Discoveries and Inventions of the Nineteenth Century

much higher than that of copper-–22 or more times as much—the metal is so much lighter that a lb. of aluminium occupies nearly 3⅓ times the space of a lb. of copper, so that, taking bulk for bulk, aluminium is only about seven times as dear as copper. [1890.] When first introduced by Deville, in 1854, aluminium cost £20 per lb.; but its prospective value for application in the arts was recognised, and in two or three years afterwards it was put on the market at 40s. per lb. 723It was then, as already remarked, applied to many purposes where lightness is desirable, such as for the tubes of telescopes, opera-glasses, the mounting of photographic lenses, &c. And in 1888, when the production of sodium had been cheapened and applied to the separation of aluminium, the price of the latter metal fell to 18s. per lb. In the meantime, the cheap electricity of the dynamo caused attention to be again directed to the original electrolytic method; but many difficulties in detail had to be overcome in applying this process on the commercial scale. At length the sodium process was superseded; and by the beginning of 1890, a Swiss company was producing aluminium at 11s. per lb. In the course of the following year they succeeded in bringing the price down to 2s. per lb.; and again three years later, namely at the beginning of 1894, they could offer the metal at 1s. 7d. per lb. The conditions required for effecting this great reduction were found in driving the dynamo machinery by water-power, and in an abundant supply of cryolite at moderate cost. This cheapness of production at once placed the Swiss company in the position of being the largest and most successful aluminium manufacturers in the world, so that in 1892 they had realised a net profit of £21,563, paying their shareholders 8 per cent., and, further, in 1893, the net profit was half as much again, and the dividend was increased to 10 per cent. A British aluminium company has recently been formed in London for acquiring the rights of working all the processes of the successful Swiss company, purchasing outstanding English patents, amalgamating with certain existing companies, and for working the bauxite deposits in Ireland, &c., &c. There is every reason to believe that an important result of this enterprise will be a still further reduction in the price of this metal, and consequently a great extension of its applications. And now (September, 1895) we have already heard of a further reduction in the price of this metal, which, at the present time, can be purchased in bulk for about 1s. 6d. per lb. 724 Fig. 337.—Portrait of Mr. Thomas Hancock. INDIAN-RUBBER and GUTTA-PERCHA. INDIAN-RUBBER. Researches into the history of the human race in remote ages have revealed the fact, that before man knew how to extract metals from their ores, his only implements were formed of stone; and before he became acquainted with iron, there was an intermediate period in which the more easily obtained metal, copper, had to serve as the material for all tools and weapons. Hence archæologists speak of the stone age, the bronze age, and the age of iron. If we were obliged to name the nineteenth century after the material which distinctively serves in it for the most extensive and varied uses, surely we should call it the Age of Indian-rubber! The industrial application of Indian-rubber is entirely modern. The substance itself appears, however, to have been known to the natives of Peru from time immemorial, and to have been used for the preparation of some kind of garments. Although the first specimens were sent to Europe so long ago as 1736, and the substance was from that time submitted to 725many investigations, no other use was found for it up to the year 1820 than to efface from paper the marks made by pencils. From this it derives the name by which it is commonly known. It has also been called “gum elastic,” and caoutchouc from the Indian name. Crude caoutchouc is the product obtained by the spontaneous solidifying of the milky juice of certain tropical plants—such as the Hævea elastica, Jatropha elastica, and the Siphonia cautshu. The first grows chiefly in South America, and in the basin of the Amazon forms immense forests. At a certain season each year bands of persons, called “seringarios,” armed with hatchets, visit these forests for the purpose of extracting the caoutchouc. They make incisions into the trunk, and the milky juice immediately runs out, and drops into a vessel placed to receive it, and attached to the tree by means of a lump of clay. In about three hours the juice ceases to flow, and the seringario collects the products of the incisions in one large vessel. By dipping a board into this vessel, it becomes covered with the juice; and when this is allowed to dry, the caoutchouc remains as a thin brownish yellow layer. The caoutchouc is not dissolved in the juice, but is merely suspended in it; and to hasten the drying and coagulation of the liquid, the board is warmed over a smoky fire made with green wood. When alternate immersions and drying have covered the board with a sufficient thickness of caoutchouc, the layer is slit open with a knife, and the board is withdrawn. This is the best kind of crude caoutchouc, because it is free from all admixture of foreign bodies except the carbon derived from the smoky flame. The bottle Indian-rubber is moulded on pear-shaped lumps of clay, which are covered with successive layers of the milky juice; when a sufficient thickness has been attained, the clay is removed by soaking in water. Up to 1820, as already mentioned, Indian-rubber was used only for effacing pencil-marks, and about that time a piece half an inch square sold for two shillings and sixpence. But the extreme elasticity and extensibility of this singular substance was attracting the attention of practical men in England, Scotland, and France. One of the earliest patents obtained in this country for applications of caoutchouc was taken out by Mr. Thomas Hancock, of Newington, in 1820. This gentleman has written an account of the Indian-rubber manufacture from the commencement, and the book is extremely interesting from the clear and simple manner in which the inventor describes how he effected one improvement after another in his processes and machinery. Mr. Hancock had, previous to his turning his attention to Indian-rubber, no acquaintance with chemistry; but he was skilled in mechanical engineering and the use of tools, and this knowledge proved to be precisely the kind most valuable for dealing with the first stages of caoutchouc manufacture. His first patent was for the use of Indian-rubber for the wrists of gloves, for braces, for garters, for boots and shoes instead of laces, and for other similar purposes. The rings for the wrists of gloves, &c., were simply cut from the bottle Indian-rubber by machinery the patentee himself contrived for that purpose. Mr. Hancock next arranged an apparatus for flattening the raw Indian-rubber by warmth and pressure, so as to make it available for the soles of boots, &c. He relates the practical difficulties he had to encounter in his operations, and the manner in which he overcame them. He soon noticed and utilized the fact that two clean freshly-cut surfaces of caoutchouc, when pressed together, cohere and unite perfectly. This further led him to devising a machine by which all the waste cuttings and parings might be worked up. This machine consisted of a cylinder revolving within a cover, both being 726provided with steel teeth, by which the pieces of caoutchouc placed between them were torn into shreds, and then kneaded into a solid coherent mass of homogeneous texture. The first machine of this kind made by Mr. Hancock would work up about 1 lb. of Indian-rubber; but now machines on the same principle are in use operating on more than 200 lbs. of material at once, and turning it out on a roll 6 ft. long, and 10 in. or 12 in. in diameter. While Hancock was thus successful in mechanically working Indian-rubber, Macintosh, of Glasgow, found means of effecting its solution by coal-naphtha, and he obtained, in 1823, a patent for the application of his discovery to the fabrication of waterproof garments. Waterproof cloth, or “Macintosh,” is prepared by varnishing one side of a suitable fabric with a solution of caoutchouc, or by covering one side of a cloth with a thin film, and then bringing it into contact with a second piece similarly prepared—the two caoutchouc layers becoming incorporated when the double cloth is passed between rollers. Other solvents for Indian-rubber have been discovered in ether, chloroform, sulphide of carbon, and rectified turpentine. By treatment with these liquids it swells up, and eventually dissolves, producing a viscid ropy mass, which, by evaporation of the solvent, leaves the caoutchouc with all its original elasticity. By the use of these last-named solvents the persistent and disagreeable odour occasioned by coal-oil is avoided. Mr. Hancock relates that when the manufacturers had overcome all obstacles, and had succeeded in producing thin, light, pliable, and perfectly waterproof fabrics, they had to encounter another quite unexpected difficulty—the tailors set their faces against the new material, and could not be induced to make it up! The manufacturers were, therefore, obliged themselves to fashion waterproof garments, and retail them to the public. This, however, turned out to be a benefit, for the seams were made waterproof, so as to exclude even the little water which would otherwise pass in by capillary attraction at the stitches. It will now be observed that there are two distinct modes of working caoutchouc: by dealing, viz., with the solid material, or with the solutions. Thus, from a solid disc of caoutchouc long ribbons of the material may be cut, and these ribbons, by being passed between a set of circular knives, may be divided into a number of square threads. These threads may then be drawn out to six or ten times their length; and, if wound and maintained in this state of tension for forty-eight hours in a warm place, they will lose their condition of tension, and their elongated form will become their natural or unstrained one. In this manner are the Indian-rubber threads prepared, which, covered with silk or other material, form elastic fabrics such as those used in the sides of boots. The circumstance of caoutchouc, when heated for some hours at a temperature a little above the boiling-point of water, retaining whatever form it has during the heating, is the basis of methods of obtaining thin sheets and other forms of the material. Tubes are made by forcing the heated caoutchouc through an annular opening by application of great pressure; it sets in cooling, preserving a section corresponding with the orifice through which it issues. In another mode of forming tubes, a paste composed of caoutchouc, oxide of zinc, and lime, is formed into sheets, which are cut into strips. The strips are folded longitudinally, and the edges are cut together at an angle of 45° with the surface, so that the cut surfaces may meet each other when the strip is rolled on a mandril to give it a cylindrical form. A slight pressure suffices to solder together the cut surfaces, and the tube is then “vulcanized” by a process to be presently described. 727The dissolved caoutchouc serves to prepare waterproof garments, round threads, sheets of Indian-rubber, &c. Fabrics are coated with the solution by pouring it on the material as it is passing horizontally from a roller. A straight-edge, under which the charged cloth passes, distributes the caoutchouc in a uniform layer, the thickness of which is regulated by the space between the knife-edge and the fabric. When sulphide of carbon is the solvent used, its evaporation is complete in about ten minutes, but with other solvents two or three hours are required. The caoutchouc is usually mixed with lampblack before being spread on the cloth, and the article is finished by giving the Indian-rubber layer a coat of gum-lac varnish.