IMPROVEMENTS IN THE MANUFACTURE OF ORNAMENTAL AND NATED SIMILAR ARTICLES"
Year: 1859

page_text: LETTERS PATENT to George Skinner, of Stockton-on-Tees, County of
Durham, Earthenware Manufacturer, and John Whalley, of South
Stockton-on-Tees; County of York, Earthenware Manufacturer, for the.
Invention of IMPROVEMENTS IN THE MANUFACTURE OF ORNAMENTAL AND
NATED SIMILAR ARTICLES"
PROVISIONAL SPECIFICATION left by the said George Skinner and
John Whalley at the Office of the Commissioners of Patents, with their
Petition, on the 1st January 1859.
We, GEORGE SKINNER, of Stockton-on-Tees, County of Durham, Earthen-
ware Manufacturer, and JOHN WHALLEY, of South Stockton-on-Tees, County
of York, Earthenware Manufacturer, do hereby declare the nature of the
Invention for "IMPROVEMENTS IN THE MANUFACTURE OF ORNAMENTAL AND OTHER
TILES, AND OTHER SIMILAR ARTICLES," to be as follows:-
This Invention has for its object improvements in the manufacture of
encaustic tesselated tiles and other similar articles of either large or.
small dimensions.
For this purpose we use the materials of their composition in a semi-fluid
state, (and not as heretofore, in either a plastic or dry disintegrated state,
and moulded by pressure), and we employ a metal case, in two parts, of the
size and form suitable; the sides of which are lined with filtering material,
and when used, are firmly bolted together, so as to constitute a species of
filter; this instrument we call a power loom, and in it tiles or similar articles
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page_text: are not only formed but decorated at the same time; the materials in a semi-
fluid state being forced into the loom by a pump or other means, which con-
tinues to operate as long as any superfluous water escapes through thefiltering
material, the loom being thus full of the clay or paste in a solid plastic mass,
which is then taken out of the loom to be dried and finished preparatory to
burning in the usual way. To produce a tile or other similar article, having
an ornamental surface, the ornament desired is modelled in clay or other
suitable material on a flat surface, so as to rise or project the height required,
and be a model, or (as we call it), a stereotype plate of the ornament, from
this a plaster cast is taken, and the cast so obtained is the mould employed to
reproduce in clay or paste any number of similar stereotype plates required,
which is done by filling the depressions in the mould with colored clays in a
plastic state, and then covering the mould with a thin sheet, or, (as we call it)
a bat of the clay or paste in a plastic state of similar materials to the semi-
fluid to be injected when taken from the mould; this is a stereotype plate of
the ornament in the colours desired, and when sufficiently dry, is placed in the
loom before-named, and the clay or paste in a semi-fluid state being forced
into the loom it becomes imbedded in the mass, the top of the projecting
ornament alone remaining visible, and when dried sufficiently, the surface is
freed by scraping from any superfluous matters, and the ornament appears
clear and distinct. In order to facilitate the removal of the stereotype plate
from the plaster mould, and to obtain other advantages in the process, it
is made broader at the bottom than at the top, and this causes it to become
more firmly fixed in the finished tile or other similar articles.
per-
In addition to proceeding as above, we use another modeofdecoration, viz.:—
to outline any pattern or design on a flat surface of plaster, wood, or other
suitable material, it may be in relief or engraved into the surface to the depth
required. A plaster cast is taken from it, which serves as a mould; upon this
mould is pressed a bat of colored clay or paste, which receives the impression
of the design, and is a stereotype plate of its parts in the design may be
forated through the colored sheet, the other parts being indented on its surface
when placed in the loom, as before-mentioned; the semi-fluid matter is forced
into the loom, and fills up every perforation and indent of the stereotype plate,
and becomes one united mass of plastic tile, or other similar article filling the
cavity of the loom, and when it is taken out, and the surface cleaned from any 3
superfluous matter, presents the design in or upon the colored surface of the
tile in white, or whatever may be the tint of the materials of the semi-fluid
used. Thus, our Invention enables us to produce in plastic materials every
variety of design, ornament, or inscription deeply inlaid in the tile or other

page_text: similar articles, yet clear on the surface, and indestructible for a longer
period, from ordinary use, than any other tesselated encaustic tile hitherto
produced, and at less expence.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said George Skinner and John Whalley in the Great Seal
Patent Office on the 1st July 1859.
TO ALL TO WHOM THESE PRESENTS SHALL COME, we, GEORGE
SKINNER, of Stockton-on-Tees, County of Durham, Earthenware Manu-
facturer, and JOHN WHALLEY, of South Stockton-on-Tees, County of York,
Earthenware Manufacturer, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the First day of January, in the year of our Lord
One thousand eight hundred and fifty-nine, in the twenty-second year of Her
reign, did, for Herself, Her heirs and successors, give and grant unto us, the
said George Skinner and John Whalley, Her special licence that we, the said
George Skinner and John Whalley, our executors, administrators, and
assigns, or such others as we, the said George Skinner and John Whalley,
our 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 Man, an Invention for "IMPROVEMENTS IN THE MANU-
FACTURE OF ORNAMENTAL AND OTHER TILES, AND OTHER SIMILAR ARTICLES," upon
the condition (amongst others) that we, the said George Skinner and John
Whalley, our executors or administrators, by an instrument in writing under
our or their hands and seals, or under the hand and seal of one of us or
them, should particularly describe and ascertain the nature of the said Inven-
tion, 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 John Whalley, on behalf of myself and
the said George Skinner, do hereby declare the nature of the said Invention,
and in what manner the same is to be performed, to be particularly described
and ascertained in and by the following statement thereof, that is to say:-
This Invention has for its object improvements in the manufacture of
encaustic tesselated tiles and other similar articles of either large or small

page_text: dimensions. For this purpose we use the materials of their composition in a
semi-fluid state (and not as heretofore in either a plastic or dry disintegrated
state, and moulded by pressure), and we employ a metal case, in two parts, of
the size and form suitable, the sides of which are lined with filtering material,
and when used are firmly bolted together, so as to constitute a species of
filter; this instrument we call a power loom, and in it tiles or similar articles
are not only formed but decorated at the same time; the materials in a semi-
fluid state being forced into the loom by a pump or other means, which con-
tinues to operate as long as any superfluous water escapes through the filtering
material, the loom being then full of the clay or paste in a solid plastic mass,
which is then taken out of the loom to be dried and finished preparatory to
burning in the usual way. Figures 1 and 2 shew vertical sections of the
apparatus we call a power loom suitable for manufacturing flat tiles, slabs, and
other similar articles from materials in a semi-fluid state. The loom consists
of a strong metal case or box a formed in two parts, which can be united
together by screws and nuts b'; each part of the case a is lined with wood
furrowed on the surface, as shewn at Figure 2; the wood is covered with per-
forated zinc, and the zinc is covered with calico, which forms an even surface
to the interior of the mould. Attached to one part of the case a is a rim of
wood c, one or two inches broad, and one inch or one-and a half inches thick,
of the form required for the tile or slab. This rim is covered with calico, and
placed upon the perforated zinc before named, and forms the boundary to the
mould. The case a is formed with projecting pins or axes a², which turn in
bearings in the standard d, so that the case a is supported by and may be
turned over on these axes. In one part of this rim there is a hole, through
which a pipe passes, which is connected to a pipe d, through which the semi-
fluid composition to be used for forming the tile or slab is forced by means of
a force pump, which is placed in a bath of the semi-fluid composition. On
the pipe d¹ there is a tap d*, which, when opened, permits the force pump to
inject the semi-fluid composition into the mould,which acts as a filter, allowing
the water in the conposition to escape until it is filled with the solid plastic
material. When the mould is full and the filtering ceases, the tap d* is
turned off, and the screws b', which connect the two parts of the case a, are
unscrewed, and one part of the case is removed, the filtering calico is then
taken of, and the surface of the tile or slab exposed; a level board is then
placed upon the uncovered surface, and is retained there while the case a
is turned over on its axis until the bat or board is under the case a, and
supports the tile or slab which leaves the mould, and may then be removed
to the drying room, and is afterwards burnt in the ordinary manner.

page_text: One mode of making and applying the subjects of decoration or inscription
to be veneered into the surface of the tile or tablet is as follows:-The orna-
mentation desired is modelled in clay, wax, or other suitable material, or may
be carved upon or cut into wood or metal, and a mould in plaster is taken in
the usual way; the mould is employed to reproduce, in clay or paste, any
number of similar stereotype plate required, which is done by filling in the
depressions in the mould with colored clays or pastes in a plastic state, and
then covering the mould with a thin sheet, or (as we call it) a bat of clay or
paste in a plastic state of similar materials to the semi-fluid to be injected;
when taken from the mould, this is a stereotype plate of the decoration in the
colors desired, and when sufficiently dry or hard that it may be handled, is
placed in the cell of the loom or mould above described, and the clay or paste
in a semi-fluid state being forced into the loom by the pump to which it is con-
nected, it becomes embedded in the mass, the top of the projecting decoration
alone remaining visable, and when removed from the mould, and sufficiently
dry, the surface is freed by scraping from any superfluous matters, and the
ornament appears clear and distinct. In order to facitate the removal of the
stereotype plate from the mould of the plaster, and to obtain other advantages
in the process, the parts of the decoration are modelled a little broader at the
base than the top, and when filled in the mould, the thin bat of clay covers
the base of the decoration, and presents a stereotype plate, which is inverted
when placed in the cell of the loom, so that it is embedded by the semifluid,
as a wedge, which must prevent it ever leaving the tile or tablet, and
instead of being obliterated by wear or use, must become broader and more
distinct, until the base of the decoration is worn out, which will be in pro-
portion to the thickness of the veneered decoration or mosaic, and the
density of the encaustic materials used.
In addition to the above proceeding, we use another mode of decoration,
viz. To outline any pattern or design on a flat surface of plaster, wood, or
metal, engraved into the surface to the depth required; from this a plaster
mould is taken, or stereotype plate, on this stereotype plate we press a bat or
sheet of plastic colored clay or paste, which gives an indented surface in the
same in various parts, as the decoration may require; we pierce or perforate,
with a proper tool, the form of ornament, in the same manner as the potter.
pierces the fish drainers, and it is then placed in the cell of the loom, as before
mentioned; the semi-fluid matter is forced into the loom, and fills up every
line and indent of the decoration and the parts pierced in the stereotype plate,
and becomes one united mass of plastic tile, or other similar article filling the
cavity of the loom, and when taken out and the surface cleaned from any

page_text: superfluous matter, presents the design in or upon the colored surface of
the tile in white, or whatever tint the the injected semi-fluid may be.
A pattern in detached parts and colors can be placed on the covered
zinc plate of the cell, which is moveable, for all purposes of decoration,
according to any desired arrangement, and fastened on it by suitable pins, or
even sewed on the covered zinc plate, so as to hold it in position while filling
the loom with the injected semi-fluid, and freed when the operation is completed
by either taking out the pins, or cutting the thread on the back of the
perforated zinc plate. Thus, our Invention enables us to produce in plastic
materials every variety of design, ornament, or inscription deeply inlaid in the
tile or other similar articles, yet clear on the surface, and indestructable for a
longer period from ordinary use than any other tesselated or encaustic tile
hitherto produced, and at less expense for any like or similar production, as
the materials have not to be made into clay in a plastic state (except for the
decoration), or if dried, to be reduced to dust or disintegrated for any
mechanical pressure which requires both fuel and labour.
Our Invention is adapted to the manufacture of tiles, tablets, panels, or
slabs in any geometrical form, and for their decoration, and can be applied
to cylindrical formations for the casing of brick pillars or other architectural
purposes, so as to case them with a vitreous indestructable material from wet
or atmospheric changes, however much exposed to them; also for inscription
tablets, the type not being simply superficial but veneered deep into the tablet,
which may be let into stone, or built in a brick surface, and remain legible
as long as there is any thing to describe or to be annotated for mosaic and
tesselated pavements; it has this peculiarity, they do not wear into indistinct-
ness, which is the case when the decoration is simply superficial, but as the
apex of the decoration is to the surface, being deep imbedded into the tile, the
wear from use must give the decoration greater breadth and distinctness.
Our Invention applies to porcelain, stoneware, earthenware, and vitreous
pastes, or other cohesive materials, or that can be made so by mixture, so
as to be manipulated by the process herein before described.
In witness whereof, I, the said John Whalley, have hereunto set my
hand and seal, this First day of July, in the year of our Lord One
thousand eight hundred and fifty-nine.
JOHN WHALLEY. (L.S.)