Improvements in the Manufacture of Hollow Building Blocks and Tiles.
Year: 1899

page_text: Date of Application, 20th Dec., 1899
Complete Specification Left, 20th Sept., 190-Accepted, 3rd Nov., 1900
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Hollow Building Blocks and
Tiles.
I, JOHN CARRINGTON SELLARS, of 68, Bridge Street, Birkenhead, in the County
of Chester, Cement Manufacturer, do hereby declare the nature of this inven-
tion to be as follows: -
This invention has reference to the manufacture of hollow building blocks
or tiles, and, more particularly, to those wherein the material of which the
blocks are formed is the residue of town's refuse destructors (or other materials
which have been exposed to heat at an elevated temperature) and a small
quantity of silicate of soda or its equivalent, the blocks being first formed,
with the addition of a small quantity of Portland or equivalent cement, or
cement and water, or water alone; and then dipped or steeped in or damped
with silicate of soda, or the like, and dried.
The object and effect of the present invention is to utilize such waste material
or residue, and produce from it such hollow building blocks, or tiles-of con-
siderable size if required-by machinery or apparatus rapidly and inexpensively;
and, at the same time, to produce such articles of true and uniform shape,
and of good and serviceable quality.
The material, viz., refuse destructor material, ground, or in a fine state, is
mixed with a small quantity of cement, or cement and water or water alone,
and in a semi-dry condition-i.e. in contradistinction from a wet or sloppy
condition is pressed in a mould having a stationary perforated or equivalent
core, and also a perforated base, preferably. And in connection with such
mould, a discharging means, actuated from below, is provided, and also a
pressing means acting upon the top of the mould. And the blocks, thus formed,
are then treated with the silicate of soda or ground material, and dried.
According to one construction or form of apparatus under this invention,
there is employed a hollow mould or box, placed upon a table or platform, and
having a perforated or grated bottom. These perforations serve to allow of
the escape of air contained in the material during the filling and pressing of
the mould and also facilitating cleaning.
Within the mould or box a tapered core is disposed, and it has flanges at the
bottom which fit the box: and this core is perforated or grooved for the pur-
pose of allowing air to escape during the filling of the mould, and pressing,
and dirt to be removed.
Through the flange of the core uprights or spindles pass, these spindles being
disposed below the moulding box during the filling operation.
A beaded or indented frame, for the purposes of forming interlocking por-
tions on one of the surfaces of the articles, rests upon the flange of the core
when moulding: and an opposite interlocking or ornamented surface of the
article is formed by means of a second beaded or indented frame, placed over
the material, when in the mould. Or, beadings, indentations, or ornamenta-

page_text: tions may be formed upon the upper die or frame to ornament or provide con-
figurations on one face of the blocks.
core,
The moulded articles will be ejected from the press after pressing, by means
of said uprights or. spindles, which, passing through the flange of the
lift the lower frame, with the article upon it out of the mould or press. The
uprights or spindles may be actuated by means of a rack and pinion, or in any
of the manners as may be found suitable or convenient; and the lower or
indented frame may serve as a carrying off plate.
In some cases, the core may be used without a flange, and firmly secured on
the table, and the moulded block ejected in a manner substantially as above
described.
A measuring box or jacket may be placed on the, mould in order to accurately
gauge the amount of material to be employed in each charge, and be com-
pressed.
The form and size of the cores may be varied as may be required.
In some cases, two or more stationary cores may be employed in the manu-
facture of the articles. Also, in cases where I employ an ornamental pattern
for one or more of the faces of the block, the die or plate is constructed of
perforated metal, as brass or zinc, covered with a metal gauge, or fine cloth, or
the like.
The moulded article in this case may be ejected from the press by means of
a plate and uprights or spindles, as above described, or the moulding box may
be turned over, if tapered, and the pattern lifted off.
By the employment of patterns as described, air which may be contained
in the material to be compressed is forced through the pattern and out of the
mould.
The annonatus mor be onerated by hand or power.
Improvements in the Manufacture of Hollow Building Blocks and
Tiles.
I, JOHN CARRINGTON SELLARS, of 68, Bridge Street, Birkenhead, in the County
of Chester, Cement Manufacturer, do hereby declare the nature of this inven-
tion, and in what manner the same is to be performed, to be particularly
described and ascertained in and by the following statement:-
This invention has reference to the manufacture of hollow building blocks
or tiles, and, more particularly, to those wherein the material of which the
blocks are formed is the residue of town's refuse destructors (or other materials
which have been exposed to heat at an elevated temperature), and a small
quantity of silicate of soda or its equivalent, the blocks being first formed,
with the addition of a small quantity of lime, Portland, or equivalent cement,
or cement and water, or water alone, or other adhesive: and then dipped or
steeped in or damped with silicate of soda, or the like, and dried.
The object and effect of the present invention, amongst others, is to utilize
such waste material or residue, and produce from it such hollow building
blocks, or tiles of considerable size if required or other articles, by machinery
or apparatus, rapidly and inexpensively and at the same time, to produce
such articles of true and uniform shape, and of good and serviceable quality.

page_text: The material, viz., refuse destructor material, or other suitable material,
ground, or in a fine state, is mixed with a small quantity of lime, cement, or
cement and water, or water alone, or a suitable adhesive, and in a semi-dry
condition-i.e. in contradistinction from a sloppy or running condition, is pressed
in a mould having a stationary perforated or equivalent core, and also a per-
forated base, preferably. And in connection with such mould, a discharging
means, actuated from below, is provided; and also a pressing means acting
upon the top of the mould. And the blocks, thus formed, are then treated
with the silicate of soda, or other alkali, and dried.
According to one construction or form of apparatus under this invention,
there is employed a hollow mould or box, placed upon a table or platform, and
having a perforated or gridded bottom. These perforations serve to allow of
the escape of some of the air contained in the material during the filling and
pressing in the mould; and also facilitate cleaning.
Within the mould or box a tapered core is disposed and in one construction
it has flanges at the bottom, which fit the box. This core is perforated or
grooved for the purpose of allowing air to escape during the filling of the
mould, and pressing, and dirt to be removed. Through the flange of the core
ejecting uprights or spindles pass, these spindles being disposed below the
moulding box during the filling operation.
A beaded or indented frame, for the purposes of forming interlocking por-
tions on one of the surfaces of the articles, rests upon the flange of the core
when moulding and an opposite interlocking or ornamented surface of the
article is formed by means of a second beaded or indented frame, placed over
the material, when in the mould. Or, beadings, indentations, or ornamenta-
tions may be formed upon the upper die or frame to ornament or provide con-
figurations on one face of the blocks.
The moulded articles will be ejected from the press after pressing, by means
of said uprights or spindles, which, passing through the flange of the core,
lift the lower frame, with the article upon it out of the mould or press. The
uprights or spindles may be actuated by means of a rack or pinion or in any
manner found suitable or convenient; and the lower or indented frame may
serve as a carrying off plate.
In some cases, the core may be used without a flange, and firmly secured on
the table, and the moulded block ejected in a manner substantially as above
described.
A measuring box or jacket may be placed on the mould in order to accurately
gauge the amount of material to be employed in each charge, and be com-
pressed.
The form and size of the cores may be varied as may be required.
In some cases, two or more stationary cores may be employed in the manu-
facture of the articles. Also, in cases where I employ an ornamental. or other
pattern or special shape for one or more of the faces of the block, the die, plate,
or part which comes next the material is covered with metal gauze, or fine
cloth, or with gauze and cloth, or the like, whereby the escape of air is effected.
The moulded article in this case may be ejected from the press by means of
a plate and uprights or spindles, as above described, or the moulding box may
be turned over, if tapered, and the pattern lifted off.
By the employment of patterns as described, air which may be contained
in the material to be compressed is forced through the pattern and out of the
mould.
The apparatus may be operated by hand or power.
The invention, the nature of which is above described, is illustrated in the
annexed drawings, in which Figure 1 is a longitudinal sectional elevation, and
Figure 2 is a cross section, shewing my improved machinery or apparatus.
And Figures 3, 4, 5, 6, and 7, shew details thereof, and modifications.
Referring to the drawings, a designates generally the hollow mould or box

page_text: in which the blocks or articles are made; and b is the perforated table or plat-
form carrying the mould a. c is the tapered core within the box or mould a;
is the beaded or indented frame in the bottom of the box or mould a; and e
is a frame or bar placed over the material in the mould at the top. f are the
upright spindles which pass through the table or platform b, and lift the frame d
and block out of the mould a. g is a sliding frame carrying the spindles f,
it being worked up and down by the chains and chain wheel on the operat-
ing shaft ; the chains being connected at their lower ends to uprights ; fixed
on the underside of the frame g, and at their upper ends to the periphery of
the chain wheel h¹. The shaft is operated by the levers ; or by belt wheels
and belts, as shewn in dotted lines on this shaft: or, by an engine working
directly on said shaft: or by any other suitable motor or power.
The table or platform is supported by upright frames 7; and these frames
also serve as a guide to the sliding frames g. carrying the spindles f. These
frames also support the bearings in which the ends of the operating shaft i
rest and work.
In the machine represented in the drawing, an auxiliary mechanism is shewn,
for use in case of need, for starting the block ejecting action. This gear con-
sists of a worm m mounted on the shaft m¹: a worm wheel n driven by m,
mounted on the shaft ¹, and carrying at each end a cam n²; and rollers o
carried in brackets o¹, fixed on the underside of the sliding frame g. The
shaft m¹ is actuated by the levers m² on the end of same, or by any suitable
means. By means of this worm and worm wheel gearing, great power for
starting the moulded block from the mould is obtained.
The mould is made up of side plates a¹, and end plates a², held together by
transverse through bolts 3; and the end plates are made to interlock with the
side plates by providing grooves or recesses in the ends of the plates a¹, and
sliding or fitting the edges of the plates into these grooves or recesses, as shewn.
The end plates a² are provided with grooves internally, in which upright
bars a fit, these bars being for the purpose of giving special formations, such
as grooves and ridges, in the ends of the blocks, for interlocking or keying
them together when built into a structure or building, or for any other purpose.
Consequently, according to the kind of formation of the end of the blocks
required, and the special purposes to which such blocks are to be applied, so
will be the form or construction of the inner surfaces or parts of these bars at.
In the mould illustrated in Figure 6, the end plates a² are shewn provided
with dovetail grooves: and in these grooves internal face plates or devices a²,
having a specially formed internal contour or shape of face, are fitted for the
purpose of forming ornamental surfaced blocks, or blocks having special forma-
tions of surface. In the case of these blocks requiring to be split or grooved
at their sides in order to enable them to be split after manufacture, cutters
may be provided on each side at the upper edge of the mould, to accomplish
this object.
In any case, the internal surfaces of the mould a may be provided with plates
having surfaces other than plain surfaces, for imprinting special forms in or
on the surface of the blocks: and these plates may be adapted to come away
with the block when ejected from the mould. and subsequently removed from it.
The plate or table is provided with a large number of holes, to take the
holding down bolts of the mould. and to enable various sizes and forms of
moulds to be used and fixed on the machine. And they also serve to enable
some of the air which is pressed out of the mould when the material is being
filled into it, to escape downwards through the table.
The core is provided with vertical holes. through which the holding down
bolts pass and these bolts also pass through the table b, and are held down to
it by nuts on their lower ends, as shewn. The core c is grooved vertically, as
shewn in Figure 7 (or is made hollow, and the walls perforated), for the pur-

page_text: pose of allowing the air carried by, and displaced by, the introduction of the
material into the mould, to escape during the filling and pressing actions. By
this means, a sound, even, and fine finish of surface of the blocks is assured.
The core is tapered from the bottom upwards to assist in the act of the
ejection of the blocks from the mould.
In the case of the bottom of the block requiring a plain surface, the upper.
surface of the ejecting frame d is also plain; but, to produce a surface having
a longitudinal projecting centre or portion, or edges, the surface of the frame a
is made in the form to produce it, .e. provided with longitudinal ledges as
shewn in the drawing, corresponding with the form of the lower surface required
upon the blocks. The frame or bar e, at the top of the core, and the top of the
core itself, are so formed and placed in relation to each other, that a corre-
sponding but converse form of upper surface of the block is produced, so that
the projection of one block at one part will fit in the corresponding recess in
another upon or under which it is disposed.
In most cases, a thin sheet metal division plate is employed between the
upper surface of the frame and the block made in the mould. This light
metal plate will come away with the block, that is, adhere to it, and can be
subsequently removed. The frame d and this plate p are provided with grooves
at their ends, as shewn, to enable them to pass up over the bars a'; and the
ends of the frame d are provided with grooves 9 in their surface, for intro-
ducing a tool for raising the blocks off the frame, when they are ejected.
After a mould is filled, and it is required to eject the block, the spindles g
are passed up by means of the gearing or power above described; and pressing
on the under side of the frame d, they force this frame, and with it the block
resting upon it, out of the mould; and when raised sufficiently high, or clear
of the mould, the blocks are taken away, and dealt with as may be required.
The kind of block above referred to, which is capable of being made by this
machine, is specified particularly as having for its base material, the ground
residue of town's refuse destructors, or materials that have been exposed to heat;
it is to be stated, however, that the invention is not restricted to the manufac-
ture of building blocks, and other articles, from that material exclusively;
but the improvements hereunder may be employed with advantage in connection
with the manufacture of machine moulded blocks or articles, from any other
suitable base material, and in various degrees of dryness, or in a more or less
moist or wet state.
With regard to the introduction and pressing of the material in the mould,
this may be effected by any suitable pressure applied to it through the open top.
For instance it may be done by hand ramming, in a similar way to that adopted
by metal moulders; or by pressure applied over the surface of the moulded
material from above; or in other suitable ways. Or, according to another
mode, a suitable ramming tool held by the hand, and worked by flexible shaft
or fluid pressure, may be used and applied in the manner of hand ramming.
Having now particularly described and ascertained the nature of this inven-
tion and in what manner the same is to be performed, I declare that what
I claim is:-
1. For or in the manufacture of hollow moulded blocks or articles, a mould
constructed and adapted to permit of the escape of air from the mould and
material when being filled; substantially as and for the purposes set forth.
2. For or in the manufacture of hollow moulded blocks or articles, a mould
having a core with grooves in its surface, or perforations, by which the escape
of air from the mould and material is effected when it is being filled; substan-
tially as and for the purposes set forth.
3. For or in the manufacture of hollow moulded blocks or articles, a machine
having a mould a, with a tapered core c, constructed and adapted to effect the

page_text: escape of air from the mould and material when being filled, and an ejecting
ring or device d at the bottom of same, adapted to be pressed upwards when the
block is to be ejected; substantially as set forth.
4. For or in the manufacture of hollow moulded building blocks or articles,
a machine having a mould a with a core c, and an indented, beaded, or irregu-
larly formed frame at the bottom of the mould; substantially as and for the
purposes set forth.
5. For or in the manufacture of hollow moulded building blocks or articles,
a machine having a mould a with a core c, ejecting frame d, and spindles f,
constructed and adapted to operate as set forth with reference to and shewn in
the drawings.
6. For or in the manufacture of hollow moulded building blocks or articles,
the machine having a mould a, core c, ejecting frame d, and frame or bar e,
and ejecting means; substantially as set forth with reference to and shewn in
the drawings.
7. In the manufacture of hollow moulded blocks or articles, effecting the
escape of air from the mould and material, by the employment on the surface
of one or more of the plates or parts comprising the mould, of gauze or cloth,
or the like; substantially as and for the purposes set forth.
CHEESBROUGH & ROYSTON,
Applicant's Patent Agents, 15, Water Street, Liverpool.