US2217164A - Process for producing facsimiles - Google Patents

Description

Oct. 8, 1940- c. GONGOLSKY PROCESS FOR PRODUCING FACSIIILBS Filed Jan. 5, 1938 2 Sheets-Sheet 1 CHRlS Goneousxy INVENTOR ATTORNEYS Oct 8, c. GONGQLSKY 2,217,164

\ radcsss FOR Paonucfne mcsnuus Filed Jan. '5, 1938' 2 Sheets-Sheet 2 CHRIS GON GOL$KY ATTORNEYS Patented Oct. 8, 1940,

UNITED STATES PATENT- OFFICE 2,217,164 PnocEss FOR PRODUCING FAcsimLEs Chris Gongolsky, Brooklyn, N. Y. I Application January 5; 1938, Serial No. 183,523

3 Claims.

This invention relates to improvements in processes for making molds and more particularly to improvements in processes for making finely detailed molds of ornamental bas-reliefs, such as so-called Wedgwood ware and the like.

It is a major object of the present invention to provide a process for producing facsimile basreliefs which shall be economical and adapted to the requirements of mass production and which shall also provide a method for obtaining molds, faithful in detail, of relatively small ornamental objects.

It is another object of the present invention to provide a method of obtaining positive and negative relief facsimiles of ornamental structures without materially altering the original structures, that is to say, it is an object of the invention and a feature of the process in accordance therewith that an object such, for example, as

' a wedgwood plaque, vase or the like can be reproduced either as a negative or as a positive facsimile of the original without necessitating any substantial alteration in the appearance or structure of the original object from which the facsimile is made.

It is another object of the present invention to provide a method for producing metallic facsimiles of objets dart which are faithful in detail to the details of the original piece but which are economical as regards manufacture and especially are adapted to the requirements for mass production.

It is a further object of the process according to the present invention to provide means for the electrolytic production, in one piece, of metallic relief facsimiles whereby an irregular object, especially one having reliefs and under-cut figures on the surface thereof, can be substantially reproduced without the necessity of separately molding a plurality of portions of the object and subsequently joining the sections of the mold together as is now the practice, or of molding the object to produce a one-piece negative facsimile and then cutting the mold or facsimile into sections to permit removal of the object after molding. It is also notable that in the process according to the present invention the aforesaid single piece metallic facsimile relief, positive or negative, can be built up by processes including electro-deposition or spraying of hot metal upon the mold surface.

The invention will be fully and comprehensively understood from a consideration of the following detailed description when read in connection the rubber positive therefrom;

with the accompanying drawings which form part of the application. v

In the drawings- Fig. 1 is a side view of an object carrying basreliefs and under-cut figures on the surface thereof, being either the original object of which the facsimile is to be madev or the final positive facsimile product;

Fig. 2 is a side view of the object illustrated in Fig. 1 showing, in section, a portion of the nega- 10 tive mold in place;

Fig. 3 shows the inflated rubber negative mol with supporting means after removal of the object being molded;

Fig. 4 shows the rubber negative mold of Fig. 3 with additional supporting means positioned circumjacent thereto;

Fig. 5 illustrates diagrammatically the preparation of a metallic positive from the negative mold;

Fig. 6 illustrates substantially the same step in the process as illustrated in Fig. 5 except that a substantially flat instead of a hollow vase-like relief-carrying object is shown;

Fig. 7 illustrates a clay negative mold or facsimile with a rubber positive facsimile positioned therein, parts being broken away for clearness;

Fig. 8 is a side view of a rubber positive facsimile after removal of the mold;

Fig. 9 is substantially a side view of the rubber facsimile shown in Fig. 8 during the step of forming a metallic negative moldby spraying said rubber positive facsimile with metal;

Fig. 10 shows substantially the same step as Fig. 9 except that the object being treated is a 35 substantially flat relief surface instead of a hollow vase-like object;

Fig. 11 is substantially a vertical sectional view of a metallic negative facsimile after removal of Figs. l2, l3 and 14 are vertical sectional views 40 showing different methods of supporting rubber positive facsimiles; and

Fig. 15 is substantially a diagrammatic elevational view showing electrical circuit and apparatus used in electro-deposition of metal upon facsimiles in one step of the process according to the present invention.

' Regarded in certain of its broader aspects, the present invention comprises processes for preparing positive relief-carrying facsimiles by means including rubber molds whereby the object of which the facsimile is to be made is not substantially altered in any way during the process.

The process according tothe present invention 55 can comprise one of two modifications, the first including the substantially direct preparation of a positive facsimile from the object to be copied and the other comprising intermediate steps including the preparation of metallic negative facsimiles.

In the following description, which is given purely by way of illustration and in order to facilitate comprehension of the matter of the present invention, these processes will be discussed and described in the order named; it being clearly understood that the specific embodiments of the present invention hereinafter referred to are non-limitative.

According to the first of the hereinbefore mentioned processes, which 'is best illustrated in Figs. 1 to 6 inclusive, it is desired to prepare a metallic positive facsimile of an object, such as the vaselike structure 20, having under-cut portions generally designated 2| and carrying reliefs, one of which is indicated at 22, on the surface thereof. In the first step of the process the object 20 is dipped in a solution or suspension of latex or similar material high in rubber content, sprayed or otherwise coated therewith whereby, referring now to' Fig. 2, a film of plastic rubber-like material 25 is formed on the outer surface of the object of which it is desired to prepare a facsimile. It will, of course, be understood that, if desired, other coating compositions instead of the aforementioned can be used, the determining factor in each instance being that the composition used should produce an extensible rubber-like coating substantially free from air bubbles and the like. It will be noted that the plastic rubber-like film or coating substantially envelops the object and penetrates into even the smallest of the interstices of the reliefs carried on the surface of the object especially when the fluid used is characterized by relatively low viscosity and surface tension. It will be apparent, of course, that the dipping or spraying can be continued until a film of substantially any desired thickness and strength is formed upon the surface of the object. The film or coating so prepared can then be dried or otherwise solidified and vulcanized, the latter being preferably accomplished by incorporating high speed low temperature vulcanization accelerators or analogous materials in the rubber mixture prior to the coating operation, and thereafter peeled off or otherwise removed from the object.

It will be apparent that the solidified film forms a negative facsimile of the object 20, that is to say, the inner surface of the film will have depressed and/or raised portions formed therein corresponding in location and magnitude to the raised or depressed configurations on the surface of the object.

As hereinabove mentioned, after formation of the film on the surface of the object and solidification thereof, the film is removed in one piece by stretching and/or peeling over and from the object being reproduced. The solidified negative facsimile so prepared, generally designated at reproduced, and also furnishing some, though small, support for the negative during the next step in the process.

The outside parts of inflated negative 30 are then treated with a substantially fluid but solidifiable material whereby a self-supporting coating, generally designated at 35, is formed thereon, the negative being maintained inflated until the material is at least largely solidified. It is preferred to form the coating of a material such as wax or similar easily fusible substance whereby the inflated negative facsimile can be coated with molten material and .the material allowed to cool thereby hardening. The coating so formed, which is preferably at least substantially adherent to the negative facsimile, serves to protect and support same and to minimize distortion thereof during subsequent steps in the process.

The next step in the process involves the preparation of the final positive facsimile from the negative facsimile prepared as hereinbefore described. Referring now to Fig. 5, after the supporting medium surrounding the negative facsimile has hardened sufficiently, as indicated by experience, the relationship between the block-like member SI and the negative is severed and the interior of the negative mold supported in the aforesaid manner is sprayed or otherwise coated with metal. It will be noted that the object 40 so formed is substantially a metallic positive facsimile of the original object 20 and is provided with raised and depressed localities corresponding to projections and depressions on the original both in magnitude and location. Although it is preferred that the metallic positive facsimile be prepared by spraying the metal on the negative facsimile, it will be apparent of course that other methods of coating can be employed. For instance, the interior of the negative facsimile can be dusted with finely divided graphite or similar material and, using the conductive coating as a cathode, metal can be electro-deposited therein. Or if otherwise deemed preferable, metal can be directly molded in the negative facsimile, it being understood of course that a metal of relatively low fusing point be used, for instance so-called Wood's metal and the like. In the preferred process however, a so-called atomic sprayer is employed which usually comprises a stream of superheated metal fed into a current of gas such as air under high pressure whereby molten metallic particles are thrown against the surface. The metal so employed is usually heated to a temperature substantially higher than the melting point of the metal in order that the particles will retain their fluidity and properly coalesce upon striking a relatively cold surface, in this instance the negative facsimile. It will, of course, be apparent in spraying in this manner a mold or negative facsimile supported by a material characterized by a relatively low temperature of fusion, that the exterior of the mold, especially the readily fusible supporting means should be cooled, particularly if the metal being used has a relatively high melting point.

Substantially the same step, namely, prepara tion of the metallic positive facsimile by coating the negative facsimile with metal, is diagrammatically illustrated in Fig. 6, the difference being that in this instance the object being reproduced isa relatively flat surface having reliefs thereon.

Having thus described the first type of process according to the present invention, the second the outer parts thereof with supporting material type wherein metallic negative facsimiles are madewillnow be described. In this connection reference is made to Figs. '7 to inclusive,

' wherein certain features of the second type of.

process are best illustrated. a

In the process according to this embodiment of the present invention, theobject of which it is desired to prepare a facsimile reproduction, is treated in substantially the-same manner as hereinbefore described whereby a substantially elastic rubber-like negative film or facsimile is prepared, said negative facsimile being coated on as in accordance with the hereinbefore described embodiment.

The supported negative facsimile is then filled with an easily destructible medium adapted to fill and register the various indentations and projections in the body of the negative. For example, experience indicates that a composition of this nature can be prepared from ingredients including glue and/or commercial gelatin which when heated is substantially fiuid, or at least plastic, butwhen cooled exhibits gel-like characteristics. After the gel has set or substantially solidified within the negative facsimile mold, the supporting material is removed from the outside parts -.of the mold and the mold itself removed from the gel by peeling or stretching therefrom, care being exercised in this step of the process to prevent injury to the facsimile details on the gel.

It will be apparent that the gel so prepared will be substantially a positive facsimile or reproduction of the original object from which the rubber mold was prepared. The gel is then coated on the outside with clay or similar porous material,

for example plaster of Paris, whereby the details and surface characteristics of the gel are reproduced in the coating material. Inthis manner a substantially porous, hard negative facsimile is prepared from the gel and after complete solidification and hardening of the negative, the gel is removed therefrom by any convenient physical or chemical means and the interior of the cleaned dried negative is coated with a rubber-like composition substantially as used in the preparation of the plastic negative mold described in connection with the first embodiment of the present invention, whereby a substantially plastic positive facsimile of the original object is produced. It will be noted that the depressions and proturberances in the original object are faithfully duplicated and reproduced in the rubber positive facsimile -both as regards magnitude and locality.

The positive facsimile positioned within the mold is illustrated in Fig. 7 wherein the facsimile is designated by the numeral 50 and the mold by the numeral 5|.

For purposes of illustration one method of preparing a positive rubber facsimile has been hereinabove described but it will be apparent to those skilled in the art that other processes of producing this result can,be employed without substan-' tial departure from the spirit or scope of the present invention. t

The rubber positive facsimile is removed from the plaster of Paris or clay mold preferably by peeling and stretching it from the walls of same and after removal presents substantially the appearance illustrated in Fig. 8. V

In the next step of the process the positive facsimile-is supported, for example, by associating same with a block 60 having an opening therein communicating with a source of gas under pressure, generally designated at 6|, in a manner I tallic positive facsimile therefrom.

substantially analogous to that described in connection with the first embodiment of the inventio port can be employed, for example referring to Fig. 12, the positive facsimile can be filled with sand or the'like or, referring to Fig. 13, the positive, 50, can be filled with separable cooperating blocks 63 forming a core generally designated at 64. Fig. 14 shows the positive facsimile 60 supported within a vacuum chamber, it being noted that the chamber 65 connected with a vacuum line by the tube 66 is at a substantially lower pressure than atmospheric and that the interior parts of positive facsimile 50 are open to the atmosphere whereby the facsimile is supported substantially as shown.

The next step in the process comprises treating the supported positive facsimile with an easily fusible metal whereby a self-supporting coating of metal is formed on the surface of the facsimile thereby producing a metallic negative facsimile. This step in the process is illustrated in Figs. 9

a vase-like object and the latter in connection with a flat plaque-like object 10, whereon is shown a coating of metal II. It is preferred that the metal be deposited upon the positive facsimile by spraying although, of course, other methods of deposition can be employed if deemed desirable.

When the outer surface of the positive facsimile has been substantially coated with metal Ifdesired, however, other means of supand 10, the former showing it in connection with and the metal fully solidified to provide a selfsupporting negative facsimile therearound, the positive facsimile is withdrawn from the interior of the negative facsimile by peeling or stretching the former, the latter, generally designated at I0, after removal of the positive facsimile Presenting substantially the appearance shown in Fig. 11.

It will be apparent that in following the hereinabove described steps in the process according to this embodiment of the present invention, a metallic negative facsimile 10 of the original object has been prepared, the interior of which is 7 characterized by depressions and protuberances corresponding both in magnitude and locality to protuberances and, depressions in the original object of which the positive facsimile is being prepared.

It is preferred in preparing the metallic negative facsimile as hereinbefore described that the characterized by substantially low melting point,

- 22.9% tin, and the balance lead.

Having prepared an easily fusible negative facsimile as hereinbefore described, the next step in the process comprises the preparation of a me- In this connection reference is made to Fig. 15 wherein a system for electro-depositlon is diagrammatically illustrated.

Referring now to Fig. 15, a pair of substantially readily fusible metallic negative facsimiles 80 and BI are shown positioned upon an electrically con- 50 metal used in the fabrication of the facsimile be I ductive plate 82 associated with one pole of a generator 83, the other pole of said generator being electrically connected to a pair of anodes 84 and 85. It will be noted that, with connections established as aforesaid, the negative facsimiles 88 and 8| serve as cathodes and the members 84 and 85 as anodes when an electrolyte at least partially fills the interiors of said negative facsimiles. A tank 81 associated with the supply line 88 is provided to feed the lines 89 and 9ll,'connected to the caps 9| and 92 covering and sealing the negative facsimiles 88 and 8| substantially as shown, it being understood of course that although a gravity feed system is 11-. lustrated, other means can beemployed if desired to insure flow of electrolyte into the negatives. Similarly, outlet lines 93 and 94 carry spent liquor to the line 95 from whence it passesto a storage tank 96 and thence by means of a It will be apparent, of course, that although only two negative facsimiles are shown in the illustration a greater or lesser number can be used if desired by proper extension of the plate 82, the lines 88 and 95 and cooperating lines. In use a fluid electrolyte is placed in the tank 81 whereby, through gravity, it flows through the lines 89 and 90, circulates within the interiors of the negative facsimiles and 8|, passes out through the lines 93 and 94 to the line 95, thence to the storage tank 96 from which, by means of the pump 91, it is returned to the tank 81. It will be understood, of course, that air or other gases, trapped within the facsimiles 88 and 8| above the open end-of the lines 93 and 94, will be at least mostly removed prior to sealing the covers 9| and 92 upon said facsimiles.

Positive facsimiles are prepared from the substantially easily fusible negative facsimiles, prepared as aforesaid, by electro-depositing metal upon the interior parts of the negative facsimiles, utilizing, in substance, the apparatus illustrated diagrammatically in Fig. 15. It will, of course, be understood that the weight or thickness of the positive facsimile so prepared can be varied by altering and controlling the current flowing through the electrolyte, as well as the time in which the current is passed. It is also to be understood that the anodes 84 and 85 can be varied in composition to accord with the composition of the electrolyte and the metal in which it is desired to deposit. For example, if it is desired to deposit gold, gold anodes are used and an electrolyte of potassium auri-cyanide is used, or if preferred a bath of aurictri-chloride is used. Similarly, if it is desired to produce a facsimile in nickel, nickel anodes are employed and a bath of nickel sulphate or similar material commonly known and used in electro-deposition. Other electrolytes and anodes can be used in a similar manner. Experience indicates that suflicient agitation of electrolyte occurs by disposing the outlet parts of the lines 89 and 98 and the inlet parts of lines 93 and 94 substantially as shown.

It will be apparent that after electro-deposition of metal within the interior of the metallic negative facsimile, the product will be a substantially composite structure comprising a relatively easily fusible shell with a metallic positive facsimile positioned therein. The positive facsimile having been prepared of relatively infusible metal such as, for-example, copper, nickel, gold, platinum or the like, it is removed from association with the relatively fusible negative facsimile by melting the latter. The product so obtained is characterized in possessing indentations, depressions, protuberances and projections similar to and corresponding in magnitude and locality to analogous contour characteristics of the object before described are especiallywell adapted to the needs of mass production, for example, in the first described embodiment of the present invention it will be noted that the rubber negative facsimile 30 can be used many times without replacement by returning the facsimile after use in the step illustrated in Figs. 5 and 6 to the step illustrated in Fig. 3 and repeating the subsequent operations. Thus it will be seen that in the first described embodiment of the invention the preparation of the negative facsimile is the" only step in the process not cyclical.

Similarly, in the second described embodiment of the invention it will be noted that the rubberlike positive facsimile, after use in the step illustrated in Figs. 9 and 10, can be used again merely by removing the facsimile from the interior of the substantially fusible metallic negative facsimile, supporting it and again spraying it with metal. It will, of course, be obvious that the fusible metal used in the preparation of the negative facsimile in the step illustrated in Figs. 9 and 10, can be recovered after removal from the electro-positive facsimile, to be subsequently re-used.

It will also be obviousto those skilled in the art that the weight and/or thickness of the metallic positive facsimiles produced according to 3 the hereinabove described processes can be varied according to the user's requirements, these characteristics being merely dependent upon the amount of'metal deposited, whether by' spraying, electro-deposition or other means, upon the negative facsimiles.

As hereinbefore mentioned, either or both of the processes hereinabove described can be utilized for the reproduction of relief-carrying objects whether the reliefs be 'stiacciato as in coins, bassoor mezzo-rilievo, wherein the figures are in relatively low relief, that is to say the cutout figures are exposed to 'an extent substantially not more than half their circumference, as well as in relatively high relief or alto-rilievo, wherein the figures are exposed to an extent substantially greater than half their circumference. It is in applications of the last mentioned type that the presentinvention is of especial value inasmuch as it provides means, it is thought, for the first time, or preparing facsimiles of this type of relief.

It is to be understood that this improvement is capable of extended application and is not confined to the exact showing of the drawings nor to the precise construction described and, therefore, such changes and modifications may be made therein as do not affect the spirit of the invention nor exceed the scope thereof as expressed in the appended claims.

What is claimed is:

1. Process for preparing one piece positive facsimiles of undercut objects having relief figures on at least one face thereof, comprising forming a substantially elastic one piece negative facsimile directly on said-object, extending parts of said one piece negative facsimile whereby saidobject can be removed therefrom without substantially altering the. relationship of parts and figures on said object, supporting said negative facsimile whereby the figures and parts thereon are disposed in relationship relative to each other substantially corresponding to the relationship between similar parts on the object, preparing a substantially elastic one piece positive facsimile from said negative facsimile, supporting said positive facsimile whereby cutaway parts and relief figures thereon are disposed in a relationship corresponding to that of equivalent parts on the object, coating said elastic positive facsimile with a relatively easily fusible metal whereby a metallic negative facsimile is produced, stretching parts of said one piece positive facsimile whereby said metallic negative facsimile can be dissociated therefrom, removing said negative facsimile, electro-depositing relatively difiicultly fusible metal upon portions of the surface of said metallic negative facsimile, and fusing said negative facsimile whereby said relatively difiicultly fusible positive facsimile can be separated therefrom.

2. Process for preparing one piece positive facsimiles of undercut objects having relief figures on at least one face thereof, comprising forming a substantially elastic one piece negative facsimile directly on said object by coating same with a solidifiable rubber-containing mixture, at least largely solidifying said coating, extending parts of said one piece negative facsimile whereby said object can be removed therefrom Without substantially altering the relationship of parts and figures on said object, supporting said negative facsimile whereby the figures and parts thereon are disposed in relationship relative to each other substantially corresponding to the relationship between similar parts on the object, covering the useful faces of said negative facsimile with a solidifiable material, solidifying said material, removing said negative facsimile therefrom whereby a positive facsimile formed of said material is obtained, supporting said positive facsimile whereby figures and cutaway parts thereon are disposed in substantially the relationship of corresponding parts on the object, coating said positive facsimile with a hardenable composition, hardening said coating, removing said positive facsimile from relationship with the material coating same without severing said coat- 7 ing, covering portions of said hardened coating with solidifiable plastic material, solidifying said material, removing said coating from said solidified plastic material, spray-coating said solidified plastic mass with relatively fusible metal whereby a metallic negative facsimile is obtained, stretching parts of said one piece positive facsimile whereby said metallic negative facsimile can be dissociated therefrom, removing said negative facsimile, electro-depositing relatively difficultly fusible metal upon portions of the surface of said metallic negative facsimile, and fusing said negative facsimile whereby said relatively diflicultly fusible positive facsimile can be separated therefrom.

3. Process for preparing one piece positive facsimiles of undercut objects having relief figures on at least one face thereof, comprising forming a substantially elastic one piece negative facsimile directly on said object, extending parts of said one piece negative facsimile whereby said object can be removed therefrom without substantially altering the relationship of parts and figures of said object, supporting said negative facsimile whereby the figures and parts thereon are disposed in relationship relative to each other substantially corresponding to the relationship between similar parts on the object, preparing a substantially elastic one piece positive facsimile from said negative facsimile, supporting said positive facsimile whereby cutaway parts and relief figures thereon are disposed in a relationship corresponding to that of equivalent parts on the object, coating said elastic positive facsimile with a relatively easily fusible alloy of bismuth, lead, and minor proportions of other metals whereby a metallic negative facsimile is produced, stretching parts of said one piece positive facsimile whereby said metallic negative facsimile can be dissociated therefrom, removing said negative facsimile, electro-depositing relatively difficultly fusible metal upon portions of the said metallic negative facsimile, and fusing said negative facsimile whereby said relatively diflicultly fusible positive facsimile can be separated therefrom.

CHRIS GONGOLSKY.

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