Decorations, Ornamental Designs, or Patterns.
Year: 1884

page_text: Decorations, Ornamental Designs, or Patterns.
J
I, EDUARD GRACH, of Triers in the Kingdom of Prussia, German Empire,
Gentleman, do hereby declare the nature of said invention for "IMPROVEMENTS
IN THE MANUFACTURE OF MOSAIC AND SUCH LIKE DECORATIONS, ORNAMENTAL
DESIGNS, OR PATTERNS," to be as follows: -
This invention of improvements in the manufacture of mosaic and such like
decorations designs or patterns for mural and other purposes has reference to
"
(1.) The employment of alveolate moulds containing within their cells the outlines
of the mosaic pattern or design. and in the upper surfaces of which moulds are
formed, by a process differing from those heretofore employed, the required mosaic
designs or patterns, in accordance with the Roman art of mosaic covering that is to
say, in pieces of irregular, quadrangular, or similar shape.
(2.) An easy mode of production of such alveolate or reticulated moulds (which
may be compared to honeycombs), carried out by first drawing the mosaic design
full size, upon plates or pieces of dried soap, wax, wood, gypsum or the like, then
carving out engraving or stamping the design to the desired depth and afterwards
pouring liquid plaster of Paris or other suitable substance upon the surface,
(previously oiled) of the said plates or pieces of soap or other material, the mass
being then finally allowed to set and harden.
(3.) The mode of setting the different artificial stones used and previously
coloured, in the various cells of a honey-combed mould according to the arrange-
ment and the shades of the design, these stones being in some cases left in the
mould or more generally removed from the same in the form of a slightly cohesive
layer of loose pieces arranged in close proximity to one another, in such a manner
that a basis of paper, clay, or the like may be temporarily or definitely fixed to the
said stones by means of some adhesive substance, either before or after the setting
is hardened. This last operation completes the mosaic pattern.
(4.). The mode of colouring the stones, which are of a uniform colour when set
in the mould but are painted after a first baking and subsequently baked anew.
When the mosaic subject is of very large dimensions it is formed in several
parts, these parts being fitted together after completion.

page_text: The mosaic pattern or design produced according to this invention may serve for
paving, flagging or tiling purposes, in the manufacture of table tops, for mural
decorations, or in the manufacture of articles used for building purposes or in other
trades or when made of glass as transparent windows and the like. The process
of preparation of moulds and mosaic, and the mode of employing the same are as
follows:
Full size detailed drawings are made of the mosaic design which is required to
be manufactured or reproduced, these drawings being afterwards transferred either
in parts or in toto upon plates of soap, wax, wood, clay, gypsum or other suitable
material. These drawings which are of alveolate or reticulated form are carved
out engraved or stamped in these plates, to the desired depth according to the
thickness of the mosaic required.
When ornamental but not Roman subjects or designs are required, the reticulated
drawing is carved out, engraved, or stamped in larger type, cells being either partly
or altogether dispensed with.
The partition walls of the cells will present the form of recesses on the first
plate.
GL.
Melted wax, liquid plaster of Paris, or other suitable substance is now poured
upon the oiled surface of the plate and allowed to cool or set thus forming the
desired mould. When moulds, consisting of wax, plaster of Paris or the like are
not to be used directly for setting therein material serving to form the small
mosaic stones or otherwise of the subject. or design, a matrix may be formed by
covering the above moulds with a layer of copper by galvanoplasty, and employed
for the reproduction of moulds by means of paper pulp or other suitable material
of soft consistence which is pressed in the said matrix.
,"I
When the mould is formed, the material previously, coloured is pressed or cut
and placed in the hollow cells (which may be slightly tapered at their lower part)
in such a manner that each cell receives its corresponding colour, so that when the
mould is filled up the mosaic design is complete. When it is required to utilisé
the mould for filling material that is to say when the material pressed or poured in
the mould is intended to reinain in the same in order to. form inlaid plates which
may be used for table tops, cupboards and the like, the mould. is manufactured
either of thin paper pulp, metal or other material which can be firmly fixed to
the bottom and sides of the cells and thus form a hard mass. When metallic
moulds are used, they may be lightened by grinding down the partition walls of
the cells.
"
When the mosaic subject design or pattern has to be removed from its mould
and used as a loose layer of small stones, a piece of paper or linen provided with
some adhesive substance is laid, after the stones in the cells have become hardened
and compact and have not previously been fastened upon plates, on the top of the
mosaic layer this paper or linen being pressed firmly enough upon the said layer to
prevent the subject, pattern or design from falling to pieces when the mould is
reversed; the former is then removed and laid where required.
The mosaic thus produced is set when used for paving, mural decorations or other.
purposes, in the surface which requires decorating by means of cement, mortar or
putty, and according to this process the pattern or design may be placed in one
piece when not too large, the paper holding the different pieces of stone together
being afterwards removed.
:
The interstices in the mosaic tiles used for mural decoration or paying purposes
may be filled, according as required, with cement or other material and in the case
of articles of considerable value such as table tops, or the like, they may be filled.
with metal.
When it is required to obtain a fac-simile of the ancient Roman mosaic as laid
on walls or paving tiles, the process is as follows:-
Sheets of wet blotting paper are laid upon the mosaic and made to, adhere
thereon by means of a brush, and in order to strengthen the mould thus obtained,
several sheets of blotting paper are moreover pasted upon it, a brush being again

page_text: used to make them adhere, and finally dried. The mosaic may be previously
painted with chalk colours, in this case the matrix when withdrawn gives a true
copy of the mosaic with its natural colours. Liquid plaster of Paris is subsequently
poured upon the matrix thus produced and the reticulated impression is cut out
by means of an engravers tool a mould being thus formed which permits a true
reproduction of the original to be obtained.
1117
When a double metallic mould is employed, the same is made of two parts, the
layer of stones being removed when required by first withdrawing one half of the
mould and pasting a piece of paper or linen over the upper surface of the mosaic
stones and repeating the same operation for the second half without there being
any risk of the mosaic pattern falling into pieces.
Instead of using a stony material which has been previously coloured the same
may be set in the mould before such operation is carried on, that is to say when
the material has a uniform colour, in this case the latter whether Kaolin, clay or the
like is thoroughly mixed with a small quantity of powdered carbon, sawdust, or
with any suitable and easily combustible material and then set in the mould.
The design or pattern is then allowed to dry, and subsequently heated to a
temperature which must be sufficiently high to allow all the combustible material
added to be consumed and the different pieces of the pattern to be converted into
stone.
1.
The stones thus burnt are highly porous and most suitable for the application of
colours the liquid colouring matter when applied thereon being immediately
absorbed.
.
. In order to enable the said stones to become very hard a suitable substance is
added to assist flow of the colour.
I
+
The various stones in the mould which compose the mosaic, are then saturated
with suitable colours by means of a brush or sponge, allowed to dry and finally
burnt afresh.
When cheap mosaic patterns are required, plates of Kaolin, clay or the like are
laid upon the whole pattern or, in case the pattern. is too large several plates may
be used; upon this plate or plates is laid, while the mass, is still of a sufficiently
soft and plastic consistence to be engraved, the corresponding pasteboard and the
pattern is transferred upon the plate below with some pointed instrument; the
plates employed in this case may be of any desired shape quadrangular, circular, or
otherwise according to the outlines of the pattern and providing that they fit one
another. A mosaic pattern thus produced may also serve as a matrix for the
production of other similar patterns or may serve itself as a finished pattern.
In the first case. the reticulated drawing is engraved much deeper than in
ordinary cases.
When glass is employed, the same is poured, pressed or rolled in the corre-
sponding moulds, in a liquid state, or the liquid glass is poured upon a flat iron
table and rolled to the necessary thickness and the mould containing the pattern
which is being reproduced is pressed or rolled in the said glass while the latter is
still in a plastic state; then painted and burnt. Thus the finest glass mosaic or
transparent window glass may be easily manufactured.
Dated this 18th day of October 1884

page_text: Decorations, Ornamental Designs, or Patterns.
I EDUARD GRACH of Triers in the Kingdom of Prussia German Empire
Gentleman do hereby declare the nature of my said invention for "IMPROVE-
MENTS IN THE MANUFACTURE OF MOSAIC AND SUCH LIKE DECORATIONS ORNA-
MENTAL DESIGNS OR PATTERNS, and in what manner the same is to be performed
to be particularly described and ascertained in and by the following statement :-
This invention of improvements in the manufacture of mosaic and such like
decorations designs or patterns for mural and other purposes has reference to
(1.) The employment of alveolate moulds containing within their cells the outlines
of the mosaic pattern or design and in the upper sufaces of which moulds are
formed by a process differing from those heretofore employed, the required mosaic
designs or patterns in accordance with the Roman art of mosaic covering that is to
say in pieces of irregular, quadrangular or similar shape.
1
(2.) An easy mode of production of such alveolate or reticulated moulds (which
may be compared to honeycombs) carried out by first drawing the mosaic design
full size upon plates or pieces of dried soap, wax, wood, gypsum or the like, then
carving out engraving or stamping the design to the desired depth and afterwards
pouring liquid plaster of Paris or other suitable substance upon the surface
(previously oiled) of the said plates or pieces of soap or other material, the mass
being then finally allowed to set and harden.
(3.) The mode of setting the different artificial stones used and previously
colored, in the various cells of a honey-combed mould according to the arrange-
ment and the shades of the design, these stones being in some cases left in the
mould or more generally removed from the same in the form of a slightly cohesive
layer of loose pieces arranged in close proximity to one another, in such a manner
that a basis of paper, clay, or the like may be temporarily or permanently fixed to
the said stones by means of some adhesive substance, either before or after the
setting is hardened. This last operation completes the mosaic pattern.
(4.) The mode of coloring the stones, which are of a uniform colour when set in
the mould but are painted after a first baking and subsequently baked anew.
When the mosaic subject is of very large dimensions it is formed in several parts,
these parts being fitted together after completion.
The mosaic pattern or design produced according to this invention may serve for
paving, flagging or-tiling purposes, in the manufacture of table tops, for mural
decorations, or in the manufacture of articles used for building purposes or in other
trades or, when made of glass, as transparent or translucent windows and the like.
The process of preparation of moulds and mosaic, and the mode of employing the
same are as follows:
Full size detailed drawings are made of the mosaic design which is required to
be manufactured or reproduced, these drawings being afterwards transferred either

page_text: in parts or in toto upon plates of soap, wax, wood, clay, gypsum, or other suitable
material. These drawings which are of alveolate or reticulated form, are carved
out engraved or stamped in these plates to the desired depth according to the
thickness of the mosaic required.
When ornamental but not Roman subjects or designs are required, the reticulated
drawing is carved out engraved or stamped on a larger scale, cells being either
partly or altogether dispensed with.
The partition walls of the cells will present the form of recesses on the first
plate.
Melted wax, liquid plaster of Paris, or other suitable substance is now poured
upon the oiled surface of the plate and allowed to cool or set, thus forming tho
desired mould. When moulds, consisting of wax, plaster of Paris, or the like are
not to be used directly for the reception of the material serving to form the small
mosaic of the subject or design, a matrix may be formed by covering the above
moulds with a layer of copper by galvanoplasty, and employed for the reproduction.
of moulds by means of paper pulp or other suitable material of soft consistence
which is pressed into the said matrix.
When the mould is formed the material previously colored is pressed or cut and
placed in the hollow cells (which may be slightly tapered at their lower part) in
such a manner that each cell receives its corresponding colour, so that when the
mould is filled up the mosaic design is complete. When it is required to utilise
the mould as part of the completed article that is to say when the material pressed
or poured in the mould is intended to remain in the same in order to form inlaid
plates which may be used for table tops, cupboards and the like, the mould is
manufactured either of thin paper pulp, metal or other material which can be firmly,
fixed to the bottom and sides of the cells and thus form a hard mass. When
metallic moulds are used they may be lightened by grinding down the partition.
walls of the cells..
When the mosaic subject design or pattern has to be removed from its mould
and used as a loose layer of small stones a piece of paper or linen provided with
some adhesive substance is laid on the top of the mosaic layer after the stones in
the cells have become hardened and compact. This paper or linen is pressed firmly
upon the said layer to prevent the subject pattern or design from falling to pieces
when the mould is reversed and the stones are then removed and laid where
required.
The mosaic thus produced is set when used for paving, mural decorations or
other purposes in the surface which requires decorating by means of cement,
mortar.or putty, and according to this process the pattern or design may be erected
in one piece, when not too large, the paper which holds the different pieces of stone
together being afterwards removed.
The interstices in .the mosaic tiles used for mural decoration or paving purposes
may be filled according as required, with cement or other material and in the case
of articles of considerable value such as table tops or the like, they may be filled
with metal.
When it is required to obtain a fac-simile of ancient Roman mosaic as laid on
walls or paving tiles, the process is as follows:
Sheets of wet blotting paper are laid upon the mosaic and made to adhere
thereon by means of a brush, and in order to strengthen the mould thus obtained,
several sheets of blotting paper are pasted upon the first, a brush being again used
to make them adhere, and the whole is finally dried. The mosaic may be previously
painted with chalk colors. In this case the matrix when withdrawn gives a true
copy of the mosaic with its natural colors.. Liquid plaster of Paris is subsequently
poured upon the matrix thus produced and the reticulated impression is cut out by
means of an engraver's tool, a mould being thus formed which permits a true repro-
duction of the original to be obtained. When a double metallic mould is employed

page_text: it is made of two parts,, the layer of stones being removed when required by
first withdrawing one half of the mould and pasting a piece of paper or linen
over the upper surface of the mosaic stones and then repeating the same operation
for the second half without there being any risk of the mosaic pattern falling
to pieces..
Instead of using stones
stones which have been previously colored the material may be
set in the mould uncoloured that is to say when it has a uniform colour.. In this
case the material whether kaolin clay or the like is thoroughly mixed with a small
quantity of powdered carbon, sawdust or with any suitable and easily combustible
material and then set in the mould.
The design or pattern is then allowed to dry, and is subsequently heate
heated to a
temperature which must be sufficiently high to allow all the combustible material
added to be consumed and the different pieces of the pattern to be vitrified.
In t
The stones or blocks thus burnt are highly porous and most suitable for the
application of colors, the liquid coloring matter when applied thereon being imme;
diately absorbed. In order to enable the said stones or blocks to become very
hard a suitable substance is added to assist the flow of the color. The various
pieces in the mould which contains the mosaic are then saturated with suitable
colors by means of a brush or sponge, allowed to dry and finally burnt afresh.
.
When cheap mosaic patterns are required, plates of kaolin clay; or the like are
laid upon the whole pattern or if the pattern be too large several plates may be
used; upon this plate or plates is laid; while the mass is still of a sufficiently soft
and plastic consistence to be engraved, the corresponding paste board and the
pattern is transferred to the plate below with some pointed instrument. The
plates employed in this case may be of any desired shape quadrangular, circular or
otherwise according to the outlines of the pattern and providing that they fit one
another. A mosaic pattern thus produced may also serve as a matrix for the
production of other similar patterns or may serve itself as a finished pattern.
"
In the first case the reticulated drawing is engraved much deeper than in
ordinary cases.
When glass is employed, it is poured pressed or rolled on or into the corre
sponding moulds, in a liquid state, or the liquid glass is poured upon a flat
iron table and rolled to the necessary thickness. The mould containing the
pattern which is being reproduced is then pressed or rolled on or into the glass
while the latter is still in a plastic state; and finally the mosaic is painted and burnt.
Thus fine glass mosaic or transparent or translucent window glass may be easily
manufactured.
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
In the manufacture of mosaic and such like decorative ornamental designs and
patterns:
1. The production of an alveolate or reticulated mould by drawing the mosaic
upon soap, wax, wood, gypsum or the like, then carving, engraving or stamping
the design to the desired depth, and then pouring, laying, or depositing liquid
plaster of Paris, metal, or other suitable material upon the said design and allowing
it to harden substantially as described.
2. Forming a mosaic by placing coloured stones or pieces of suitable material in
due order in a honeycombed mould, such as referred to in the preceding claim; and
causing them to adhere together sufficiently for removal by the application of a
temporary or permanent backing substantially as described.
3. Forming a mosaic by constructing a mould as described in the first claim and
arranging within it stones or pieces of suitable material, which are firmly embedded
in the mould; the said mould forming a part of the completed mosaic substantially
as described..

page_text: 4. Forming a mosaic by pressing into a mould of the kind referred to in the first
claim a plastic substance mixed 'with a material, such as sawdust, which will be
destroyed by heat, burning the mosaic, applying colour to the various parts, and
finally burning it again substantially as described..
5. Obtaining a fac-simile copy of a mosaic pattern or other ornamental design by
using an impression taken with paper from the original design substantially as
described.