IMPROVEMENTS IN THE METHOD OF AND APPARATUS FOR MOULDING INLAID DESIGNS IN THE MANUFACTURE OF ORNAMENTAL TILES
Year: 1876

page_text: LETTERS PATENT to Alexander Melville Clark, of 53, Chancery Lane, in the
County of Middlesex, Patent Agent, for the Invention of "IMPROVEMENTS IN
THE METHOD OF AND APPARATUS FOR MOULDING INLAID DESIGNS IN THE
MANUFACTURE OF ORNAMENTAL TILES." A communication from abroad by
Jean Larmanjat, of Paris, France.
Sealed the 8th June 1877, and dated the 28th December 1876.
PROVISIONAL SPECIFICATION left by the said Alexander Melville Clark
at the Office of the Commissioners of Patents on the 28th December 1876.
ALEXANDER MELVILLE CLARK, of 53, Chancery Lane, in the County of Middlesex,
Patent Agent. "IMPROVEMENTS IN THE METHOD OF AND APPARATUS FOR MOULDING
INLAID DESIGNS IN THE MANUFACTURE OF ORNAMENTAL TILES." A communication
from abroad by Jean Larmanjat, of Paris, France.
This Invention rolates to an improved mode of and apparatus for moulding inlaid
designs in the manufacture of ornamental tiles.
The Invention is illustrated by way of example only in the accompanying
Drawings. Figure 1 shows a plan, and Figure 2 a transverse section of one
form of compound mould for producing the inlaid pattern of the tile shown in
Figure 3.
The compound mould is made of copper and is composed of a number of separate
adjustable parts corresponding in shape to the various parts of the design to be
inlaid. The parts of the mould are separated from one another by strips of sheet
copper a set edgewise to prevent the mixing of the different colors of which the
design is composed. The strips a are fixed to a plate b.
Three other plates c, d, e, serve each as supports for certain parts of the compound
mould which are capable of sliding up and down independently, so as to he
adjustable relatively to each other, the several parts being held in position on their
respective base plates by small pillars, and the motion of the different parts being
limited by the hollow pillars or sleeves f; g, g, are legs or supports for the
compound inould.
In order to produce the pattern of different shades or colors, as indicated in
Figure 3, the following is the method of operation. One of the plates e, for example

page_text: which corresponds with parts h of the compound mould is first lowered below the
general level of the mould, as shown in Figure 2, so as to forin recesses or cavities
to receive the material of which the colored design to be inlaid in the tile is
composed, the same operation being repeated for each of the other platos which are
lowered or raised successively.
The compound moulds may be provided with a greater or less number of plates,
according to the degree of complexity of the design.
The vertical copper strips a are made to follow the exact outlines of the various
portions of the design, and are connected to the external strip or frame and fixed to
the base plate b, the whole forming a complete mould.
The advantage of such an arrangement of compound mould is that the whole of
the upper portion to form the design may be deposited at one time upon the
material forming the body of the tile which has been previously placed in a suitable
mould, where the whole is subjected to pressure in order to render it homogeneous.
Figure 4 shows a plan, and Figures 5 and 6 vertical sections of another form of
compound mould, also composed of metal plates cut out or shaped to conform to
the design desired, and supported by pillars on plates i, i; j, tubular pillars upon
which the adjustable portions of the compound mould rest in their lowered position,
leaving spaces or cavities to receive the material of which the pattern is formed.
This is effected in two operations for the dark and light shades in the example
shown.
It will be understood that on lowering one or other of the plates i, the cavities
thus produced in the compound mould may be forthwith filled in with material of
the color chosen, which is then deposited, one color at a time, on the material forming
the base in the other mould in which pressure is to be applied. The parts of the
compound moulds should be so adjusted as to leave sufficient space between them
to allow of the second portions of the design being deposited in the spaces left for
its reception between the portions of that first deposited. This compound mould is
also provided with an outside border or frame k of sheet copper enclosed in a metal
frame which rests on the pressing mould in order to facilitate the deposit of the
material from the cavities of the mould which is effected by pressure applied to
the plates 1.
In another arrangement of mould the plate or plates of which it is composed are
not cut out so as to follow the contour of the design in the manner of fretwork, and
the different parts separated by copper strips, as in the moulds above described, but
the mould consists of a single plate having cavities of uniform shape, and at regular
intervals over its surface, to which the copper strips are affixed according to any
desired design, so that the same plates may be used for any design; by using two
such plates obtain a universal mould capable of producing all kinds of designs.
Figure 7 shows a plan of a copper plate A pierced with numerous square cavities a
having pistons b of corresponding form and dimensions fitted to work therein.
These pistons or blocks are attached to rods c, shown separately in Figure 10,
having notches & at bottom by which the rods are connected to plates B, C, D,
when inserted in oblong holes e therein and turned partly round. One of these plates
is shown partly in plan in Figure 9.
Figure 8 shows a section of the universal mould complete; f, Figure 7, handles of
plates B, C, D. The following is the method of operation:-The mould is first
arranged to suit the design to be produced by means of the plates B, C, D, and
rods carrying the pistons b, which slide in the holes a of the copper plate A
and the plate D is then drawn down, carrying with it all the pistons b attached
thereto, leaving the corresponding cavities in the plate A vacant to receive the
colored material of which the design is to be composed. The operation is the same
for the plates C and B which are lowered successively. When all the square holes a
in plate have been filled in the manner described, the universal mould is placed
upon the other mould containing the material to form the body of the tile, and the
plates B, C, D, are then pierced so as to force out, by means of the pistons 6 attached

page_text: thereto, the material contained in the square holes a. As the plate A contains an
equal number of blank spaces intervening between the cavities a, a second
operation is then performed with the aid of the second plate, the square cavities a
of which are so arranged as to fill the spaces left by the first deposit; this second
operation terminated, the whole is then subjected to considerable pressure in order
to agglomerate the material, and produce a tile bearing upon its face the design
which the universal mould has been arranged to produce.
The composition of the design to be produced in the universal mould is effected
in the following manner-Supposing that the surface of the tile is to bear three
colors, black, red, and white, for example, as many rods e with pistons bare attached
to plate D as are required to form the black part of the design, and similarly for the
plates C and B for the white and red parts respectively. As the holes are all
separated one from the other several colors may be applied at the same time.
When the design to be produced is of a curved or other form not corresponding
with the square cavities a strip of metal is affixed according to the desired design,
said strip having teeth or lateral extensions fitting in the square cavities a, and
dividing them throughout their depth into two parts of the desired forin, so that
two colors may be introduced into the same cavity without mixing, since they are
temporarily separated, as above mentioned. The material is pressed down by hand
into the cavities of the universal mould sufficiently to allow of its being transported
and turned over to be deposited in the pressing mould as before described. All
kinds of designs inay thus be produced with this universal mould.
SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said Alexander Melville Clark in the Great Seal Patent Office on the
28th June 1877.
ALEXANDER MELVILLE CLARK, of 53, Chancery Lane, in the County of Middlesex,
Patent Agent.
"IMPROVEMENTS IN THE METHOD OF AND APPARATUS FOR MOULDING
INLAID DESIGNS IN THE MAnufacture oF ORNAMENTAL TILES." A communication
from abroad by Jean Larmanjat, of Paris, France.
This Invention relates to an improved mode of and apparatus for moulding inlaid
designs in the manufacture of ornamental tiles, called "mosaic tiles," for floors and
cognate purposes.
The apparatus of this Invention is illustrated by way of example in the accom-
panying Drawings, in which Figure 1 shows a plan, and Figure 2 a transverse
section of one form of mould for producing at one operation the whole of the inlaid
pattern of the mosaic tile, which is itself represented in Figure 3.
In these three Figures the saine letters of reference indicate the same parts wher-
ever they recur.
This mould is composed of a plate of copper cut out or divided into a number of
separate adjustable parts fitting together and corresponding in shape to the various
parts of the design. The parts of the mould are separated from one another by thin
strips of sheet copper a set edgewise to prevent the mixing of the various colors
composing the design. These vertical strips a are soldered to an iron plate b, and
follow the exact outlines of the various portions of the design, and extend close up
to the external boundary or frame of the mould, the whole, with the parts hereafter
mentioned, forming a compound or multiple mould producing the whole of the
design.
Three other iron plates c, d, e, serve each as supports for the different parts of the
mould, which are free to slide up and down, and are independently adjustable
relatively to each other, the several parts being fixed to their respective plates c, d, e,
by pillars or rods f, and their motion being limited by the tubes or sleeves f¹

page_text: through which said pillars pass. 9, g, are legs or supports for the entire mould
whilst being filled.
To produce the pattern of various colors, as indicated by the different shades in
Figure 3, I proceed as follows:-One of the plates, e for example, is first lowered,
thereby drawing down those of the parts which are attached to it below the
general level of the surface of the mould, as shown in Figure 2, so as to form cavities
of the proper shape to receive the colored material for this portion of the design to
be inlaid. These cavities having been carefully filled with colored material, the
same operation is repeated for each of the other portions of the design, the several
parts of the mould being lowered successively by means of plates c, d, until all are
filled with colored material.
It will be understood that the mould may have a greater or less number of the
plates by which the different portions of the mould are thus operated, according to
the number of colors and complexity of the design.
The advantage of this compound mould is that the whole of the inlaid design that
forms the upper portion of the tile can by inverting the mould be deposited at one
tine upon the substratumn of material forming the body or base of the tile, which
substratum has been previously placed in a pressing mould, where the whole tile is
subjected to great pressure, and thereby rendered homogeneous.
Figure 4 shows a plan of another form of compound mould; and Figures 5 and 6
show vertical sections of a pair of such moulds.
In these three Figures the same letters of reference indicate the same parts.
These moulds are also composed of metal plates cut out or shaped to conform to
the parts of the design to be produced, the several parts being supported by pillars
on two plates i, i;j, tubes to limit the sliding movement of the different portions
of the mould. In this case there are no separating strips between the parts of the
mould, but there is a vertical strip of sheet copper h, which surrounds the entire
mould, and is enclosed in a metal frame 1. The latter rests on the pressing mould
in order to facilitate the deposit of the material from the cavities of the mould,
which in this case is performed in two operations. In the example shown I have
supposed two colors to have been employed, represented by the dark and light
shades in Figure 4 of the Drawing.
It will be understood that on lowering, say, the bottom plate i, the cavities thus
left in the surface of one or other of these moulds may be filled with the colored
naterial, which is forthwith deposited, one color at a time, on the substratum or;
base of the tile in the pressing mould. The moulds should be so adjusted as to
leave sufficient space to allow of the second portion of the design being readily
deposited in the spaces left for its reception between the portions first deposited.
In a third arrangement of mould, termed a "composing" or universal mould, the
moulding plate or plates are not cut out to correspond to the contour of the various
portions of the design, as in the moulds above described, but a solid plate of copper
or other metal pierced with holes of uniform shape and disposed at regular intervals
.over its surface is employed. To this plate separating strips of sheet copper are
affixed, according to any design it is desired to produce, so that the saine plate may
be employed for any design. By using a pair of these plates I obtain a universal
mould capable of producing designs of all shapes.
Figure 7 shows a plan of one of the plates A pierced with numerous square
holes a, each fitted with a plunger b of corresponding shape and size. The plungers
are capable of sliding in their holes, and are attached to rods c, shown separately in
Figure 10. The heads of these rods are oblong, and have notches & at opposite i
sides, by which they are connected to one or other of the plates B, C, D, when
inserted and turned a quarter round in oblong holes e in said plates (see Figure 9,
which represents a part of one of these plates in plan view). The plates B, C. D,
are provided with handles f for operating them and the different groups of plungers
connected thereto, as above mentioned.
"
..Figure 8 shows a vertical section of the universal mould. The mould having

page_text: been "composed" or arranged according to the design to be produced by connecting
certain of the plungers to one of the plates B, C, D, by their rods c, as above
described, the plate D, say, is then drawn down together with all the plungers
attached to it, thereby leaving the corresponding cavities in the plate A vacant to
receive the colored material to form the design; the same operation is repeated
with the plates C and B successively. When all the square holes a in plate Â have
been filled in the manner described the mould is inverted upon the pressing mould,
which already contains the material to form the base of the tile, and the
plates B, C, D, are then pressed until the plungers b force out the material con-
tained in the holes a. Since there are as many blank spaces formed by the solid
parts of the plate A between the holes a as there are holes, the same operation must
be repeated with a second plato A, having also square holes a, but so arranged as
to coincide with the blanks of the first plate in order to fill up the vacant spaces
left in the design at the first deposit. This second operation terminated, the whole
tile is then subjected to great pressure in order to consolidate the material and
produce a pressed tile, bearing upon its face the design for which the pair of plates
forming the universal mould have been "composed."
The "composition" of the mould for any desired design is effected in the following
manner-Suppose the surface of the tile is to be of three colors, black, red, and
white, for example, as many plungers b are attached by their rods c to plate D as
are required for the black parts of the design, and as many others are similarly
attached to the plates C and B for the white and red parts respectively. It will be
understood that as the holes a are quite soparate from one another all those left
vacant each time a plate is drawn down need not be filled with the same color, but
may be filled with different colors.
When the design to be produced is of a curved or other form not corresponding
with the square cavities the strip of metal before referred to, bent according to the
desired design, is temporarily affixed edgewise to the plate A, said strip being of
extra width wherever it crosses the square cavities a, so as to extend down into the
cavities, and divide them throughout their depth into two parts of the desired form
in order that two colors may be filled into the same cavity at once, without
becoming mixed. The material is impressed by hand into the cavities to con-
solidate it sufficiently to allow of the mould being carried about and turned over to
deposit the contents of the cavities in the pressing mould.
The materials of which the tiles to be made in these moulds are composed are in a
pulverulent condition, very slightly moistened to make them bind. The materials I
use are clean sharp sand and hydraulic lime in about equal quantities for the base
of the tile, the inlaid design being composed of the same materials, of a rather
finer quality, with the addition of a suitable mineral coloring matter.
Having described the nature of the said Invention, and the inanner of perforining
the same, I declare that what I claim as the Invention to be protected by the
herein-before in part recited Letters Patent is,—
1st. The construction and use of a mould for producing inlaid designs on tiles,
consisting of thin strips a conforming to the outlines of the design, in combination
with parts h, corresponding in shape to and fitted to nove up and down in the
spaces enclosed by the strips a, the said parts h being connected to and operated
by different plates c, d, c, all substantially as herein described and illustrated in
Sheet 1 of the Drawings.
2nd. The construction and use of a mould or pair of moulds consisting of a plato
or plates divided into separate and independent parts corresponding in shape to the
outlines of the design, and capable of adjustment relatively to each other, sub-
stantially as and for the purpose described and illustrated in Sheet 2 of the
Drawings.
3rd. The construction and use of the universal or "composing" mould or moulds,
consisting of a pair of metal plates A, having small square holes fitted with plungers
connected to and operated by different plates B, C, D, strips of metal conforming to
the outlines of any desired design being also applied to the plates when necessary

page_text: to prevent the mixing of the colors, all substantially as described and shown in
Sheet 3, for the purpose specified.
In witness whereof, I, the said Alexander Melville Clark, have hereunto set
my hand and seal, this Twenty-eighth day of June, in the year of our
Lord One thousand eight hundred and seventy-seven.