Process of Manufacturing Metallic Cross-bars and Rails for Window Sashes and Analogous Structures.
Year: 1889

page_text: COMPLETE SPECIFICATION.
Process of Manufacturing Metallic Cross-bars and Rails for Window
Sashes and Analogous Structures.
A communication from WILLIAM HENDERSON, Glass Cutter, residing at 210 East
Kinzie Street, in the City of Chicago, County of Cook, and State of Illinois,
United States of America.
I, ALFRED JULIUS BOULT of 323 High Holborn, in the County of Middlesex,
M.I.M.E., 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 :-
This invention relates to improvements in the process of manufacturing metallic'
cross-bars and rails for window sashes, skylights and other structures and it consists
in certain peculiarities of the method of operation as will be hereinafter more fully
set forth.
In order to enable others skilled in the art to which this invention pertains, to use
the same, I will now proceed to describe it referring to the accompanying drawing
in which I have illustrated the machine or devices I prefer to use and which shows
how the process is carried on.
In the drawing:
Figure 1 is a side elevation of this machine as it appears when in operation.
Figure 2 is a plan view of the same. Figure 3 shows a view in side elevation of
the bending or conforming device. Figure 4 is an end view of the same. Figure 5
is a plan view of the machine for forming or notching the ends of the bars.
Figure 6 is a view in side elevation of the same. Figure 7 shows a face view of a
die for making the lower portion of the bar. Figure 8 is a cross section of figure 7,
taken on line 8, 8. Figure 9 is a face view of a die for forming the cap or upper
portion of the bar. Figure 10 is a cross-section of the same on line 10, 10.
Figures 11, 12, 13, 14, 15, 16, and 17 show end views of modifications of the bars or
rails when completed. Figure 18 is an end view of the die retaining device.
Figure 19 is a view of a strip of metal with end formed for insertion into the
opening of the die.
Similar letters refer to like parts throughout the different views of the drawing.
A represents the main or supporting frame of the machine on and near one end of
which the pulley B, and a small pinion 6, mounted on and rigidly secured to a suitable
shaft 61, is journalled in the ordinary manner. To the pulley B, and by means of a
belt a, or otherwise is applied the power for operating the entire machine. On the
frame A at a proper distance from the shaft b¹, rigidly mounted on a shaft 62, is
journalled a cogged-gear wheel C, and a sprocket wheel c.
Near the other end and on the frame A is journalled a suitable pulley c², over which
the endless chain D, freely passes, being drawn over said pulley by engagement with
the sprocket-wheel c as will be clearly seen by reference to figures 1 and 2 of the
drawing. At the end of the frame and near the pulley c³, I provide the frame with a
table or platform c³, upon which is secured the die retaining device or frame E, which
consists of a base plate d, and two upright side pieces d', d², and a cross-bar d³, at the
top provided with set-screws d', the whole forming a hollow for the reception and
retention of the die plate H or H', which is firmly held in place by the set screws and
prevented being drawn through the hollow of the frame by the inwardly projecting
lugs d, as shown, or otherwise. Within this hollow frame or retaining device the
die plate H or H', provided with desirable apertures i and ¹, is removably secured,
and a strip of metal a', having its end formed tapering so as to be easily inserted in
said apertures is forced through until it projects sufficiently to allow the gripper M to
grip the same as will be presently explained. In figures 7 and 9, I have shown two

page_text: dies H and H, preferably made of steel and of two pieces, which I use in forming
the metallic bar and cap. They may be formed with openings or apertures i, i¹, of
any form, to produce a bar of any desired contour or shape and in numerous styles
of configuration, but the present form of apertures shown in the die plates are a lapted
to produce a bar with form as illustrated in figure 11, which is the construction
preferred by my correspondent, yet it is apparent that a form of die may be employed
to produce any of the forms shown in figs. 11 to 17 inclusive, or in fact almost any
conceivable shape. In the present instance I have shown the dies H, and H', formed
with two openings i and i, each through the same, said openings being made with a
wide flaring mouth 2, on the face of the plate for the easy insertion of the end of the
metal strip. The opening i, in each of the dies is for giving to the metal the first
formation, and the other opening ", the finished or completed form; the die H forming
the lower portion or bar, and die H, the cap or fastening or upper portion, which
when joined together produces a bar of form shown in fig. 11.
The figures 11 to 17 inclusive may represent either modifications of the form of the
aperture in the die or the end views of bars produced by the respective dies, and I
shall refer to them as either. Figure 11 shows the end of a bar, formed by a die of
that shape, having a rib k, and on one or both sides of the said rib a groove k'. for
the reception and retention of the edge of the glass, formed by the shoulders, ledges
or rests k². In this construction as well as others the die forming the rib k, may be
made so as to form a flange or enlargement 1, at the top, as shown or without the
same, or in forming a bar of three separate pieces of metal as shown in figure 14,
I may use a die of such shape as to form it with or without enlargement at the top or
bottom of the rib, but I prefer a flange or enlargement as it affords a more secure
fastening. In the different modifications I have shown them with a hollow m, ahove
and beneath the shoulders or rests k², but of course this could be dispensed with and
a die used to form the bar with a flat top and bottom surface yet having the shoulders
and grooves as before, or one may he used to form a cap with an opening having
parallel sides for the rih, or a projection having parallel sides so that the joint can be
made at any point on the rib. Figure 17 shows the product of a form of die
especially adapted for sky-light bars, and it is made to form the bar with a rib k,
and shoulder or shoulders kas before, and in addition a trough n, on one or both
sides of the rib, which trough is designed to catch the condensed moisture which may
accumulate on the under surface of the glass.
In figures 1 and 2 will be seen the gripping device M connected to the chain
belt D, and grasping the end of the bar, as it appears when being drawn through the
die. The gripper is made of two pieces o, pivotted together near one end by a pin o¹,
and has the inner surface of its jaws p, p, roughened so as to prevent slipping. To
the other end of the pieces o, is secured a toggle joint r, and at the elbow of this
joint is loosely provided a hook S, which hooks into the link of the chain belt, and is
drawn along by said belt, the toggle-joint thus forcing the upper ends of the pieces o, o
apart, and closing more tightly the jaws p, p on the bar as is obvious.
In figures 3 and 4 I have shown the bending or conforming device or machine
which is used after the bar has been formed as desired on the die machine, and
it consists of a suitable frame E upon which is journalled a series of rollers,
(preferably three in number) F, F1 and F2, two of which, F F', are geared together
at one end by suitable cogged gears, and are operated by means of a handle e, secured
to one of them or otherwise if desired. At the opposite end of the rollers and outside
of the frame I provide each roller on its surface with a groove or grooves of a form
to conform to the shape of the bar after it has been finished by the dies. In the drawing
the groove is shown as formed in the roller, but 1 may use suitable collars, formed with
any desired form of groove, and adjust them to the rollers and accomplish the same
results. Of course the form of the grooves may be of any shape that the bar may be,
but I have shown in the drawing at e³, the same formation illustrated in the dies and
at Figure 11.
To the rear of these rollers in a suitable recess e, vertical in length I place the
roller F2, which is provided with a similar groove to those just described. This roller

page_text: is journalled on a vertically sliding or adjustable bearing e, which is adjusted to any
point by means of the screw-threaded crank-rod e. It will be seen that by inserting
the end of the bar into the opening e³, between the rollers F and F¹ and revolving the
rollers it will be drawn through and will pass over the roller F2, by raising or lowering
which will produce any degree of a curve desired and at the same time will fit the
cap and bar to each other when they are made in separate pieces.
Figs. 5 and 6 illustrate the device for cutting the bar into proper lengths and for
notching or finishing the ends of the same, and it consists of the shaft G journalled in
suitable bearings on a frame and having mounted on said shaft near one end an
ordinary circular saw g and on the other end a plurality of circular discs but pre-
ferably three in number h, h¹ h² two of these are bevelled at an angle as shown at g¹
in figure 5 and are provided on their bevelled peripheries with sharp oblique teeth g².
The disc h is located between the discs h and 2 and has a smooth periphery thus
acting as a guide or stop to the bar. Between the disc h³ and the saw 9 upon the
shaft G is secured a pulley g³ to which is applied the power for operation. On one
side of the discs and adjacent thereto is provided a suitable table or support R pro-
vided with a raised bead on its upper surface as shown. The table serves as a
support when the ends of the bars are pressed against the discs and the bead r¹ fitting
in the groove of the bar serves as a guide in this operation.
The operation of the invention is simple and as follows;-
The die is placed in the retaining device and is firmly secured there by the set
screws at the top of this device for this purpose. The gripping device M is then
hooked to the chain belt and the end of the metal is forced through the die until it
projects far enough to allow the gripper to take hold of the end of the bar. The
power is then applied to the pulley B and the chain belt engaging with the sprocket
wheel tightens the gripper on the bar and draws it through the die. When this
process is completed the bar is applied horizontally to the saw and cut into proper
lengths after which the ends of the same are notched by holding them against the
revolving discs after which the bar is passed through the bending or conforming
device and formed into any desired curve when the cap may be removed and the
upper angular part of rib K cut away so as to admit of the end of the bar so pre-
pared being fitted close up against the side of a bar which may be perpendicular
to it.
I
may sometimes form the bar and cap in one piece and afterwards separate them
by cutting the rib K in a longitudinal direction. This arrangement admits of the
two pieces being adjusted to glass of any thickness.
The drawing illustrates the bending device and cutter and end notching machine, as
separate devices from the die, or bar forming machine, but it is evident that they may
all be mounted on the same frame and operated by the same power and it is some-
times so constructed that after the metal is drawn through this die and given any
desired form it may be cut in suitable lengths and have its ends notched and then
passed through the rollers and curved or bent in any shape or form.
Having now particularly described and ascertained the nature of the said inven-
tion and in what manner the same is to be performed, as communicated to me by
my foreign correspondents, I declare that what I claim is :-
1. The herein described process of manufacturing cross bars rails and fastenings
for window sashes consisting first in passing the strips of metal through a die or dies
giving the bar the desired conformation or shape then cutting or sawing the formed
strips into proper lengths then notching the ends of the strips and then passing the
notched strips through a device for bending the same into suitable shape or curve
ready for use substantially as and for the purpose set forth.
2. The herein described process of manufacturing metallic cross bars rails and
fastenings for window sashes consisting first in drawing the strips of metal through a
die or dies making the proper conformation or shape then placing the strips horizon-
tally against a revolving circular saw and cutting them to proper lengths then
notching the ends of the formed strips by placing them longitudinally against a series

page_text: of revolving discs then passing the notched 'strips through a series of rollers thus
-bending them to a proper curve ready for use substantially as shown and described and
for the purpose set forth.
3. The herein described process of manufacturing metallic cross bars rails and
fastenings for window sashes consisting first in passing strips of metal through a die or
dies forming a bar and cap of desired conformation then placing the cap on the rib
of the bar and cutting them into proper lengths then notching the ends of the strips
then passing the notched strips through a device for bending the same to a desired
curve then removing the adjustable cap and clipping the ends of the rib of the bar
at a desired angle substantially as shown and described and for the purpose set
forth.
4. The herein described process of manufacturing hollow metallic cross bars rails
and fastenings for window sashes consisting first in forming metallic bar and cap in
separate pieces then adjusting the cap on the rib or web of the bar then bending
cutting and notching the same as a whole then removing the adjustable cap and
cutting the ends of the web or rib of the bar substantially as and for the purpose
'specified.
5. The herein described process of manufacturing metallic cross bars rails and
fastenings for window sashes consisting first in forming a bar and cap integral then
cutting bending and notching the same and then sawing or cutting it longitudinally
substantially as and for the purpose specified.
Dated this 15th day of October 1889.
W. P. THOMPSON & BOULT,
Agents for the Applicant.

page_text: Date of Application, 15th Oct., 1889-Accepted, 12th Apr., 1590
COMPLETE SPECIFICATION.
Process of Manufacturing Metallic Cross-bars and Rails for Window
Sashes and Analogous Structures.
A communication from WILLIAM HENDERSON, Glass Cutter, residing at 210 East
Kinzie Street, in the City of Chicago, County of Cook, and State of Illinois,
United States of America.
I, ALFRED JULIUS BOULT of 323 High Holborn, in the County of Middlesex,
M.I.M.E., 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 :-
This invention relates to improvements in the process of manufacturing metallic
cross-bars and rails for window sashes, skylights and other structures and it consists
in certain peculiarities of the method of operation as will be hereinafter more fully
set forth.
In order to enable others skilled in the art to which this invention pertains, to use
the same, I will now proceed to describe it referring to the accompanying drawing
in which I have illustrated the machine or devices I prefer to use and which shows
how the process is carried on.
In the drawing:
Figure 1 is a side elevation of this machine as it appears when in operation.
Figure 2 is a plan view of the same. Figure 3 shows a view in side elevation of
the bending or conforming device. Figure 4 is an end view of the same. Figure 5
is a plan view of the machine for forming or notching the ends of the bars.
Figure 6 is a view in side elevation of the same. Figure 7 shows a face view of a
die for making the lower portion of the bar. Figure 8 is a cross section of figure 7,
taken on line 8, S. Figure 9 is a face view of a die for forming the cap or upper
portion of the bar. Figure 10 is a cross-soction of the same on line 10, 10.
Figures 11, 12, 13, 14, 15, 16, and 17 show end views of modifications of the bars or
rails when completed. Figure 18 is an end view of the die retaining device.
Figure 19 is a view of strip of metal with end formed for insertion into the
opening of the die.
Similar letters refer to like parts throughout the different views of the drawing.
A represents the main or supporting frame of the machine on and near one end of
which the pulley B, and a small pinion 6, mounted on and rigidly secured to a suitable
shaft b, is journalled in the ordinary manner. To the pulley B, and by means of a
belt a, or otherwise is applied the power for operating the entire machine. On the
frame A at a proper distance from the shaft b', rigidly mounted on a shaft b², is
journalled a cogged-gear wheel C, and a sprocket wheel c.
Near the other end and on the frame A is journalled a suitable pulley c², over which
the endless chain D, freely passes, being drawn over said pulley by engagement with
the sprocket-wheel c as will be clearly seen by reference to figures 1 and 2 of the
drawing. At the end of the frame and near the pulley c², I provide the frame with a
table or platform c³, upon which is secured the die retaining device or frame E, which
consists of a base plate d, and two upright side pieces d', d³, and a cross-bar d³, at the
top provided with set-screws d, the whole forming a hollow for the reception and
retention of the die plate H or H¹, which is firmly held in place by the set screws and
prevented being drawn through the hollow of the frame by the inwardly projecting
lugs ³, as shown, or otherwise. Within this hollow frame or retaining device the
die plate H or H³, provided with desirable apertures i and, is removably secured,
and a strip of metal a², having its end formed tapering so as to be easily inserted in
said apertures is forced through until it. projects sufficiently to allow the gripper M to
grip the same as will be presently explained. In figures 7 and 9, I have shown two

page_text: dies H and H, preferably made of steel and of two pieces, which I use in forming
the metallic bar and cap. They may be formed with openings or apertures i, ¹, of
any form, to produce a bar of any desired contour or shape and in numerous styles
of configuration, but the present form of apertures shown in the die plates are a lapted
to produce a bar with form as illustrated in figure 11, which is the construction
preferred by my correspondent, yet it is apparent that a form of die may be employed
to produce any of the forms shown in figs. 11 to 17 inclusive, or in fact almost any
conceivable shape. In the present instance I have shown the dies H, and H', formed
with two openings i and i, each through the same, said openings being made with a
wide flaring mouth, on the face of the plate for the easy insertion of the end of the
metal strip. The opening i, in each of the dies is for giving to the metal the first
formation, and the other opening ", the finished or completed form; the die H forming
the lower portion or bar, and die H, the cap or fastening or upper portion, which
when joined together produces a bar of form shown in fig. 11.
The figures 11 to 17 inclusive may represent either modifications of the form of the
aperture in the die or the end views of bars produced by the respective dies, and I
shall refer to them as either. Figure 11 shows the end of a bar, formed by a die of
that shape, having a rib k, and on one or both sides of the said rib a groove k', for
the reception and retention of the edge of the glass, formed by the shoulders, ledges
or rests 2. In this construction as well as others the die forming the rib k, may be
made so as to form a flange or enlargement 1, at the top, as shown or without the
same, or in forming a bar of three separate pieces of metal as shown in figure 14,
I may use a die of such shape as to form it with or without enlargement at the top or
bottom of the rib, but I prefer a flange or enlargement as it affords a more secure
fastening. In the different modifications I have shown them with a hollow m2, above
and beneath the shoulders or rests, but of course this could be dispensed with and
a die used to form the bar with a flat top and bottom surface yet having the shoulders
and grooves as before, or one may be used to form a cap with an opening having
parallel sides for the rih, or a projection having parallel sides so that the joint can be
made at any point on the rib. Figure 17 shows the product of a form of die
especially adapted for sky-light bars, and it is made to form the bar with a rib k,
and shoulder or shoulders kas before, and in addition a trough n, on one or both
sides of the rib, which trough is designed to catch the condensed moisture which may
accumulate on the under surface of the glass.
In figures 1 and 2 will be seen the gripping device M connected to the chain
belt D, and grasping the end of the bar, as it appears when being drawn through the
die. The gripper is made of two pieces o, pivotied together near one end by a pin o¹,
and has the inner surface of its jaws P, P, roughened so as to prevent slipping. To
the other end of the pieces o, is secured a toggle joint r, and at the elbow of this
joint is loosely provided a hook S, which hooks into the link of the chain belt, and is
drawn along by said belt, the toggle-joint thus forcing the upper ends of the pieces o, o
apart, and closing more tightly the jaws p, p on the bar as is obvious.
In figures 3 and 4 I have shown the bending or conforming device or machine
which is used after the bar has been formed as desired on the die machine, and
it consists of a suitable frame E upon which is journalled a series of rollers,
(preferably three in number) F, F' and F2, two of which, F F', are geared together
at one end by suitable cogged gears, and are operated by means of a handle e, secured
to one of them or otherwise if desired. At the opposite end of the rollers and outside
of the frame I provide each roller on its surface with a groove or grooves of a form
to conform to the shape of the bar after it has been finished by the dies. In the drawing
the groove is shown as formed in the roller, but I may use suitable collars, formed with
any desired form of groove, and adjust them to the rollers and accomplish the same
results. Of course the form of the grooves may be of any shape that the bar may be,
but I have shown in the drawing at e³, the same formation illustrated in the dies and
at Figure 11.
To the rear of these rollers in a suitable recess e, vertical in length I place the
roller F, which is provided with a similar groove to those just described. This roller

page_text: is journalled on a vertically sliding or adjustable bearing es, which is adjusted to any
point by means of the screw-threaded crank-rod ee. It will be seen that by inserting
the end of the bar into the opening e³, between the rollers F and F and revolving the
rollers it will be drawn through and will pass over the roller F, by raising or lowering
which will produce any degree of a curve desired and at the same time will fit the
cap and bar to each other when they are made in separate pieces.
Figs. 5 and 6 illustrate the device for cutting the bar into proper lengths and for
notching or finishing the ends of the same, and it consists of the shaft G journalled in
suitable bearings on a frame and having mounted on said shaft near one end an
ordinary circular saw and on the other end a plurality of circular discs but pre-
ferably three in number h, h² two of these are bevelled at an angle as shown at gl
in figure 5 and are provided on their bevelled peripheries with sharp oblique teeth g².
The disc is located between the discs h and 2 and has a smooth periphery thus
acting as a guide or stop to the bar. Between the disc 2 and the saw g upon the
shaft G is secured a pulley g³ to which is applied the power for operation. On one
side of the discs and adjacent thereto is provided a suitable table or support R pro-
vided with a raised bead on its upper surface as shown. The table serves as a
support when the ends of the bars are pressed against the discs and the bead r¹ fitting
in the groove of the bar serves as a guide in this operation.
The operation of the invention is simple and as follows;-
The die is placed in the retaining device and is firmly secured there by the set
screws at the top of this device for this purpose. The gripping device M is then
hooked to the chain belt and the end of the metal is forced through the die until it
projects far enough to allow the gripper to take hold of the end of the bar. The
power is then applied to the pulley B and the chain belt engaging with the sprocket
wheel tightens the gripper on the bar and draws it through the die. When this
process is completed the bar is applied horizonially to the saw and cut into proper
lengths after which the ends of the same are notched by holding them against the
revolving discs after which the bar is passed through the bending or conforming
device and formed into any desired curve when the cap may be removed and the
upper angular part of rib K cut away so as to admit of the end of the bar so pro-
pared being fitted close up against the side of a bar which may be perpendicular
to it.
I may sometimes form the bar and cap in one piece and afterwards separate them
by cutting the rib K in a longitudinal direction. This arrangement admits of the
two pieces being adjusted to glass of any thickness.
The drawing illustrates the bending device and cutter and end notching machine, as
separate devices from the die, or bar forming machine, but it is evident that they may
all be mounted on the same frame and operated by the same power and it is some-
times so constructed that after the metal is drawn through this die and given any
desired form it may be cut in suitable lengths and have its ends notched and then
passed through the rollers and curved or bent in any shape or form.
Having now particularly described and ascertained the nature of the said inven-
tion and in what manner the same is to be performed, as communicated to me by
my foreign correspondents, I declare that what I claim is :-
1. The herein described process of manufacturing cross bars rails and fastenings
for window sashes consisting first in passing the strips of metal through a die or dies
giving the bar the desired conformation or shape then cutting or sawing the formed
strips into proper lengths then notching the ends of the strips and then passing the
notched strips through a device for hending the same into suitable shape or curve
ready for use substantially as and for the purpose set forth.
2. The herein described process of manufacturing metallic cross bars rails and
fastenings for window sashes consisting first in drawing the strips of metal through a
die or dies making the proper conformation or shape then placing the strips horizon-
tally against a revolving circular saw and cutting them to proper lengths then
notching the ends of the formed strips by placing them longitudinally against a series

page_text: of revolving discs then passing the notched strips through a series of rollers thus
-bending them to a proper curve ready for use substantially as shown and described and
for the purpose set forth.
:
3. The herein described process of manufacturing metallic cross bars rails and
fastenings for window sashes consisting first in passing strips of metal through a die or
dies forming a bar and cap of desired conformation then placing the cap on the rib
of the bar and cutting them into proper lengths then notching the ends of the strips
then passing the notched strips through a device for bending the same to a desired
curve then removing the adjustable cap and clipping the ends of the rib of the bar
at a desired angle substantially as shown and described and for the purpose set
forth.
4. The herein described process of manufacturing hollow metallic cross bars rails
and fastenings for window sashes consisting first in forming a metallic bar and cap in
separate pieces then adjusting the cap on the rib or web of the bar then bending
cutting and notching the same as a whole then removing the adjustable cap and
cutting the ends of the web or rib of the bar substantially as and for the purpose
'specified.
5. The herein described process of manufacturing metallic cross bars rails and
fastenings for window sashes consisting first in forming a bar and cap integral then
cutting bending and notching the same and then sawing or cutting it longitudinally
substantially as and for the purpose specified.
Dated this 15th day of October 1889.
W. P. THOMPSON & BOULT,
Agents for the Applicant.