and a porous fabric interposed between each of said plates and the plastic material,
means whereby said plastic material is subjected to heat while under confinement
between said plates and means whereby a yielding pressure is produced by said plates
upon said plastic material as the same is being subjected to heat, substantially as
described.
44. In combination, two plates adapted to press a plastic material between them;
each of said plates being provided with ducts for the escape of moisture from the

page_text: plastic material, a porous fabric interposed between each of said plates and the
plastic material, means whereby said plastic material is subjected to heat while under
confinement between said plates, and means whereby a yielding pressure is produced
by said plates upon said plastic material as the same is being subjected to heat,
substantially as described.
Dated this 11th dow of January 1890
HASELTINE, LAKE & Co.,
45, Southampton Buildings, London, Agents for the Applicant.