IMPROVEMENTS CARBONS APPLICABLE FOR ELECTRIC CANDLES POLES BATTERY PLATES AND ACCUMULATORS
Year: 1882

page_text: LETTERS PATENT & Frederick Henry Varkey of 4 Mildmay Grove in the
County of
Middlesex, Electrical Engineer for an Invention of IMPROVE-
56
TEEDS
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PATENT to Frederick Henry Varkey of 4
Mildmay Chove in the
County of Middlesex, Electrical Engineer for an Invention of "IMPROVE-
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MANUFACTURING GARDENS, APPLICABEN
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County of Middlesex, Electrical Engineer for an Invention of
MENTS IN MANUFACTURING CARDONS, APPLICABER FOR
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County of Middlesex, Electrical Engineer for an Invention of
MENTO IN
CARBONS, APPLICABLE FOR DELCTRO CANDEL
PROVISIONAL SPECIFICATION left by the said Frederick Henry Varley at
the Office of the Commissioners of Patents on the 13th June 1882.
FREDERICK HENRY VARLEY of 4 Mildmay Grove in the County of Middlesex,
Electrical Engineer, "IMPROVEMENTS IN MANUFACTURING CARBONS APPLICABLE
FOR ELECTRIC CANDLES POLES BATTERY PLATES AND ACCUMULATORS,"
The object of this Invention is the production of carbon rods poles or plates of
required size or form, of solid perforated or cellular structure suitable for electric
light candles or plates or poles in galvanic batteries secondary batteries or
accumulators.
My Invention consists mainly in calcining or charring vegetable or other fibres
saturated with a hydrocarbon substance or fluid twisted into rope or string, plaited
into bobbin or gimp woven into fabrics, or knitted or felted together, according to
the special purpose intended in their subsequent employment.
The carbon candles, rods or bars I prefer to make as follows:-A string
cord, rope, or band made in the usual way by twisting or in some cases plaited
knitted or felted together when cotton or flax is employed.-The former I
generally prefer.-I first stretch the rope cord or band on a bar or frame or suitable
appliance for stretching, and whilst so stretched, submit same to the action of
caustic alkali, preferably in a solution of high temperature, after which it is rinsed
or washed to reinove the alkali and dried. It is then submitted to the action of
sulphuric acid, and again rinsed and dried-When thus prepared it is iminersed in
a hot solution of petroleum and tar or other suitable hydrocarbon, until it becomes
saturated It is then placed in a carbonizing chamber or retort. This chamber or
retort is constructed of iron or porcelain, or any suitable refractory substance which
will bear a considerable degree of heat, the opening of the retort being provided

page_text: with a cover or cap, which may be hinged as a door or otherwise fitted so as to be
air tight, and also provided with an inlet and outlet channel or pipe for the
circulation of a stream of coal gas or a hydrocarbon gas or vapour, which is caused
to flow during the time the carbonizing chamber is heated, for charring the fibres,
and converting same into conducting carbon, the vapour of the hydrocarbon adding
to the cementation of carbon fibres.-The rods or bars produced thus are cellular,
and require to be removed whilst warm and again immersed in the liquid hydro-
carbon, until the cells or pores are filled, when same are again placed into the
carbonizing chamber and reheated, and by a succession of heatings and immersions,
the cells become filled with conducting carbon, and the rods or bars become solid
and specially adapted for burning in are lamps
In making galvanic battery plates, I employ preferably solid or thick woven
fabrics of sufficient substance, such as solid woven cotton or flax driving bands,
These bands may be cut into the required size, treated in the manner already
described for carbon rods and converted into carbon plates-These are cellular or
porous and according to the purpose for which they are to be employed are rendered
more or less solid by repeating the charring and immersion process-When a large
surface is required in a compact form, 1 employ preferably four lengths of the
cotton or flax driving bands, or similar woven, sewn, felted, or knitted fabric rolled
into a volute or coil, or folded backwards and forwards.
They are then subjected to the treatment already described, and converted into
conducting carbon, either cellular or solid, according to the purpose required, each
alternate coil or volute or folded carbon is removed thus in the volute form beginning
with the interior, calling it No. 1, the next No. 2, and so on; it obvious that by
taking Nos. 1 and 3, 2 and 4, and placing the volutes within each other, they will
leave a space for the polarizing liquid. In employing these carbons for an accu-
mulator battery, the cellular carbon is preferable, as it affords more polarizing or
accumulating surface. The polarizing fluids which I have found most efficient are
as follows (but these may be varied, and others equally suitable for these special
carbon accumulator plates inay be employed.
(No. 1) solution of sulphate of mercury and sulphate of zinc in dilute sulphuric
acid.
(No. 2) sulphate of manganese, sulphate of zinc and sulphate of mercury in dilute
sulphuric acid.
(No. 3) sulphate of manganese dissolved in dilute sulphuric acid.
(No. 4) sulphate of zinc and sulphate of manganese dissolved in dilute sulphuric
acid.
(No. 5) sulphate of manganese dissolved in water
(No. 6) sulphate of zinc dissolved in water.
By applying the current either from a battery or other suitable source of
electricity, a large storage of force can be obtained by means of these carbon plates.
-Carbons for battery plates may be constructed of any form desired by shaping
the fabric previous to its subjection to the heating process-And in some cases it
is not necessary to submit the cotton or similar fibres to the alkali and acid
treatment simply immersing in the hydro-carbon fluid and charring being all that
is necessary.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said Frederick Henry Varley in the Great Scal Patent Office on the
13th December 1882.
FREDERICK HENRY VARLEY of 4 Mildmay Grove in the County of Middlesex
Electrical Engineer, IMPROVEMENTS IN MANUFACTURING CARBONS, APPLICABLE
FOR ELECTRIC CANDLES, POLES, BATTERY PLATES AND ACCUMULATORS
The object of this Invention is the production of carbon rods poles or plates
of required size or form of solid perforated or cellular structure suitable for electric
light candles or plates or poles in galvanic batteries secondary batteries or
nccumulators, also applicable to telephone and microphone transmitters. My
Invention consists mainly in caleining or charring vegetable or other fibres
saturated with a hydrocarbon substance or fluid, twisted into rope or string, plaited
into bobbin or gimp, woven into fabrics, or knitted, or felted together, according
to the special purpose intended in their subsequent employment.—The carbon
candles rods or bars I prefer to make as follows:-A string, cord, rope, or
band made in the usual way by twisting, or in some cases plaited, knitted or
felted together, when cotton or flax is employed.-The former I generally prefer.―
I first stretch the rope, cord or band on a bar or frame or suitable appliance for
stretching, and whilst so stretched, submit saine to the action of caustic alkali,
preferably in a solution of high temperature, after which it is rinsed or washed to
remove the alkali and dried It is then submitted to the action of sulphuric acid
and again rinsed and dried.-When thus prepared, it is immersed in a hot solution
of petroleum, and tar or other suitable hydrocarbon, until it becomes saturated It
is then placed in a carbonizing chamber or retort.-This chamber or retort is
constructed of iron or porcelain, or any suitable refractory substance which will
bear a considerable degree of heat, the opening of the retort being provided with
a cover or cap, which may be hinged as a door or otherwise fitted so as to be air
tight and also provided with an inlet and outlet channel or pipe for the circulation
of a stream of coal gas, or a hydrocarbon gas or vapour, which is caused to flow
during the time the carbonizing chamber is heated, for charring the fibres and
converting same into conducting carbon, the vapour of the hydrocarbon adding to
the cementation of carbon fibres.-The rods or bars produced thus are cellular, and
require to be removed whilst warm, and again immersed in the liquid bydrocarbon
until the cells or pores are filled, when samme are again placed into the carbonizing
chamber and reheated, and by a succession of heatings and immersions, the cells
become filled with conducting carbon and the rods or bars become solid, and
specially adapted for burning in are lamps.-In making galvanic battery plates, I
employ preferably solid or thick woven fabrics of sufficient substance, such as solid
woven cotton or flax driving bands.-These bands may be cut into the required
size, treated in the manner already described for carbon rods, and converted into
carobn plates. These are cellular or porous, and according to the purpose for which
they are to be employed, are rendered more or less solid by repeating the charring
and immersion process. When a large surface is required in a compact form, I
employ preferably four lengths of the cotton or flax driving bands, or similar
woven, sewn, felted or knitted fabric, rolled into a volute or coil, or folded backwards
and forwards. They are then subjected to the treatment already described, and
converted into conducting carbon, either cellular or solid, according to the purpose
required, each alternate coil or volute or folded carbon is removed, thus in the
volute form, beginning with the interior, calling at No. 1, the next No. 2, and so on,
it is obvious that by taking Nos. 1 and 3, 2 and 4, and placing the volutes within
each other, they will leave a space for the polarizing liquid.-In employing these

page_text: serves not only to recharge the carbon preparatory for a second process of car-
bonizing, but also to cool the carbon after leaving the carbonizing chamber a, and
prevent its burning by contact with the air.
Fig. 6. V shaped rests or troughs for holding the carbon rods straight during the
process of manufacture.
Fig. 7, furnace with a horizontal carbonizing chamber, for holding coiled or
folded fabrics. The products of combustion are shown as being introduced under
the grate of furnace, and adding to the amount of combustion.
Fig. 8 represents a vertical carbonizing chamber or converter for holding coils
of flat woven and similar fabric, or may be used to hold bundles of short carbon
rods, in which the gas inlet and outlet pipes are affixed to the lid or cover of the
same, the inlet being of sufficient length to reach near to the bottom of the
chamber. A and B represent the coils in process of carbonizing.
In Fig. 9, A represents a helical coil of carbon.-B, a double helix
Fig. 10 shows the double helix as applied to secondary batteries or accumulators.
Fig. 11 shows the folded form of carbon plates for the same purpose, + and
representing the terminals, which may be clamped on in the usual way, or the
carbons may be electro-plated with copper or suitable metal at the upper or
unimmersed portion, the same being afterwards saturated with paraffin or other
suitable dielectric to prevent the corrosion of the contact, or the carbon nay be
connected by interweaving fine platinum wire into the fabric previous to the
carbonizing process, or contact may be obtained either by casting on lead or other
metal in the usual way.
Figs. 12, 13, and 14 show another method of connecting the helical coils of
carbon by contact frame or clamp.
Fig. 15 shows a pair of coils employed for a secondary battery.
Fig. 16, form of carbon for tension regulator for microphone contacts.
Fig. 17, application of volute or spiral arrangement of carbon for producing the
electric light
In the manufacture of electric conducting carbon by this Invention, I find it
desirable to continue the charring or calcining process over a considerable period
of time, if the cementation of the conducting particles and fibres be effected by the
absorption of the carbon deposited by the hydrocarbon gas entering by the inlet
pipe represented by B in Figs. 1 and 2.
No rule can be laid down as to the length of time necessary to effect the
complete conversion of the fibre into conducting carbon but an exposure of 3 to
hours in an intense heat I find desirable-That also it is not necessary that
the gas which enters by the inlet pipe be a heavy carburetted hydrogen,-
-a gas
which like nitrogen is a non-supporter of combustion may be employed, and the
carbon by continued exposure in the retort to an intense heat, will cement of
itself and become continuously conducting, the heat I have found necessary for this
purpose being that temperature which causes cast iron or steel to inelt.-The
chambers or retorts, when made of wrought iron, welded or rivetted together,
require to be lined inside and coated outside with a. non refractory substance such
as fire-clay, or a mixture of clay and plumbago.-Crucibles made of this mixture,
known as plumbago crucibles I find very efficient, and withstand the heat of the
furnace, and may be employed for several charges, as they bear several reheatings.―
They are well adapted for use in the vertical furnace shown in Figs. 3 and 8.-The
crucibles being made nearly cylindrical form efficient carbonizing chambers, and are
fitted with a metal or plumbago cover, through which are inserted the inlet and
outlet pipes, the former being of sufficient length to reach or nearly reach to the
bottoin of the carbonizing chamber. The cover is rendered air tight by a luting, and
held firmly either by a frame fitting over or a bolt inserted through the cover and
base of the carbonizing chamber, and drawn together by means of nuts, screws, or
wedges, there being several methods by which the cover of the combustion chamber
may be maintained sufficiently firm to keep the luting intact, which are obvious to
any practical operator, and therefore unnecessary to describe.-The conversion of

page_text: cellular into solid carbon rods or plates is effected most readily by the re-immersion
in the hydrocarbon fluid already described.-There are several which I find
suitable for this purpose, and would mention that nearly all fluids capable of
depositing carbon when subjected to heat are available.-Paraffins, turpenes, oils,
fatty substances, treacle, dissolved sugar, dissolved resins, are all useful for this
purpose. The carbon coils made of woven fabric retain a considerable amount of
elasticity, and are rendered more rigid by the immersion and reheating process, but
if the paraffins or turpenes be employed they retain the elasticity though immersed
and reheated several times, but to render the coils rigid, such substances as tar,
resin, or dissolved sugar or treacle are preferable, and to render the carbon solid
with fewer reheatings, I find it desirable to mix fine carbon or farinaceous
substances or powders and dissolved sugar, into a thick and viscous fluid.-The
carbon absorbs it like a sponge filling the interstices. Two or three reheatings
are generally sufficient for flat poles or battery plates. For carbon candles made
of round or twisted rope, or fabrics, the number of reheatings and immersions
depend upon the specific density required.--Burnt treacle or caramel may be used
in place of the carbon powder.-Farinaceous powders or meal may also be mixed
with paraffins, turpenes etc into a paste, instead of sugar, caramel ete, as described
Carbon poles and plates made by this process retain the form of the substance
acted upon, if a tube, such as cotton or flax hose pipe has a bottom of canvas or
woven cotton belting sewn to it, and the same being converted into conducting
carbon, it forms a very efficient porous cell, and may be employed for a galvanic
battery without the necessity of employing a lining made of porous clay
compressed cotton wool or fibre be converted into conducting carbon, it possesses
a peculiar felt like appearance and elasticity, which renders it suitable for employ-
ment in tension regulators or microphone contact poles.-A brush made of cotton
thread as shown in Fig. 16, when converted into conducting carbon, retains
a brush like elasticity, and placed across each other, make very efficient variable
contact poles, and can be employed in microphones in the usual way, the
current represented by + and in Fig. 16 passing from one brush contact to the
other.
-
If
Among several of its applications are those of plates for secondary batteries,
shown in spiral form in Figs. 9, 10, 12, 13, and 15.
Figs. 12, 13, 14, and 15 show a second mode of employing a pair of coils for a
secondary battery-The several turns of the coil are clamped together by means of
a carbon or conducting frame.
A A¹ are two carbon plates, with dovetail or wedge shape slots or holes
into which are fitted dovetail pieces B B' -The piece B is inserted through
centre of carbon coil, and into the hole of plate A and B likewise, but on
the outer edge or periphery of the coil, the opposite plate A¹ is then placed
over the wedge or dovetail pieces B B¹, and the wedges C C are inserted
between coil D, and the dovetail piece B compressing the layers or turns
of the coils into close contact, whilst the dovetailed cross pieces also draw the plates
A A, toward each other, and thus clamp the margin or edges of the coils, forming
a clamping frame, that makes contact firmly with the edges of the layers or sides of
the coil, the clamping plates may be immersed in paraffin or non-absorbent wax, to
prevent the moisture from creeping up and corroding the contacts, as the coiled
plate can be made of several feet of carbonized fibre it offers especially capacity
for storage batteries, as a large accumulative surface can be obtained in a very
compact form. Another application of the coiled carbon is its employment for
electric lamps.
Fig. 17, A and B represent two open coils or volutes. These are attached to
rotatory axis shown in Fig. by lines E F.-The direction of rotation is shown by
the curved arrow.-C D are stops against which the margin of the outer layer of
the coil is made to rest, if rotatory motion in the direction of the arrow be given to
the axis E and F, it is clear that the free ends of the carbon coils will come into
contact, if the same axis be connect d to a source of electricity for producing

page_text: electric light, the poles would burn away as in a contact or semi-incandescent lamp,
or the ends of the coil may be made to open by means of regulating mechanism
controlled by the current, and burn as an arc lamp.
Having now particularly described and ascertained the nature and object of the
said Invention, and in what manner the same is to be performed or carried out in
practice, I hereby declare that I claim:-
(1.) The carbonizing or carbonization of fibres or fibrous material, substantially
as hereinbefore set forth and described
(2.) The use of said fibrous material substantially as and for the purposes
hereinbefore set forth and described.
(3.) The use and manufacture of flexible brushes from carbon fibres, substantially
as, and for the purposes described.
(4.) The use of carbon made from compressed cotton, wool, and such like suitable
material, for microphone contact poles, as described
(5.) Tho application of cellular or porous carbon plates made from fibrous
material, for accumulator plates as described.
(6.) Though I hereby disclaim per se, the carbonizing of fibres or threads for use
in incandescent lamps, yet I do claim, substantially as hereinbefore described, making
large surfaces suitable for secondary and primary battery plates, whereby plates of
considerable magnitude can be produced such surface of carbon being according to
my experience hitherto unobtainable.
(7.) In manner substantially as described, inaking poles of carbon of sufficient
substance for electric candles, to be employed for are and contact lamps.
In Witness whereof I the said Frederic'
TT
7 Varley have hereunto set
my hand and seal this thirteenth day of December one thousand eight
hundred and eighty two.
FREDERICK HVARLEY
(L.S.)