Improvements in and relating to Continuous Casting or Pouring of Metal into Moulds, and in the Construction of said Moulds.
Year: 1894

page_text: Date of Application, 19th June, 1894--Accepted, 21st July, 1894
COMPLETE SPECIFICATION.
Improvements in and relating to Continuous Casting or Pouring of
Metal into Moulds, and in the Construction of said Moulds.
I, STEPHEN JARVIS ADAMS, a citizen of the United States of America,
residing at the corner of Fourteenth and Etna Streets, in the City of Pittsburgh,
County of Allegheny and State of Pennsylvania, one of the United States of
America, Manufacturer, do hereby declare the nature of this invention, and in what
manner the same is to be performed, to be particularly described and ascertained
in and by the following statement :-
My invention relates to the making of sand moulds and to the casting or pouring
of the metal into the same, its object being to overcome the great labour heretofore
experienced in the pouring of approximately small moulds by means of hand
ladles.
The present invention includes as its main feature the method of pouring metal
in sand moulds, consisting in causing the metal to flow horizontally through an
enclosed continuous runner in a series of sand moulds and above the mould cavities
thereof, and feeding the metal from such continuous runner downwardly into the
mould cavities of the sand moulds, and preferably directing the metal first flowing
through any one of the sections of the continuous runner formed in the respective
sand moulds by a down-take runner into a mould cavity, so that it is not
caused to heat more than one section of the continuous runner. The main features
of advantage to be obtained are the protection of the hot metal from contact
with the atmosphere so that it can be carried for a long distance through the
series of moulds, the overcoming of the spilling of the metal such as might
take place in an exposed runner, and the providing of a suitable head of metal
by the employment of the continuous runner above the mould cavities which will
prevent the back movement of any gases through the molten metal in the runner,
and by the weight of the metal will force such gases through the sand walls of the
mould and insure the formation of practically perfect castings.
To enable others skilled in the art to practise my invention, 1 will describe the
same more fully, referring to the accompanying drawings, in which-
cope
Figure 1 is a cross section illustrating the formation of a mould embodying the
invention desired to be covered, said figure showing the formation of the of
the mould, for example, the position of the parts in forming the continuous runner
through the mould, while Figure 2 shows the position of the parts upon completing
the formation of such runner.
Figure 3 is a perspective view of the flask showing the application of the
continuous runner forming device thereto, and also illustrating generally the
construction of the same.
Figure 4 is a separate view of the cutter for forming such continuous runner or
passage.
Figure 5 is a longitudinal section showing a series of these moulds in position
for pouring, that is, ready to receive the metal;
Figures 6 and 7 are longitudinal sections of other forms of moulds embodying
the invention;
Figure 8 is a part side view and part sectional view of another form of mould
embodying the invention;
Figures 9 and 10 are perspective views of the separate moulds in Figure 8;
Figure 11 is a perspective view of a series of moulds showing the preferred
means of supporting the series of moulds during pouring ;
Figure 12 is a cross section of Figure 11;

page_text: Figures 13 and 14 are cross sections of other forms of moulds embodying my
invention;
Figure 15 is a view of the cutter employed for cutting the metal in the continuous
runner and
Figure 16 is a perspective view illustrating the mould projector employed in
handling the finished mould while arranging it in line with the other moulds."
Like letters of reference indicate like parts in each of the figures above
described.
The general invention as embodied in the moulds themselves, is illustrated in
Figures 5, 6, 7 and 8, showing longitudinal sections of the moulds to be formed,
and in order that the invention may be understood both as to the method and
apparatus, and the uses of the different parts shown, I will first describe these
figures. The invention is illustrated in Figures 5, 6 and 7, in connection with any
suitable cope and drag mould, though it is evident that it may be well employed
with single part moulds its application to one form of such moulds is illustrated in
Figure 8. As the moulds are to be held in line and in contact with each other,
and the enclosed runners or metal passages between the several moulds must be
made to communicate, the first essential of the invention is an even floor, and for
this purpose I prefer to employ a floor made of one or more metal or like plates to
give a rigid support, as at A, single plates being preferably employed so that there
may be no fear of the parts getting out of alignment. These plates may, of course,
be suitably supported on the foundry floor, and on them are placed the soveral
moulds. The bottom boards a are also required to be carefully made, and are
preferably made of metal, so insuring in this way an even and regular support for
the moulds which will not warp, burn, or get out of shape.
The moulds B in
Figures 5 to 7 are shown as made of the cope and drag 4, and, as is seen by said
figures, the moulds fit closely against each other, so that a sand joint is formed
which will prevent the escape of the metal between the moulds during the pouring
operation. The moulds shown are for brake shoes, being illustrated in connection
with the casting of these articles because the invention has heretofore been employed
with moulds for making brake shoes.
Extending continuously through the series of moulds is the enclosed runner or
passage which, as is apparent in the drawing, leads through all the different
moulds placed in line, and communicates by the down-take runners d with the
mould cavities d' of each mould. This enclosed continuous runner may be formed
in any suitable way, either in the mould section containing the mould cavity in a
separate mould section resting thereon, as in Figure 13, or between two mould
sections, as in Figure 14. It will be noticed that the vertical runners d extend
down from the main passage e between the several moulds, and that leading from
them are cross passages or runners which feed into the mould cavities. The
purpose of this is to provide for the formation of clean, unobstructed feeding
passages which could not well be obtained if such vertical runners were formed
enclosed with the bodies of the separate moulds; open and free feeding passager
being thus formed from the common continuous runner passage to the mould
cavities. It will also be noticed that, as illustrated, these down-take runners
are as large as the main runner passage, this being intentional, so as to provide
for the flow of the metal into the mould cavity or cavities fed by the first
down-take runner before the metal enters the next down-take runner, or to
provide so that the metal is only feeding into a limited number of the down-
take runners at the same time. The principle on which the runners is made is
that the down-take runners shall be of sufficient size to receive so much of the
metal from the continuous runner that only a limited number of down-take
runners be receiving the metal at one time, and the metal shall not chill in
henting up the continuous runner, and therefore that the metal first passing
through any section c¹ of the continuous ruuner shall be carried by the next
down-take rummer to the mould cavity, and no two sections of the continuous
runners shall be heated by the same portion of metal. The reason for this is

page_text: that it is not desirable to carry the metal which first passes along the
continuous runner for any long distance through the same, because it would be
chilled by contact therewith and would finally lose its fluidity so as to clog
the continuous passage and prevent the further flowing of the metal. By
constructing the runner passages in the way above described, however, the
metal first travelling through a section part of the continuous runner is carried
into the down-take runner and into one of the mould cavities before it has
been in contact with the sand long enough to be chilled, and it simply therefore
serves to heat up a short section of the continuous runner, such as that part
extending through one mould, and then enters into one of the mould cavitics,
and when it is filled, a fresh body of hot, metal being provided to pass through
and heat the section of the continuous runner in the next mould, and that
portion again being carried into the mould cavity as soon as it passes through
it. It is found by practical experience that in the handling of the metal in
this way within the continuous runner the metal may be carried any distance
desired, and maintained at practically the same heat as that in the pouring
ladle, the only limit heretofore found being the length of the foundry floor.
In Figure 6 the series of moulds are placed at a slight incline and the metal
entered at about the lowest point in the runner so that it will flow gradually
up the incline runner and naturally flow into the down-take runners before
passing further up the inclined runner to the other mould cavities. In Figure 7
the continuous runner as shown is formed of a series of separate inclined runners,
one in each mould, and each inclined section c¹ of the continuous runner c in
each mould has at one end an enlargement or pocket e³, which, in connection
with the face of the mould, forms a pocket to receive the metal at the end of
each inclined section, the face of the mould against which such pocket fits
forming a shoulder or abutment as at c. The metal can either flow downwardly
through these inclined runners, in which case it will strike against the shoulder
or abutment c³ which will direct the metal into the down-take runner d, or else,
it may flow upwardly through the inclined runner section, in which case it will
flow over the abutment c and enter the pocket and naturally feed into the
mould cavities before passing into the next inclined section of the runner.
either of the latter cases, it will be seen that though the metal does flow in at a
slight incline, it flows in a substantially horizontal course in the continuous runner
above the mould cavities, and the metal first passing through any section of the
runner is directed by one or the other means, so that it is not required to heat up
more than one section of the continuous runner.
In
As hereinafter described, the continuous runner is made to pass entirely through
each mould, and, where there are two mould cavities in each mould, each mould
avity is fed by the down-take ruuner formed in the side of the mould nearest to
the mould cavity, and therefore such down-take runners extend down each side of
said mould. To cluse such down-take runners at the ends of the series of moulds
I provide abutments e supported in any suitable way, either by resting on the
foundry floor, as in Figures 5 and 7, or braced from the floor or platform, as in
Figure 8, or supported by the mould covers, as in Figure 6. Those shown in
Figure 5 have the vertical portions and the horizontal portions e which rest upon
the foundry floor, and they are made of the same width as the mould so as to
confine the ends of the series of moulds. At the point where the down-take runner
is formed in the mould, I prefer to provide the abutment with sand pocket e³ which
is filled with sand, and the metal in passing along the continuous runner will, at
each end of the line of moulds, flow against such abutment and down through the
runner d and thence into that particular mould cavity. In Figure 7 this abutment
is also made of a block resting on the foundry floor and has the pouring gate
formed in the upper part thereof. In Figure 8 the abutment is formed by a plate
or block resting against the end mould and braced by the bar e resting against a
shoulder on the abutment, and engaging with a rack face on the foundry Hoor,

page_text: ne special means of supporting the abuitinent shown in Figure 6 will be
bereinafter described.
In order to feed the metal to the moulds, 1 provide the feeding basin or
reservoir which communicates by means of a suitable passage with the
continuous runner c, the construction of which will be hereinafter described, and at
the other end of the line of moulds, in order to discover when the moulds are filled,
I provide a riser or reservoir to retain the metal, which communicates with the
like passage leading into the runner c.
I will now describe the formation of the moulds and the placing of the same in
line for casting, and after having described all the parts will then describe the
casting of the series of moulds such as illustrated in the different figures.
The drag of the mould illustrated can, of course, be formed in any suitable way,
being moulded by hand or machinery and being supported upon the bottom
board a. The cope is moulded and placed upon the drag, the cope flask and
drag flask being guided into proper relative position by suitable means and then
removed from the finished mould. The preferred method of forming the cope is
illustrated in Figures 1 and 2, the cope flask being placed over the patterns and
guided to place and the sand compacted therein by suitable means. It will be
noticed that extending along the cope flask are the ribs 4 which form the vertical
runners d above described, and that leading from such ribs to the patterns are
the ribs for forming the feeding runners communicating with the mould cavities.
After the compacting of the sand in the flask, the only necessary step to complete
the same is the formation of the section e' of the continuous runner c in that mould,
and for this purpose I employ the sand confining plate shown in Figures 1 and 2
and shown in perspective in Figure 3. It will be noticed that the flask has the
openings formed therein in line with each other and just above the ribs h¹
forming the down-take runners. It will also be noticed that the flask is provided
with the loop 4 at one end thereof. The sand confining plate & is of such size as
to fit over the entire mold formed, and it has the pin or projection A which enters
the loop and also has on each side thereof the vertical lip adapted to pass on
each side of the flask so as to direct the sand confining plate to exact position
thereon, the lips, if necessary having inclined lower ends which by passing along
pins or lugs on the flask force the projections into the loop and the plate k
into exact position. At the opposite end of the plate from the projection & is the
guide which has formed through it a guide passage which, when the plate is
brought into position on the flask, is exactly in line with the holes in the flask
body. When the parts are brought to this position, the mould is ready for the
formation of the continuous runner through the same, which is accomplished by a
runner cutter passed through the guide-way and forced through the sand of the
mould, the preferable form of cutter being shown in Figure 4.
For this purpose
any suitable solid or tubular cutter may be employed, the same being simply forced
through the guide-way and thence through the sand of the mould so as to form
the continuous runner through the same. I prefer, however, to employ a hollow or
tubular cutter, such as the cutter which has a handle, the forward end of the
cutter being sharpened as at P, and, if desirable, spun in a little so that as it
receives the sand, a free space for the reception of the sand within the cutter body
will be obtained.
To form the runner it is therefore only necessary for the operator, after having
placed the plate k in position, to grasp the tubular cutter i and force it through
the passage and thence through the sand of the mould until it passes out of the
hole, withdraw the same and by a blow drop the sand out of the tubular cutter.
He then removes the plate &, withdraws the pattern, places the cope flask upon the
drag flask, so completing the mould, the cope and drag flasks being then opened
and taken from the finished mould which is ready to be placed upon the bed
plate A. When the mould is completed, any time or loose sand which might
have been formed may be easily removed as the vertical runners are exposed at the
side of the mould.

page_text: As above stated, it is important that the mould so formed and resting upon the
bottom board shall be held intact, and especially that the face where the end of
the continuous runner opens shall be properly protected, but in carrying out the
mould it is very liable to strike against the body of the workman and even such
slight pressure is liable to crack or break off the upper edge of the mould where
the continuous runner ends. To prevent this, 1 employ the shield or mould pro-
Lector shown in Figure 16, consisting of a light angular shield 1, part of which, as
at rests upon the top of the mould, while the other part extends down the side
thereof which would be liable to strike against the body of the workman, and such
angular shield so prevents injury to the part of the mould body while it permits
the workman to support it against his own body in carrying the mould out to its
place on the plate A. It also gives a surface for the workman to press against,
in placing the mould in close contact with the mould previously made, so as to form
a sand joint between the bodies of the two moulds, this being practically the only
careful work required in the moulding operation. The workman places cach
mould in close contact with the preceding one, so that the runner section c¹
extending through the body of the same will be in communication with the like
runner section c in the adjoining mould, and that the surfaces are brought to close
contact to prevent leakage of the metal. In so doing he forms the continuous
runner through the series of moulds, and the vertical runner or down-take channel
extending down between the moulds and communicating with the cross gates
leading to the mould cavities.
Each mould in the series is formed in the manner above described, except,
possibly, the end moulds of the series.
The metal may be fed to the continuous runner from any suitable reservoir or
basin, which communicates with such runner c. That illustrated in Figure 5 is a
reservoir supported upon the end mould of the section, the reservoir being
arranged to communicate with the continuous runner by a passage formed through
the top of the mould. When such device is employed, such inlet passage, as at c²
can be easily formed in connection with the plate k. In such cases I connect to
said plate the block m which fits in the seat in the plate k and is held there
by suitable clamps, the lower face of the block corresponding in shape to that of
the tubular cutter, and as the plate & is forced down to the position in which the
cutter is passed through the mould, this block m forces the sand downwardly so as
to form a depression therein, so that when the tubular cutter is forced through the
mould, as its movement is in line with the face of the block, it passes along such
face, the result being the formation of the passage e² communicating with the
continuous runner e. Such block can be employed in forming the end moulds,
the flat plate m² being inserted in the seat m¹ of the plate in forming the other
moulds of the series. In such cases the reservoir to receive the metal and form a
head for the same, as above stated, may be simply formed of a short tubular flask
lined with sand, or of a tile having the same shape. These reservoirs are supported
on the mould bodies above the openings c, like reservoirs being preferably
employed at each end of the series of moulds, the one to direct the metal into the
continuous runner, the other to receive the metal therefrom at the end of the series
of moulds, the two together holding a surplus of metal to supply any metal during
the shrinking, necessary to fill out the moulds, and by the weight or head of metal
to insure solid castings. The metal may be poured into the feeding reservoir
directly, if desired, and in that case the reservoir be made of such shape as to
properly receive it, but I prefer to employ a movable hopper p, such as shown in
Figure 5, which may rest either upon the mould or upon the floor adjacent thereto,
the mouth of which is placed over the feeding reservoir and from which the metal
flows into the reservoir and then into the continuous runner.
In the latter case,
the hopper has the supporting legs p by which the hopper is supported at a height
above the feeding reservoir sufficient to enable the operator to see into the reservoir
aud be guided in the feeding of the metal by the amount flowing into the same.
It has also the pocket p³ into which he pours the metal, the metal flowing thence

page_text: If the
over the damp into the discharge opening of the hopper, a continuous solid
stream of metal being thus fed into the feeding reservoir. The upper portion of
the feeding reservoir is made upwardly flaring to direct the metal into the same,
its lower portion being preferably made downwardly flaring; and in such case if
the metal extends above the downwardly flaring portion when set it might lock the
same, so that the core of metal so formed therein could not be removed.
reservoir of such shape is formed of fire clay it is for this reason divided
horizontally into two parts n, n' so that the upper portion may be liſted off and the
metal contained therein, before it solidifies in the upper or reverse part, permitted
to escape. The reservoir at the other end of the series of moulds is generally
made downwardly flaring, its purpose being simply to maintain the head of metal,
as above described.
After the series of moulds has been completed, the abutments above referred
to, are placed in position and so serve to confine the exposed faces of the end
moulds in the series, and these abutments may be clamped in place as shown in
Figure 6, if not sufficiently heavy to sustain the pressure. It is also necessary to
confine the side and top walls of the series of moulds during the casting of the
metal, and different devices may be employed for this purpose. One form of such
devices consists of trough-shaped covers corresponding in shape to the moulds
formed, having a top plate and side plates extending down therefrom, such cover
corresponding in length to a single mould, or being of sufficient length to extend
over several of the different moulds and fitting smugly around the same, so as to
confine the sand of the mould during the casting operation. Figures 5 and 7 show
the top plates r of such covers, and Figure 13 shows one such side plate on one
side of the mould, the other side fitting close to the mould in like manner. Such
covers may be of sufficient weight to hold themselves in place, but for safety can
easily be clamped to the bottom boards a' at suitable points, handles for such
purpose being shown in Figure 7, the handles being mounted to turn in the covers
and having looks to engage with the bottom boards. The form of support for the
sides and top of the mould preferred by me, is shown in Figures 6, 11, and 12,
because this form covers a number of moulds, and yet is pliable, so as to conform
to the slight irregularities in the moulds. As shown in said figures, I employ the
top plate or covers which is arranged to extend for any desired distance over the
top of the moulds and which rests thereon, while the side plates or side covers
rest against the sides of the series of moulds and both are clamped in place, such,
for example, as by the clamps which are formed separate from both the top
plates and side plates . In the formation of these top and side plates confining
a number of moulds, there are two features which are found desirable, one that
they shall be pliable, so as to conform more readily and give support to the sand
moulds, even though they may not be exnetly in line, and, second, that they shall
give free escape to the gases and steam at the time of casting the metal. I obtain
both results by constructing the plates of a series of strips united to supporting
strips or cleats which give space between them for the escape of steam, and, if
formed of rather light wood work, are sufficiently pliable to conform to the series
of moulds when clamped thereon. For the top plate I generally employ the cross
strips or boards ² united by the longitudinal supporting strips, and for the side
plates generally employ the longitudinal strips or boards & united by the cross
strips. In either ease the open work necessary for the escape of the gases and
steam, and the necessary pliability to permit slight movement to conform to the
sand moulds is obtained.
In order to hold these parts in place, so that they will act as sand retainers or
covers, any suitable clamping device t, may, of course, be employed. The
preferred construction of clamping devices is shown in the drawing, a cross bar t
resting on the top plates, sucli, for example, as on the longitudinal strips, and
having the vertical arms or levers t pivoted at the ends thereof, said levers being
adapted to press against the side plates the upper ends of said levers being
connected by the toggle arms t³, one of which extends past the other in such

page_text: position that the device may be locked by means of the link t', slipping on one of
the toggle arms and along the extension of the other toggle arm, to hold them in
place. Practical use of such device has proven that even with a light board
construction such device clamps the parts sufficiently to sustain the pressure of the
metal during casting. It will be noticed that the lower or free ends of the
arms are bent or curved inwardly, and that the cleats s' have the lugs se formed
thereon so that said inwardly extending base portions may engage under the
lugs. The result of such construction is that when the clamp is forced into
engagement with the top and side plates, as the arms are clamped together they
will naturally draw down the cross bar and force the side plates against the
sides of the mould, so obtaining a downward pressure for the top plates and a
slight upward pressure for the side plates, binding firmly the several moulds over
which the plates extend. This clamping device with the hinged arms may, of
course, engage with any other portion of the supports or clamps below the top-
plate, such, for example, as the bottom boards, and when so used will serve to hold
down the top plate. The side plates, and with them the top plate, may also be
secured to the bottom boards or support for the moulds by means of clamps, such
as shown at s', which engage with a loose wedge on, or a wedge secured on the
edge of the side plate, as shown at 88.
18
It is evident that other clamping devices may be employed, and it is also evident
that the top plate and side plates while movable with relation to each other, may,
if desired, be permanently connected to the clamping device, both of which are
included within ny invention. For the purpose of confining the end portions of
the series of moulds, I prefer to employ the end plate serving as the abutment e
as above referred to, held in place by the side retainers or plates a', the side retainers
or plates having the inwardly extending ribs at the ends thereof, and the end
retainer being of sufficient width to fit within said ribs, that is, being practically
the same width as the mould, so that it may be dropped into place and secured by
any suitable wedge which bears against the ribs s, such wedges being shown at i
bearing against the ribs and against the lug t" on the end retainer t.
suitable connection between the end retainer and the side plates may, of course, be
employed.
Any other
The general invention is also illustrated in connection with Figure 13, where the
continuous runner is formed in separate mould section above a series of sets of
moulds u uu built the one on top of the other, the continuous runner in the top
mould u connecting by the common down-take runner with the several mould
cavities in the sets of moulds. This set of moulds is braced by the side plate w³
extending up from the mould floor and a cover formed of an L-shaped plate u
resting on the top and extending down one side of the set of moulds, the whole
being held by the U-shaped brace u'. This mould also illustrates the method of
cutting through the metal in the continuous runner so as to provide for the
separation of the castings, the top plate having an opening uº therein through which
a cutter u' is passed, and which is forced to cross the runner passage and through
the metal contained therein at any time after it is chilled to such extent that it will
not again unite but is yet sufficiently soft for cutting. Any suitable shape of cutter
may be employed, and it may, of course, pass through spaces between the mould
covers shown in Figure 5 or the openings in the tops of the flask such as shown in
Figure 8. It will be noticed that with the mould shown in Figure 13 the mould
cavities contain cores which are inserted from above and the one mould placed
upon the other mould holds such cores in place with their respective mould
cavities.
In Figure 14 the invention is illustrated in another form, such as with a series
of sets of two part moulds placed the one upon the other, and the continuous runner is
formed in an inverted trough r by means of either a sand or tile lining ", this
trough being inverted and placed upon a series of moulds, and in fact, form ng
another mould section on top, so that in reality the continuous runner is formed
between the two mould sections. From the continuous runner so formed, the down-

page_text: take runners v extend to the several mould cavities, and as for such moulds it is
necessary to employ bottom boards, I employ bottom boards between the
different moulds in the set or pile and arrange for the passage of the down-take
runners by recesses in the edges of the runners. To insure a close joint
between the trough and surface of the mould! I form on the trough the ribs r
which seat themselves in the mould surface and so prevent leakage of metal
between the trough and mould. This trough has also preferably horizontal
plates extending out from the same and resting on the mould to give better
support to the trough, and for the purpose of covering the top of the mould, I
also employ separate horizontal plates beyond the trough, which serves to
confine the tops of the series of moulds and side plates which confine the sides
of the series of moulds, and are braced by the U-shaped clamp fitting over
the trough and top plates and down along the side of said plates and pressing
against the side plates by adjusting screw.
Instead of employing the separate bracing covers or plates, I may employ the
flasks themselves as the means of supporting the mould such as shown in
Figures 8 to 10 which are also for the making of brake shoes. Each mould has a
mould face e extending inwardly, from which are formed mould cavities in
which the body of the moulds are formed, and on the opposite side the moulds
are irregular in shape in one direction, that is, formed to the curve of the brake-
shoe face, but straight in the other direction, and in this way by placing the
flasks to on end, mould cavities are formed upon each flask, each flask containing
a mould having mould faces on both sides of the shape above indicated. If desired.
the flasks themselves may be formed to the general curves of the mould faces
having the curved projections and curved recesses te in the edges thereof to
receive the projections. Such flasks also have recesses to and upper edges
through which the cutters may pass to cut across the metal in the continuous
runner.
The above figures illustrate different ways of supporting the moulds during the
casting of the metal and different ways of conducting the metal to the mould
cavities, all of which are included within my invention. After the moulds have
been supported in any of the ways above described, they are ready for the pouring
of the metal. For this purpose only two workmen are required, instead of a large
number of skilled metal pourers as would be required for casting the metal in each
individual mould. The metal coutained in a large ladle is brought by a suitable
railroad, overhead or on the foundry floor, to the pouring end of the series of
moulds, and the metal is then poured into the hopper or basin p. Figure 5, directly
from the indle, the one man controlling the flow of metal while the other man
watches the reservoir' at the other end of the series to see when the metal enters
the saine and direct the first workman in the pouring operation.
The metal enters
the hopper and flows thence into the reservoir, and thence through the opening c³
into the continuous runner.
It flows with such continuous runner part backwardly until it reaches the down-
tako channel at the end of that mould, striking against the face of the abutment e
flowing down through that channel and filling that mould cavity. It also flows along
the continuous runner until it reaches the first down-take channel between the two
moulds, and it passes down through that down-take channel and by the cross
runners into the mould cavities, such as into the mould cavities 2-3. The down-
take channel between the moulds receives the mass of the stream of metal, and
the metal which has first travelled along that section of the runner and acted
to heat the same (being thereby correspondingly slightly chilled) passes down
that down-take channel into the mould cavity so that it has no longer course
to travel than in the ordinary filling of a mould, the first metal which passes
through this section of the continuous runner being so prevented from flowing
along the continuous runner for such distance as would chill the same to such
an extent as would prevent its free flow and the clogging of the continuous
runner, or the formation of defective castings. That is to say, that the metal

page_text: passes along the continuous runner down the vertical channel and into the mould
cavities, and the metal continues to flow in this way until these mould cavities
are filled, and a fresh body of heated metal, which has passed through the
previously heated section of the runner, enters the section of the runner extending
through the next mould and heats that section, the metal which has served first
to heat that section then passing down into the mould cavities fed by the next
down-take channel; the flow of metal being kept in this way so that the main
runner becomes more highly heated, or practically as hot as the metal itself, as
more metal passes through it on its way into new mould cavities, so that there
is always hot metal provided to flow through the section of the continuous runner
in each mould, it being found that the metal in the last of a long series of
inoulds is practically as hot as that which enters the first of the moulds, and
all danger of such chilling of metal as would obstruct the continuous runner is
prevented. When the metal reaches the last of the series of moulds, it flows
to the end mould cavity along the end abutment as above described, and, if
so constructed, rises within the reservoir at that end of the series, and the
workman at that end of the series of moulds then directs the workman pouring
the metal so that it rises gradually within that reservoir, and then the pouring
censes. The operation is practically the same in the different moulds shown,
the metal flows in a substantially horizontal course through the enclosed continuous
runner above the mould cavities and thence downwardly into the mould cavities
this being true even though in some cases it flows at a slight incline, as shown
in Figures 6 and 7. By the term "horizontal" it is, of course, meant practically
horizontal, and on such runner arranged on a slight incline which would not affect
the practical working of the invention would be included in such term.
As the series of moulds is thus filled and the mould cavities and continuous
runner are all properly confined, and as there is a head of metal in both
reservoirs, it is evident that the metal within the several moulds of the series
is so confined that the gases cannot pass back from any of the mould cavities and
through the runners to escape; and also that a body of hot metal is provided in the
long continuous runner which will act by its weight, together with the weight of
the metal in the reservoirs, to force the metal and hold it to place within the mould
cavities and force any gases generated in the mould cavities through the sand walls
of the mould, the weight of the metal of the continuous runner and reservoirs being
such as to insure a perfect filling of the mould cavities and the metal gradually
descending into the reservoirs to feed the shrinkage of metal in the mould cavities
while the casting solidifies. As a matter of fact, in the moulds poured from this
continuous runner much more perfect moulds are obtained, what is known as
shrinking or blowing is entirely overcome, and the moulds can be formed with a
much finer grade of moulding sand, even in the formation of large moulds, than has
heretofore been considered practicable, giving a much smoother surface to the
finished castings. The operation requires no skilful pouring, all that is necessary
being to maintain in the pouring reservoir a sufficient head of metal, and what has
been considered the most skilful, heaviest and hardest work in metal founding is
overcome, while the metal enters the mould cavities at a higher heat, the moulds
are more rapidly filled, and all chilling of the metal by exposure to the atmosphere
during the operation of pouring is prevented, practical use having demonstrated
that much more perfect castings can be obtained by this method of pouring.
As soon as the pouring operation is concluded, and the metal in the continuous
runner sufficiently set, but while it is still soft, the operator may then cut through
the metal in the continuous runner at suitable points so as to separate the castings
from each other. The mould covers can then be removed and applied to another
series of moulds and the operation repeated.
Having now particularly described and ascertained the nature of my said invention,
and in wint manner the same is to be performed, 1 declare that what 1 claim, is:-
1. In sand moulds, the combination of a series of moulds in line with each other
B

page_text: and having mould cavities therein, and a horizontal continuous runner enclosed
within the several sand moulds above the mould cavities thereof and communicating
with the different down-take runners leading to the mould cavities, substantially aš
and for the purposes set forth.
2. In sand moulds, the combination of a series of sand moulds in line with each
other and having mould cavities therein, a horizontal continuous runner enclosed
within the several sand moulds above the mould cavities thereof, and communicating
with the different channels leading to the mould cavities, and a reservoir extending
above the series of moulds and communicating with the continuous ruuner,
substantially as and for the purposes set forth.
3. In sand moulds, the combination of a series of sand moulds in line with each
other and having mould cavities therein, a horizontal continuous runner enclosed
within the several sand moulds above the mould cavities thereof, and communicating
with the different channels leading to the mould cavities, a feeding reservoir
communicating with the continuous runner, and a receiving reservoir communicating
with the continuous runner, substantially as and for the purposes set forth.
4. In sand moulds, the combination of a series of sand moulds in line with ench
other, a horizontal continuous rummer enclosed within the same series of moulds
above the mould cavities, and down-take runners lending therefrom to the mould
cavities, each such down-take runner being of approximately the section of the
continuous runner, substantially as and for the purposes set forth.
5. In sand moulds, the combination of a series of sand moulds in contact with each
other, an enclosed continuous runner extending through the same,
and runners leading
therefrom to the individual mould cavities, the section of the continuous runner in
ench mould being formed on an incline, substantially as and for the purposes set forth.
6. In sand moulds, the combination of a series of sand moulds in contact with
each other, an enclosed continuous runner extending through the same, the section
of the runner extending through each mould beiug formed on an incline, and a
down-take runner or channel leading from such continuous runner at the point of
junction of two of such moulds, and communicating with the mould cavities,
substantially as and for the purposes set forth.
7. In sand moulds, the combination of a series of moulds pinced in contact with
each other, an enclosed continuous runner extending through such series, each
section of such runner in each mould being formed on an incline, and having a
pocket at the lower end thereof, and runners leading from the continuous runner to
the individual mould cavities, substantially as and for the purposes set forth.
8. In sand moulds, the combination of a series of sand moulds placed in contact
with each other, an enclosed continuous runner extending through such series, the
section of such runner in each mould being formed on an incline and having a
pocket at the lower end thereof, and the moulds having the abutments or shoulders
opposite such pockets and runners leading from the continuous runner to the
individual mould cavities, substantially as and for the purposes set forth.
9. In sand moulds, the combination of a series of sand moulds placed in contact
with each other, an enclosed continuous runner extending through such series, the
section of such runner in each mould being formed on an incline, and the moulds
having abutments or shoulders at the lower ends of such inclined sections of the
continuous runner, substantially as and for the purposes set forth.
10. In sund moulds, the combination of a mould support, a series of moulds
resting on said support and in line and contact with each other, a continuous
runner extending through the moulds above and communicating by runners with
the mould cavities, and an abutment confining the end mould of the series,
substantially as set forth.
11. In sand moulds, the combination of a series of sand moulds set in line with
each other, a horizontal continuous rummer enclosed within said several sand moulds,
separate runners or channels leading therefrom to the mould cavities, and an abut-
ment confining the end runner leading to the end mould cavity of the series,
substantially as and for the purposes set forth.

page_text: 12. In sand moulds, the combination of a series of sand moulds, a continuous
runner extending through said series of moulds, separate runners or channels
leading therefrom to the mould cavities, and an abutment confining the end runner
leading to the end mould cavity of the series, said abutment having a sand pocket
on its face, substantially as and for the purposes set forth.
13. In sand moulds, the combination of a series of moulds set in line and in
contact with each other, a continuous runner extending through said series of
moulds and runners leading therefrom to the mould cavities, abutments at the end
of the series to confine the cud faces of the series of moulds, and a series of removable
mould covers fitting over the tops and sides of the moulds and resting thereon to
confine the same, substantially as and for the purposes set forth.
14. In sand moulds, the combination of a series of moulds set in line with each
other and having a horizontal continuous runner enclosed within and extending
through the same above the mould cavities and down-take runners leading thereto,
a reservoir supported on the moulds, and a passage or opening between said
reservoir and the continuous runner, substantially as and for the purpose set
forth.
15. In sand moulds, the combination with a set or series of moulds, placed in
contact with each other, and having an enclosed continuous runner extending
through the same and runners leading therefrom to the individual mould cavities,
of a knife or cutter adapted to pass through the mould and sever the metal in the
continuous runner to separate the castings from each other, substantially as and for
the purposes set forth.
16. The herein-described method of forming castings, consisting in casting metal
within a set or series of sand moulds placed in line with each other by feeding the
metal through a continuous runner communicating with the mould cavities in said
series of moulds, and subsequently, while the metal is confined within said moulds,
severing the metal within the continuous runner to separate the castings from each
other, substantially as and for the purposes set forth.
17. The herein-described method of forming castings consisting in casting metal
within a set or series of sand moulds placed in line with each other by feeding the
metal through a continuous runner communicating with the mould cavities in said
series of moulds, and subsequently, while the metal is confined within the moulds
and before it is fully set, severing the metal within the continuous runner to
separate the castings from each other, substantially as and for the purposes set
forth.
18. In sand moulds, the combination of a series of sets of moulds placed in line
and in contact with each other, each set being formed of two or more moulds,
the one resting upon the other, a continuous runner extending along said moulds
above the mould cavities of the several sets, and down-take runners or channels
leading from the continuous runner to the cross gates communicating with the
mould cavities in the sets of moulds, substantially as set forth.
19. In sand moulds, the combination of a set of moulds placed the one on the
other, each mould having a mould cavity or cavities, and cores placed within
the same, and the mould resting on the one below it confining said cores in place,
substantially as set forth.
20. In sand moulds, the combination of a set of moulds placed the one on the
other, each mould having a mould cavity or cavities, and cores placed within
the same, and the mould resting on the one below it confining said cores in place
and forming with said mould cross runners leading from the down-take runner
to the mould cavities in the lower mould, substantially as set forth.
21. In combination with a series of sand moulds having down-take runners
leading to the mould cavities, a continuous runner above the mould cavities formed
at the parting between two mould sections and communicating with the down-take
runners, substantially as set forth.
22. In combination with a series of sand moulds having down-take channels
leading to the mould cavities, a continuous runner formed of an inverted trough

page_text: resting on said series of moulds and forming a close joint therewith, and having a
runner groove communicating with the pouring gates leading to the mould cavities,
substantially as and for the purposes set forth.
23. In combination with a series of sand moulds having down-take channels
lending to the mould cavities, a continucns runner formed of an inverted trough
resting on said series of moulds and forming a close joint therewith, and having a
runner groove communicating with the pouring gates leading to the mould cavities,
said inverted trough being formed of a metal body having a tile or like lining
therein in which the runner groove is formed, substantially as and for the purposes
set forth.
24. In combination with a series of sand moulds having down-take channels
leading to the mould cavities, a continuous runner formed of an inverted trough
resting on said series of moulds and forming a joint therewith, and having a runner
groove communicating with the pouring gates leading to the mould cavities, said
trough having longitudinal ribs formed thereon to enter the sand and insure a tight
joint, substantially as and for the purposes set forth.
25. In combination with a series of sand moulds having down-take channels
leading to the mould cavities, a continuous runner formed of an inverted trough
resting on said series of moulds and forming a joint therewith, and having a runner
groove communicating with the pouring gates leading to the mould cavities, said
trough having horizontal plates extending out at the side thereof, substantially as
and for the purposes set forth.
26. In combination with a series of ennd moulds having down-take channels
leading to the mould cavities, a continuous runner formed of an inverted trough
resting on said series of moulds and forming a joint therewith, and having a runner
groove communicating with the pouring gates leading to the mould cavities, and
separate horizontal plates extending along the sides of the trough to confine the
mould, substantially as and for the purposes set forth.
27. In sand moulds, the combination with a series of moulds arranged in line with
each other and each resting on a common horizontal support, of side retaining plates
extending along two or more of said moulds and clamps for holding the plates to the
moulds, substantially as and for the purposes set forth.
28. In sand moulding apparatus, the combination with a series of moulds set in line
with each other, and each resting upon a horizontal support extending under the
series, of a top retaining plate and side retaining plates extending along two or more
moulds in said series, and clamps holding said plates to place upon the moulds,
substantially as and for the purposes set forth.
29. The combination of a series of sand moulds set in line with each other, of a
pliable mould retaining plate extending along two or more of the moulds in said
series and a clamp for holding it in its place, substantially as and for the purposes
-set forth.
n
30. The combination with a series of sand moulds set in line with each other and
ench resting on a common horizontal support, of a mould retaining plate formed of
a series of longitudinal strips and of supports therefor cross strips connecting and
longitudinal strips extending at an angle to such longitudinal strips, substantially
as and for the purposes set forth.
31. The combination with a series of sand moulds set in line with each other nud
each resting on a common horizontal support, of a top retaining plate, side retaining
plates, and a clamp bearing on the top plate and engaging the side plates, substan-
tially us and for the purposes set forth.
32. The combination with a series of sand moulds set in line with each other and
resting on a common horizontal bed, of detachable side retaining plates and a
detachable end retaining plate held in place by the side retaining plates, substan-
tially as and for the purposes set forth.
33. In sand moulds, the combination of a bed plate, a series of sand moulds placed
thereon in line with each other, side and top confining plates, and a U-shaped clamp
.1

page_text: passing over the side and top confining plates and clamped to the side plates,.
substantially as set forth.
34. The combination with a series of sand moulds set in line with each other, of
a top retaining plate, side retaining plates, a clamping device resting upon the top.
plate and having movable arms engaging with the side plates, substantially as and
for the purposes set forth.
35. The combination with a series of sand moulds set in line with each other, of
a top retaining plate, side retaining plates, a clamping device resting upon the top
plate and having movable arms engaging with the side plates, said arms having-
inwardly extending lower ends, substantially as and for the purposes set forth.
36. The combination with a series of sand moulds set in line with each other, of
a top retaining plate and side retaining plates extending along the same, said side
plates being movable with relation to the top plate, and clamping mechanism for
holding the said top and side plates in place, substantially as and for the purposes.
set forth.
37. The combination with a series of sand moulds set in line with each other,
of a top retaining plate, side retaining plates having the cleats provided with:
lugs and the clamp having arms provided with inwardly extending lower
ends, said clamp bearing on the top plate and the free lower ends of its arms
engaging with the lugs on the cleats of the side plates, substantially as and for the
purposes set forth.
38. The combination with a series of sand moulds set in line with each other, of
a top retaining plate, side retaining plates, the clamp t having the bar t' bearing on
the top plate, the side arms t, toggle arms t³ and link t, substantially as and for the-
purposes set forth.
39. The combination with a series of sand moulds set in line with each other, of
the side retaining plates having the ribs at the ends thereof, the end retaining
plate and tightening devices between said end retaining plate and said ribs,.
substantially as and for the purposes set forth.
40. The combination with a series of sand moulds set in line and in contact
with each other, of a top retaining plate, side retaining plates, clamping mechanism.
for holding the same in place, and clamps securing the side retaining plates to the-
mould support, substantially as and for the purposes set forth.
41. In sand moulding apparatus, the combination of a flask, a pattern and pattern
plate closing the lower end thereof, a confining plate closing the upper end thereof,.
the flask having guide holes in its side walls above the pattern, a guide-way in line
with the guide-holes of the flask, and a runner former fitting in said guide-way and
adapted to be forced through said guide-holes and through the sand within the
flask, and so form a runner extending through the mould above the mould cavity,.
substantially as set forth.
42. In sand moulding apparatus, the combination of a flask, a plate adapted to be-
applied to and confine the sand in the flask, and having a guide at one end, and a
runner former adapted to be forced through said guide and through the sand within.
the flask, substantially as and for the purposes set forth.
43. In sand moulding apparatus, the combination of a flask having ribs thereon
to mould gates or runners, and a confining plate adapted to be applied to the flask,
a guide in line with said ribs, and a runner former adapted to be forced through said
guide and through the sand within the flask, in line with said ribs, substantially as
and for the purposes set forth.
44. In sand moulding apparatus, the combination of a flask having guide holes
in the side walls thereof, a guide-way in line with said guide-holes, and a tubular
cutter fitting in the guide-way and adapted to be forced through the flask, and cut
a runner therein and carry out the sand therefrom, substantially as set forth.
45. A tubular cutter for forming runners within sand moulds, having a bevelled
cutting edge and of smaller interior diameter at the cutting edge than in its body,
substantially as and for the purposes set forth.
46. In sand moulding apparatus, the combination of a flask, a plate adapted to be

page_text: applied thereto having a pattern or block adapted to be forced into the sand and
provided with a guide in line with said pattern or block and a runner former
adapted to be forced through said guide and through the sand in the flask and in
line with said block, substantially as and for the purposes set forth.
k
47. In sand moulding apparatis, the combination of the flask having the loop
and the runner forming plate & having the pin & engaging therewith, and provided
with the guide, substantially as and for the purposes set forth.
k
48. In sand moulding apparatus, the combination of the flask having the loop
and the holes and the runner forming plate & having the pin & engaging
with the loop, and provided with the guide & in line with said holes in the flask,
substantially as and for the purposes set forth.
49. In sand moulding apparatus, the combination of the flask
and lugs and the runner forming plate & having the pin
loop, and the lips K engaging with said lugs, and the guide,
for the purposes set forth.
having the loop /*
engaging with said
substantially as and
flask 4, the runner
removably attached
50. In sand moulding apparatus, the combination of the
forming plate k, having the guide, the block or pattern
to said plate in line with said guide, substantially as and for the purposes set
forth.
51. In sand moulding apparatus, the combination with the mould support, and
the sand mould resting thereon, of a protecting shield having a horizontal portion
adapted to rest upon the sand mould, and a vertical portion adapted to extend
down the side thereof and prevent direct contact therewith, substantially as and for
the purposes set forth.
Dated this 10th dov
JENSEN & SON,
77, Chancery Lane, London, W.C., Patent Agents.