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Carbon Resistance Ring: Laminated Paper Gelled with 15% Tung Oil, Graphite-Shellac Track
Mallory's quiet volume-control ring (US 2,144,925, 1939). Hard bases were noisy and soft paper ones changed with damp. Their answer: paper rings soaked in 15 % raw tung oil and baked, so the oil gels inside the paper. It shuts out moisture but stays soft and springy, and the wiper runs on it quietly. A graphite paint makes the track, silver paint the ends.
The picture: the patent's drawing (Fig. 3).
Intermediate
1 day
Instructions
1
1
Punch rings from three-ply paper
Punch rings from three-ply paper
The base is three papers stuck into one sheet: litho paper at the back, newsprint in the middle, manila on the face that takes the track. Punch rings from it. Ours: a punch press with a ring die.
Materials for this step:
Three-Ply Laminated Paper1 pieceTools needed:
Punch Press
Ring Punching Die
Rubber Gloves2
2
Soak 1 hour in 15 % tung oil in naphtha
Soak 1 hour in 15 % tung oil in naphtha
Soak the rings for about one hour in about 15 % raw tung oil in naphtha. Use raw oil, not heat-bodied or treated oil, so it can still gel.
Materials for this step:
Tung Oil15 partsTools needed:
Naphtha
Glass Beaker
Balance Scale
Stirrer
Full-Face RespiratorRubber Gloves3
3
Air-dry, then bake at 210–250 °C
Air-dry, then bake at 210–250 °C
Dry the rings in air for two hours or more, then bake 15 to 30 minutes at 210 to 250 °C. The oil gels in the paper's pores; the paper stays pliable.
Tools needed:
Drying Oven
Oven Thermometer
Heat-Resistant Gloves4
4
Spray the graphite track
Spray the graphite track
Spray on the resistance paint, for example graphite in a shellac binder. The patent gives no proportions. The track can be tapered in thickness, width or mix to shape the resistance curve.
Materials for this step:
Graphite Powder1 as required
Shellac1 as requiredTools needed:
Spray Gun
Air CompressorFull-Face RespiratorRubber Gloves5
5
Paint silver ends, bake at 220 °C
Paint silver ends, bake at 220 °C
Spray or paint the two end terminals with silver particles in shellac. Dry, then bake at about 220 °C to cure and harden the track. The slight warp from soaking flattens out again.
Materials for this step:
Silver Conductive Paint1 as requiredTools needed:
Spray GunDrying OvenOven ThermometerHeat-Resistant GlovesMaterials
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Tools Required
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