IMPROVEMENTS IN: MOULDING OR SHAPING METALS AND OTHER MATERIALS
Year: 1857

page_text: LETTERS PATENT to Richard Brown, of Glasgow, in the County of Lanark,
North Britain, Gentleman, for the Invention of "IMPROVEMENTS IN:
MOULDING OR SHAPING METALS AND OTHER MATERIALS."
Sealed the 23rd February 1858, and dated the 16th September 1857.
PROVISIONAL SPECIFICATION left by the said Richard Brown at the
Office of the Commissioners of Patents, with his Petition, on the 16th
September 1857.
I, RICHARD BROWN, of Glasgow, in the County of Lanark, North Britain,
Gentleman, do hereby declare the nature of the said Invention for "IMPROVE-
MENTS IN MOULDING OR SHAPING METALS AND OTHER MATERIALS," to be as
follows:-
This Invention relates to a system or mode of forming moulds of various
kinds, for casting articles in metal and other materials, especially hollow
articles known in the trade as cast-iron pots, kettles, goblets, and other articles.
In carrying out this process of moulding in its application to the production
of cast-iron pots or similar hollow vessels, a half pattern only is used for
moulding or shaping the surface of the sand, corresponding to the exterior
surface of the intended vessel. This half pattern has its flat side or face coin-
cident with the the axial line of the figure which it is intended to represent;
that is to say, it represents a sectional portion of a vessel as described by a
line cutting through the centre of the intended pot from top to bottom.
The operation takes place upon a horizontal metal table, upon which is laid

page_text: a thin flat plate, with a central hole cut in it to the sectional contour of the
pattern. The pattern is fitted with its flat side upon the horizontal table, the
loose plate fitting accurately to the contour of the pattern at the axial line;
the half moulding box or flask is then set by proper guiding surfaces upon the
table over the half pattern. Provision is made either in the pattern itself,
or by a raised ledge piece upon the table, for bringing the actual axial line of
the pattern even with the upper surface of the loose plate; the sand is then
rammed in at the top of the box upon the pattern, and when the ramming
operation is completed, the box is lifted directly off the pattern along with
the loose bottom plate, which serves to bring the moulded sand clear away
with a good edge. This operation being repeated, the two halves so moulded
are placed together, forming a complete mould, and so on. When feet are to
be moulded upon the pot, they are represented by loose pattern pieces, set in
suitable guides at the proper parts of the pattern. For this purpose the
pattern is made hollow, so that the pattern pieces for the feet can be pushed in
and out from the interior. On commencing to mould, these pattern pieces are
pushed into the interior of the main pattern, and when the flask has been
loosely rammed they are pushed out, so as to enter the proper distance into the
loose sand; the ramming is then completed, and the pattern pieces are again
withdrawn into the interior of the pattern, leaving accurate feet impressions
in the sand. Similarly, other projections may be moulded, where necessary,
by sliding pattern pieces.
The cores for shaping the internal surface of the pot and the flasks or boxes
are formed in the usual or any convenient way. These general arrangements
are also applicable to the moulding of articles in plastic materials, such as clay
and other substances, as well as in molten substances of other kinds than iron.
SPECIFICATION in pursuance of the conditions of the Letters Patent,
filed by the said Richard Brown in the Great Seal Patent Office on
the 16th March 1858.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, RICHARD, S
BROWN, of Glasgow, in the County of Lanark, North Britain, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Sixteenth day of September, in the year of our
Lord One thousand eight hundred and fifty-seven, in the twenty-first year of
Her reign, did, for Herself, Her heirs and successors, give and grant unto
me, the said Richard Brown, Her special license that I, the said Richard

page_text: Brown, my executors, administrators, and assigns, or such others as I, the said.
Richard Brown, my executors, administrators, or assigns, should at any time
agree with, and no others, from time to time and at all times thereafter during
the term therein expressed, should and lawfully might make, use, excrcise
and vend, within the United Kingdom of Great Britain and Ireland, the
Channel Islands, and Isle of Man, an Invention for "IMPROVEMENTS IN
MOULDING OR SHAPING METALS AND OTHER MATERIALS," upon the condition
(amongst others) that I, the said Richard Brown, by an instrument in
writing under my hand and seal, should particularly describe and ascertain
the nature of the said Invention, and in what manner the same was to be
performed, and cause the same to be filed in the Great Seal Patent Office
within six calendar months next and immediately after the date of the said
Letters Patent.
NOW KNOW YE, that I, the said Richard Brown, do hereby declare the
nature of my said Invention, and in what manner the same is to be per-
formed, to be particularly described and ascertained in and by the following
statement in writing, reference being had to the accompanying Drawings,
and to the letters and figures marked thereon, that is to say :-
My said Invention relates to a system or mode of forming moulds of various
kinds for casting articles in metal and other materials, especially hollow
articles, known in the trade as "cast-iron pots," kettles, goblets, and other articls.
In carrying out this process of moulding, in its application to the produc-
tion of cast-iron pots, or similar hollow vessels, a half pattern only is used for
moulding or shaping the surface of the sand, corresponding to the exterior
surface of the intended vessel; this half pattern has its flat side or face coin-
cident with the axial line of the figure which it is intended to represent; that
is to say, it represents a sectional portion of a vessel, as described by a line
cutting through the centre of the intended pot, from top to bottom.
The operation takes place upon a horizontal metal table, upon which is laid
a thin flat plate, with a central hole cut in it, to the sectional contour of the
pattern. The pattern is fitted with its flat side upon the horizontal table, the
loose plate fitting accurately to the contour of the pattern at the axial line;
the half moulding box or flask is then set by proper guiding surfaces upon the
table over the half pattern. Provision is made either in the pattern itself, or
by a raised ledge piece upon the table, for bringing the actual axial line of
the pattern even with the upper surface of the loose plate; the sand is then
rammed in at the top of the box upon the pattern, and when the ramming
operation is completed, the box is lifted directly off the pattern, along with the
loose bottom plate, which serves to bring the moulded sand clear away with a

page_text: good edge. This operation being repeated, the two halves so moulded are
placed together, forming a complete mould, and so on. When feet are to be
moulded upon the pot, they are represented by loose pattern pieces, set in
suitable guides at the proper parts of the pattern; for this purpose the pattern
is made hollow, so that the pattern pieces for the feet can be pushed in and
out from the interior. On commencing to mould, these pattern pieces are
pushed into the interior of the main pattern, and when the flask has been
loosely rammed they are pushed out, so as to enter the proper distance into
the loose sand; the ramming is then completed, and the pattern pieces are
again withdrawn into the interior of the pattern, leaving accurate feet impres-
sions in the sand. Similarly, other projections may be moulded where
necessary by sliding pattern pieces.
The cores for shaping the internal surface of the pot and the flasks or boxes
are formed in the usual or any convenient way. These general arrangements
are also applicable to the moulding of articles in plastic materials, such as clay
and other substances, as well as in molten substances of other kinds than iron.
And in order that my said Invention may be properly understood, I shall
now proceed to describe the several illustrative Figures on the explanatory
Sheet of Drawings, which I have hereunto appended for the purpose of showing
certain modifications under which my improvements may be judiciously carried
out in practice.
Figure 1 on my Sheet of illustrative Drawings is a side view or elevation
of one modification of the machinery or apparatus for moulding hollow vessels
suitable for culinary and other purposes. In this Figure the half moulding
box or flask is shown in vertical section; Figure 2 is an end view of the
machinery or apparatus looking upon the mechanical arrangement for
actuating the leg patterns; Figure 3 is an external view or side elevation,
showing the half moulding box or flask fixed to the loose plate on the
moulding table, and ready for forming a half mould; Figure 4 is a vertical
section of the half pattern and moulding plate, the arrangement for moulding
the legs of the vessel being removed therefrom; Figure 5 is a plan cor-
responding to Figures 1 and 2, the upper part of the flask is not shown, in
order that the internal arrangement of the parts may be more clearly seen;
Figure 6 is a vertical section of the box for moulding the "core" of the
intended vessel, the exterior of the core corresponding to the internal contour
of the vessel; Figure 7 is an elevation of the moulding boxes or flasks
complete; one half of this Figure is drawn in vertical section to show the
cavity left in the sand for the molten metal, and the "gate" for pouring in
the same.

page_text: Figures 8 to 12 on my Sheet of Drawings refer to a modification of my
improvements adapted for moulding kettles and other similarly spouted
articles. In the arrangement of machinery for moulding the three legged
culinary vessels, which in some are technically known as cast-iron "pots," the
machinery or apparatus is supported upon a triple-legged cast-iron frame or
stand A, the upper part of which forms a table B, to this table a pattern C
is fastened by means of bolts and nuts or other fastenings. The pattern C is
by preference of iron, and corresponds in its external figure to one half of the
vessel to be cast. The base line of the pattern C, and which forms the
divisional line of the half mould, passes exactly through the centre of the
mould in a direction parallel with the projecting handles or ears D. The
triple legs upon which the completed vessel stands are formed in the mould
by means of the moveable patterns E, which are made so that they may be
wholly withdrawn inside the pattern C, or thrust out therefrom, as shown in
Figures 1 and 5 of my Drawing. There are two kinds of these three legged
pots manufactured in the trade, the one known as "long legged" or "negro
pots," and the other as "short legged" or "common pots," in my Drawing.
The pattern C is shown in Figures 1 and 5 as arranged for making the
moulds for long legged pots. To mould the short legged pots it is only
necessary to change the patterns for those of the shorter kind. The part of
the leg patterns E, which extend beyond the half pattern C, is shaped to the
form which the legs of the intended vessel are to have. The other portion
of the leg patterns or that which is mainly within the pattern C, is made
sufficiently long to attach them to a pair of actuating levers fitted to one end
of the moulding machine. The prolonged inner ends or tails of two of the
leg patterns E converge, and are attached by means of a bolt and nut to
the lever F. The inner end of the other leg pattern is curved laterally, so as
to bring it in a line with the lever G, to which it is secured in like manner
to the foregoing. The levers F and G are centred upon the spindle H, the
ends of which are carried in a pair of brackets I that are bolted to the end
plate of the pattern B and the frame or stand A. Thus, by moving the
lever F to and fro, the two leg patterns jointed thereto are thrust beyond or
may be drawn entirely within the pattern C; in like manner the single
leg pattern attached to the lever G may be protruded or withdrawn, as
required, in the formation of the separate half moulds, that is to say, one
half mould contains the recesses for forming two legs of the pot or vessel,
while the other half mould contains the recess wherein the third leg
is formed. The requisite extent of traverse of the levers F and G is
regulated by a guide J, which is bolted to an eye that projects from the

page_text: upper part of the pattern B. The levers F and G are moved to and fro
in recesses cut in the sides of the guide J, and this amount of traverse
of the levers may be limited when making the moulds for short legged pots or
vessels by inserting a pin in the side of the guide J, as shown in dotted lines in
Figure 1 of my Drawing. A loose plate K, either of iron or steel, and having
an aperture cut therein exactly corresponding to the shape or contour of the
divisional line of the pattern C, is placed upon the surface of the moulding
table B. The loose plate K is made with a rim or flange, which encircles the
greater portion of the moulding table B; upon this rim are formed two eyes L
one upon each side of the plate K. Into each of these eyes is hooked a
clamp M; the slotted end of this clamp carries a cotter N, which serves to
fasten the mould box O firmly to the plate K. The thickness portion C' is
for the purpose of bringing the axial line of the pattern accurately coincident
with the upper surface of the loose plate. The gate pattern P is fast upon
the plate K, and being thus secured thereto it answers effectually for retaining
the box in its proper position. The mould box O is placed upon the plate K,
and fastened thereto by passing the clamp M into the openings in the lugs R,
which are formed on the sides of the mould O. The cotter N is driven into
the slot of each clamp, so as to wedge it firmly against its corresponding
lug R. A pin is fitted in the narrow end of each cotter, in order that the
cotters may not be driven away from the clamps when the mould box is being
released. This arrangement is to prevent loss of time in picking up and
replacing the cotters during the moulding operations. That part of each
mould box O which comes in contact with the back plate of the pattern C is
made with a groove or check, which fits the periphery of that portion of the
pattern and the raised edge K¹ of the loose plate, as shown in Figures 1 and 5.
The fitting of these two parts together insures the mould box being placed
exactly in its proper position on the plate K. When the box is lifted off, the
check or flange on the plate K prevents the loose plate from moving from its
position as it acts as a dead fixed stop. The core or mould of the internal
portion of the intended vessel is made in the core box, which is shown in
vertical section in Figure 6 of my Drawing. This core box is made in four
parts, the lower portion or "drag" S, the central portion T, which is in two
parts, and the upper portion U, the whole being held together by the
clamps V. In moulding vessels by means of this machinery the work is done
by three boys; skilled labour is not required. The duty of one of the boys is
to ram the half moulds upon the pattern C, whilst another "sleeks" or finishes
the half moulds as they are formed, the third boy being meanwhile occupied
in moulding the cores. In this manner the work proceeds with uninterrupted

page_text: regularity and despatch, the operations following each other so as to avoid any
loss of time. A half mould O is put on the plate K, and fastened by the
cotters N; the leg patterns are withdrawn within the pattern; the mould box
is partially filled with sand. And before ramming this firmly round the
pattern the lever F is moved backwards, which has the effect of protruding
the duplex legs through the pattern, and causing them to enter the moulding
sand. The mould is now filled up with sand, and properly rammed, the leg
patterns are withdrawn from the sand by moving back the lever F, the
cotters N are knocked back, and the loose plate K, with the half mould box 0,
and the mould contained therein, are lifted off from the table B, and handed
to the boy whose duty it is to sleek and finish the half moulds. The moulding
boy at the machine then puts another loose plate K, with its gate pattern P,
and half mould box O upon the table B, and proceeds to mould the other half
of the pot or vessel. In moulding the second half, the single leg pattern E,
which is actuated by the lever G, must be thrust into the sand; that is to say,
one-half of the mould contains the cavities for two of the legs, whilst the third
leg is moulded in the other half; the levers F and G and therefore actuated
alternately. During the time the first half of the mould is being made and
sleeked or finished, the third boy is moulding the core in the box shown in
Figure 6. The core box is rammed through the aperture in the "drag" of
the mould; the core box is then inverted, as shown in the Figure. The
cotters of the core box are knocked back, and the upper part lifted off; the
two pieces are removed laterally, leaving the core standing upon the " drag,"
which being sleeked, is then ready to receive the two halves, which complete
the mould. The second boy, who has in the meantime finished the first half
of the mould and removed the loose plate with its gate pattern, places it over
the core, the groove of the mould box O being made to fit the periphery of the
drag." The second half of the mould being rammed and finished in like
manner, is placed against the first half, and the two half mould boxes are
fastened together by means of the clamps W, Figure 7. The mould is now
completed and ready to receive the molten metal. The edges of the two half
moulds are so sharp, and the junction so accurately effected, as to be scarcely,
if at all, perceptible in the finished casting. The highly important desideratum
so essential in moulding, namely, a clean, sharp edge to the half mould, is
ensured in this system of moulding by the agency of the loose plate, which
serves not only to sustain the half mould when being lifted off the moulding
table, but it also preserves the edges in a perfect state while the mould
is being slecked and finished; hence this operation may be done by boys
wholly unskilled in the art of moulding. This system of moulding is

page_text: adapted for a variety of articles which come under the designation of
hollow ware," such as kettles, camp ovens, drums for gas meters, shot,
shells, and so forth. To give one other example of its application, Figures 8
to 13 of my Drawing represent its adaptation to the formation of moulds
suitable for casting ordinary domestic kettles. Figure 8 is a side view
of the modification partially in section; Figure 9 is an end view, one half of
the upper part of the Figure being in section; Figure 10 is a plan correspond-
ing to Figures 8 and 9. Figure 11 is a plan of one of the loose plates used
in this modification. Figure 12 is a sectional elevation of the core box, and
Figure 13 is an elevation of the mould complete; one half of this Figure is
drawn in vertical section, to show the internal arrangement of the mould.
The stand or frame a is similar in form to that shown in Figures 1 and 2; its
upper surface b forms a table whereon is placed a loose plate c, which is made
to fit accurately the outline of the pattern d, which corresponds to the
external figure of the body of the kettle. The pattern for forming the half
mould of the spout is cast or otherwise formed in relief upon the loose plate c,
so that to form the two parts of the spout mould there must be two of these
loose plates, the one a right-handed pattern, and the other a left-handed one.
In Figure 11 the half-spout pattern is shown at e, and in Figure 10 one of
the loose plates is shown in its position during the formation of one half of the
mould; the position of the second plate c, used for the other half mould, is
shown at the upper part of the Figure. The loose plates c are each fur-
nished with clamps and cotters f for securing the mould box 9 thereto. The
mould boxes are made with grooved edges, that fit against the back part of
the pattern d. The operation of moulding the two halves of the mould is, in
all respects, similar to that herein-before described, the right and left handed
loose plates c being used alternately. In the core box, shown in Figure 12,
in which the core for forming the internal Figure of the kettle is made, there
is a "print" h, which forms a recess in the moulded core. When the core is
properly rammed the core box is removed, and the core left standing upon the
dragi. A core for the spout, which has previously been moulded in a suitable
core box, is then placed in the cavity left by the print h, as shown at j, in
Figure 13. The two half moulds, which have meanwhile been formed on the
pattern d are then placed together over the cores, and the boxes are clamped,
which completes the mould ready for casting. The different operations are
intended to be performed by boys in a sequential other, similar to that herein-
before described, or with such modifications as the particular kind of work
may require. Although I have shown the moulding machinery or apparatus
arranged upon a frame or stand, it may in some cases be preferred to screw

page_text: the moulding table and pattern to a moulding stool or log in. lieu of the cast-
iron frame. It will be obvious that, in adapting these improvements in
moulding to the various purposes to which the Invention is applicable, certain
modification in the machinery or apparatus will be necessary, which, however,
may be effected without departing from the Invention. In adapting the
moulding machinery or apparatus to the production of articles formed of
plastic materials, or other substances suitable for moulding, the same general
routine is to be followed; but in this application the moulding apparatus
may be modified to adapt it to the material of which the article is to be
manufactured.
Having now described and particularly ascertained the nature of my said
Invention, and the manner in which the same is or may be used or carried
into effect, I may observe, in conclusion, that I do not confine or restrict
myself to the precise details or arrangements which I have had occasion
to describe or refer to, as many variations may be made therefrom without
deviating from the principles or main features of my Invention; but what I
consider to be novel and original, and therefore claim as the Invention
secured to me by the herein-before in part recited Letters Patent is,―
First, the general arrangement and construction of machinery or apparatus
for moulding or shaping metals or materials, as herein-before described.
Second, the system or mode of moulding hollow articles suitable for casting
in iron or other materials by means of machinery or apparatus as herein-before
described.
Third, the system or mode of forming the moulds of hollow ware articles
in two parts upon fixed patterns, as herein-before described.
Fourth, the use and application of a loose plate or plates in conjunction with
the moulding machinery; the said plate or plates serving to facilitate the
operation of "sleeking" or finishing the half moulds, and preserve the edges
of the same perfectly sharp, as herein-before described.
Fifth, the system or mode of moulding articles in metal and other materials
by the agency of a loose plate, which being lifted off along with the rammed
and moulded box effectually preserves the edges of the moulded material, as
herein-before described.
Sixth, the system or mode of moulding the foot portions of hollow ware
and other generally similar projections by the agency of guided pattern pieces
protruded at pleasure from the interior of the patterns.
Seventh, the system or mode of bringing the actual axial line of the pattern
even with the upper surface of the loose plate by means either of provision

page_text: made in the pattern itself, or by the use of a raised ledge piece upon the
table.
Eighth, the use and application of the machinery or apparatus, herein-before
described, to the purposes of moulding articles in plastic, or other suitable
moulding material or materials.
In witness whereof, I, the said Richard Brown, have hereunto set my
hand and seal, this Thirteenth day of March, One thousand eight
hundred and fifty-eight.
RICHARD BROWN. (L.S.)