It’s late, and you’re still awake. Allow us to help with Sleep Aid, a new series devoted to curing insomnia with the dullest, most soporific prose available in the public domain. Tonight’s prescription: “How Mechanical Rubber Goods Are Made,” first published in the Scientific American Supplement on February 13, 1892.
While the manufacture of rubber goods is in no sense a secret industry, the majority of buyers and users of such goods have never stepped inside of a rubber mill, and many have very crude ideas as to how the goods are made up. In ordinary garden hose, for instance, the process is as follows: The inner tubing is made of a strip of rubber fifty feet in length, which is laid on a long zinc-covered table and its edges drawn together over a hose pole. The cover, which is of what is called “friction,” that is cloth with rubber forced through its meshes, comes to the hose maker in strips, cut on the bias, which are wound around the outside of the tube and adhere tightly to it. The hose pole is then put in something like a fifty foot lathe, and while the pole revolves slowly, it is tightly wrapped with strips of cloth, in order that it may not get out of shape while undergoing the process of vulcanizing. When a number of these hose poles have been covered in this way they are laid in a pan set on trucks and are then run into a long boiler, shut in, and live steam is turned on. When the goods are cured steam is blown off, the vulcanizer opened and the cloths are removed. The hose is then slipped off the pole by forcing air from a compressor between the rubber and the hose pole. This, of course, is what is known as hose that has a seam in it.
For seamless hose the tube is made in a tubing machine and slipped upon the hose pole by reversing the process that is used in removing hose by air compression. In other words, a knot is tied in one end of the fifty foot tube and the other end is placed against the hose pole and being carefully inflated with air it is slipped on without the least trouble. For various kinds of hose the processes vary, and there are machines for winding with wire and intricate processes for the heavy grades of suction hose, etc. For steam hose, brewers’, and acid hose, special resisting compounds are used, that as a rule are the secrets of the various manufacturers. Cotton hose is woven through machines expressly designed for that purpose, and afterward has a half-cured rubber tube drawn through it. One end is then securely stopped up and the other end forced on a cone through which steam is introduced to the inside of the hose, forcing the rubber against the cotton cover, finishing the cure and fixing it firmly in its place.
After the mixing of the compound and the calendering, that is the spreading it in sheets, the great roll of rubber and cloth that is to be made into corrugated matting is sent to the pressman. Here it is hung in a rack and fifteen or twenty feet of it drawn between the plates of the huge hydraulic steam press. The bottom plate of this press is grooved its whole length, so that when the upper platen is let down the plain sheet of rubber is forced into the grooves and the corrugations are formed. While in that position steam is let into the upper and lower platens and the matting is cured. After it has been in there the proper time, cold water is let into the press, it is cooled off, and the upper platen being raised, it is ready to come out. A simple device for loosening the matting from the grooves into which it has been forced is a long steel rod, with a handle on one hand like an auger handle, which, being introduced under the edge and twisted, allows the air to enter with it and releases it from the mould.
Sheet packing is often times made in a press, like corrugated matting. The varieties, however, known as gum core have to go through a different process. Usually a core is squirted through a tube machine and the outside covering of jute or cotton, or whatever the fabric may be, is put on by a braider or is wrapped about it somewhat after the manner of the old fashioned cloth-wrapped tubing. The fabric is either treated with some heat-resisting mixture or something that is a lubricant, plumbago and oil being the compound. Other packings are made from the ends of belts cut out in a circular form and treated with a lubricant. There are scores of styles that make special claims for excellences that are made in a variety of ways, but as a rule the general system as outlined above is followed.
The old fashioned way of making jar rings was first to take a large mandrel and wrap it around with a sheet of compounded rubber until the thickness of the ring was secured. It was then held in place by a further wrapping of cloth, vulcanized, put in a lathe and cut up into rings by hand. That manner of procedure, however, was too slow, and it is to-day done almost wholly by machinery. For example, the rubber is squirted out of a mammoth tubing machine in the shape of a huge tube, then slipped on a mandrel and vulcanized. It is then put in an automatic lathe and revolving swiftly is brought against a sharp knife blade which cuts ring after ring until the whole is consumed, without any handling or watching.
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