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Патент USA US2405953

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Patented Aug. 20, 1946
2,405,953
UNITED STATES PATENT OFFICE
2,405,953
r ‘ PROCESS FOR MANUFACTURING A CELLU
LOSE ESTER MOLDING BATCH HAVING .A
METALLIC APPEARANCE AND THE BATCH
PRODUCED THEREBY
ri‘homas J. Hillery, Boonton, N. J., assignor to
George Benda, Inc., Boonton, vN. 5., a corpora
tion of New Jersey
N0 Drawing. Application October 2, 1943,
Serial No. 504,782
5 Claims.
1
(Cl. 106-193)
2
This invention relates to a process for manu
than the ?nal brass or gold'tone required, be
cause the molding process will oxidize the bronze
or aluminum ?ake and thereby regulate the
facturing a batch of molded material which gives
a metallic appearance as of brass, bronze, silver,
chrome or gold. The invention also applies to
plastic molding material processed so that any ob;
ject molded of the material gives the appearance
of being made of one of said metals.
bronze or gold shade desired. The same process
also applies to aluminum ortin ?ake when-used
order to obtain a
’ in place of the bronze ?ake in
_
silver or chrome ?nish.
The plastic compound used for this process may
}
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After the ?our molding substance and the
be identi?ed by its urea resin base or cellulose
?akes have been mixed, the complete ‘mixture is
acetate base. Materials of the urea resin ‘base, 10 then-‘polished in a brush mill until the metal
such as formaldehyde urea resin, is preferable in '
?akes are adhering to the ?our substance and
the natural shade and may include any of the
thereby adding lustre when brushed on the metal
varied ?llers used in molding compounds, pre
pared with this base.
The basic substance consisting of urea resin,
The basic molding substance used is ground to
such as formaldehyde urea resin, or cellulose ace
a ?neness of sand particles, which has a ?neness
> tate is ?rst prepared so that it can be ground to
suitable for introduction into a stamping ma
a, ?nish to make it suitable for introduction into
chine. The stamping machine used consists pref
a specially constructed stamping mill to be
erably of a revolving-cam, for lifting and dropping
mashed or crushed. In this mill the substance
a shaft to which are attached steel shoes that 20 is reduced to a ?our-like or ?ake-like consistency
strike against the bottom of a kettle of steel.
of about 200 mesh. Thereupon a binding grease
This process produces a ?aked or ?oured material.
such as lard is added to give the material body.
The thus obtained basic molding material is
_T.he metal ?akes, whether bronze, aluminum or
introduced in this stamping machine together
other metal after completion of the stamping
with a small quantity of binding grease such as
process, are placed in a'polishing mill and pol
lard, for instance, to give to said material body a
ished with stearic acid, a tablespoonful of which
?our like or ?aky consistency. The time required
is added to approximately 15 pounds of metal
for reducing the molding material from a grain
?ake. The polishing process, as stated, is accom
to a ?oured or ?aked consistency depends upon
plished by a series of brushes, operating on a cen
the type of material used.
30 tral shaft, rubbing against the corrugated sur
The stamping process’, no matter what basic
face of the walls of the cylindrical polishing mill.
material is used, is continued until the same is
This process is continued for 12 or 24 hours de
reduced to a ?oured or ?aked consistency of about
pending upon the brilliancy desired on the ?ake
200 mesh, '
?akes.
In order to produce a batch of molding ma
terial, which simulates brass, bronze, gold, silver
or chrome, it is now necessary to add to this ?aked
basic material a quantity of bronze in ?akes of
about 200 mesh in the case of alloys of brass,
bronze and gold or aluminum ink ?ake, and also
in case or simulation of silver or chrome.
The
bronze ?ake ink or the aluminum ?ake is treated
in the same type of stamping machine and is the
result of the reduction of hammered, leafed
metals of bronze or aluminum.
_It is to be understood that a line bronze ?ake
or aluminum ?ake will ?ow better and will perme
ate the molding material when the curing in the
>
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of metal.
35
When the ?aked part of the molding material
has been prepared and the bronze ?ake or alu
minum ?ake have been prepared in like manner,
the two ingredients, the ?aked molding material
and the bronze ?ake or the ?aked molding ma
terial and the aluminum ?ake, are mixed in quan
tities of 2 ounces of ?aked molding material to 1
ounce of bronze ?ake or aluminum ?ake.
The cylindrical polishing mill polishes by rub~
bing the bronze ?ake or enclosed material against
the inside corrugated surface of the mill with a'
series of brushes. The ?akes of the plastic ma
terial and the metal ?our or ?akes are brushed
until they adhere to each other.
molding process takes place.
It is of great importance that the mixed ma
To the ?oured molding substance a bronze 50 terials during the polishing operation do not be
?aked ink or aluminum ?ake of 200 mesh with a
come overheated since they tend to stick in the
stearine consistency is added in the proportions
mill. It is, therefore, preferable not to continue
of about one ounce of bronze ?ake or aluminum
this operation over 30 minutes, because this time
?ake to two ounces of ?our molding substance.
is su?icient for brushing the ?aked or ?oured
The bronze or aluminum ink is lighter in shade 55 substance particles and the metal particles to~
4
3
gather. This process will add an additional
lustre to the mixture. The combined material is
now suitable for molding.
.
When quantities of this material are intro
duced in the proper weights into the steel molds,
the cured product has the appearance of brass
where bronze ?ake is used or of silver or chrome
?akes to flow and permeate the molding mate
rial when cured in heat molding to simulate the
metal used.
,
3. The process for manufacturing a batch of
molding material to simulate metal when molded, -
which process consists in ?rst grinding cellulose
acetate as a base, then crushing said base to
obtain a ?aky or ?ourlike consistency of about
200 mesh and adding lard as binding material
to give body to said base, crushing a hammered
leafed metallic element into the same ?aky con
sistency as said base, then metallizing said base
where aluminum ?ake is used. This material
can be used industrially for the fabrication of
plastic hardware, pipe ?ttings, or‘ in whatever
industrial ?eld a substitute plastic product is de
sired.
body by intimately mixing therewith the ?aky
This molding material is then ready to be put
metallic element to be simulated after having
into steel molds and molded into objects which
give a striking resemblance to brass, bronze or 15 been crushed into ?ake-like consistency of about
the same mesh as the base, and then polishing
gold. Or in the case of the aluminum or tin
the mixture in a brush polishing mill with stearic
?akes, a resemblance to silver or chrome.
acid in the approximate proportions of a table
The time for curing should be limited since
spoonful of stearic acid to 15 pounds of metallic
over exposure causes added oxidation resulting
?ake and 30 pounds of base While preventing
20
in a dark appearance void of lustre.
overheating, until the metallic ?ake adheres to
It is to be understood that the invention as
the base ?ake and to cause the metallic ?ake to
here described is not limited to the details here
?ow better and permeate the molding material
in but that the same may be varied widely with
when cured in the molding process.
out departing from the spirit of theinvention as
4. The process for manufacturing a batch of
25
- de?ned by the subjoined claims.
molding material to simulate metal when molded,
invention,
7
what
1
is
Having described the
which process consists in ?rst grinding cellulose
claimed as new is:
r
_
l
acetate in the natural shade'as a base, then
/1. The process for manufacturing a batch of
crushing said base to obtain a ?aky or ?ourlike
molding material having a lustrous metallic ap
consistency of about 200 mesh and adding lard
30
pearance to simulate metal when molded, which
as binding material to give body to said base,
process consists in ?rst grinding cellulose acetate
crushing a hammered leafed metallic element
as a base, then crushing said base to obtain a
into the same ?aky consistency as said base, then
?aky or ?ourlike consistency and adding lard as
metallizing said base body by intimately mixing
binding material to give body to said base, crush
ing a metallic element into ?ake-like consistency 35 therewith the ?aky metal to be simulated in suit
able proportions after having been crushed and
as that of said base, then metallizing said ?aky
reduced from hammered leaf form into ?ake,
base material by intimately mixing with said
like consistency of about the same mesh as the
?aky base the ?aky metallic element to be simu
base, and then polishing the mixture in a brush
lated in the proportions of approximately two
mill within a time duration of 30 minutes, with
40
parts of the former to one partof the latter, to
stearic acid in the approximate proportions of a
cause adherence of the metallic ?ake to the base
tablespoonfulof stearic acid to 15 pounds of me
?ake to flow better and permeate the base mate
tallic flake and 30 pounds of base to cause ad
rial when cured in the heat molding process to
herence of the ?ake materials to each other
simulate the solid metal of the metallic element.
2. The process for manufacturing a batch of 45 with added lustre, and to cause the metal ?ake
to ?ow into and permeate the material when
molding material having a lustrous metallic ap
heat molded.
pearance, to simulate metal when molded, which
5. A molding batch simulating metal when
process consists in ?rst grinding cellulose acetate
as a base, then crushing said base to obtain a
. molded, comprising an intimate mixture of cel
?aky or ?ourlike consistency of about 200 mesh 50 lulose acetate as a base in ?ake-like ?oured form
and metal to be simulated in similar form
and adding lard as binding material to give body
polished and with the ?ake adhering to each
to said base, crushing a leafed metallic element
other with added lustre, with lard as a binder,
into ?ake-like consistency as that of said base,
in proportions of about 30 pounds of base and
then metallizing said base body by intimately
15 pounds of metal and the mixture, together
mixing therewith the ?aky metallic element to 55 with
a tablespoonful as polishing material of
be simulated in the proportions stated until the
polished
stearic acid.
metallic ?akes adhere to the base ?akes and
THOMAS J. HILLERY.
polishing the same and to cause the metallic
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