IMPROVEMENTS IN THE PATTERNS USED FOR CASTING, AND IN CASTING METALS
Year: 1846

page_text: TO ALL TO WHOM THESE PRESENTS SHALL COME, I, JOSEPH
DOUGLAS, of Cross Cheaping, Coventry, Furnishing Ironmonger, send
greeting.
WHEREAS Her present most Excellent Majesty Queen Victoria, by Her
Royal Letters Patent under the Great Seal of Great Britain, bearing date
at Westminster, the Ninth day of January, in the ninth year of Her
reign, did, for Herself, Her heirs and successors, give and grant unto me,
the said Joseph Douglas, my exors, adiuors, and assigns, Her especial licence,
full power, sole privilege and authority, that I, the said Joseph Douglas,
my exors, adñiors, and assigns, or such others as I, the said Joseph Douglas,
my, exors, alñiors, or assigns, should at any time agree with, and no others,
from time to time and at all times during the term of years therein
expressed, should and lawfully might make, use, exercise, and vend, within
England, Wales, and the Town of Berwick-upon-Tweed, my Invention of
"IMPROVEMENTS IN THE PATTERNS USED FOR CASTING, AND IN CASTING METALS;"
in which said Letters Patent is contained a proviso that I, the said Joseph
Douglas, shall cause a particular description of the nature of my said
Invention, and in what manner the same is to be performed, to be inrolled
in Her said Majesty's High Court of Chancery within six calendar months
next and immediately after the date of the said in part recited Letters Patent,
as in and by the same, reference being thereunto had, will more fully and at
large appear.

page_text: NOW KNOW YE, that in compliance with the said proviso, I, the said
Joseph Douglas, do hereby declare that the nature of my said Invention,
and the manner in which the same is to be performed, are fully described
and ascertained in and by the following. statement thereof, reference being had
to the Drawings hereunto annexed, and to the figures and letters marked
thereon, that is to say:-
My Invention consists of Improvements in the Construction of Patterns for
Casting, and in Casting Metals, and these improvements are such that the use
of parting sand between. two..parts-of a mould will be rendered. unnecessary in
casting articles in iron and other metals where there are concave and convex
surfaces required to be produced to the article cast; and the same is also appli-
cable where the article, is to have two convex or two concave surfaces, by
which not only may more true castings be made, but, owing to the avoiding
the use of parting sand, and employing metal surfaces in making the surfaces
of two half moulds which are to come together by ramming on metal surfaces,
in place of producing the like surfaces by ramming the sand of the second
half of the mould on to the sand surface of the previously made half mould,
a workman much less skilled in making moulds for casting will be able to
make moulds for the best class of work more quickly and correctly than a
better workman proceeding according to the old mode of making moulds for.
casting metals. I will, in the first place, proceed to describe the Invention'as
applied to casting metal for making articles having a convex and a concave
surface corresponding to each other in the midst of a plate or plain surface,
and then proceed to describe the Invention as applied to the manufacture of
hollow ware, to which this mode of working is particularly applicable.
Figures 1 and 2 show a plan and section of the bottom mould suitable for.
making the pattern. The pattern is so made that it is cast with and forms
part of the plate, so that that part of the plate which extends beyond the
pattern of the article to be moulded serves as the surface against which the
sand is rammed in making the parting surfaces of the two half moulds.
Figure 1 shews a plan of the bottom half mould, which is to be made in
the ordinary manner by ramming on a properly prepared pattern of the
article to be cast, and when the half mould Figure 1 has been produced,
it is to be turned over and a top half inould produced in the ordinary
manner by using parting sand over the whole surface,' by which the
top half mould Figure 3 is produced; and such. top mould having been
removed, a frame a of the figure of the intended pattern plate, so as to fit
between the flasks or boxes to be used, is to be laid on to the mould, and sand
is to be rammed round this frame; and by preference I employ an outer frame

page_text: b of the same thickness as the frame a to support the outer edges of the sand.
By this means there will be a space between the moulds produced beyond the
pattern, and when the casting has been made in such mould the pattern will
be surrounded on all sides with a plate, and this plate will be suitable for being
shut between the two flasks or boxes in making the mould from such pattern.
Figure 3. shews a plán, and Figure 4 a section of the top half of the mould
for making the pattern with convex and concave surfaces, and Figure 5 shews
two plans and sections of the pattern produced, surrounded on all sides with a
plate.c;. hence it will be understood that the plate c is not itself the pattern,
but-is-the-means of holding the pattern in the mould, and becomes the means
of obtaining the parting surfaces. in making the two half moulds. Figure 4*
shews the pattern in its place, between two half. moulds d and e, the pattern
fitting by.its. projections between guides affixed to the sides of the two flasks
or boxes. Figure 6 shows two half. moulds formed from the pattern plate ċ,
the pattern plate c having been removed. In making the two half moulds the
pattern plate c is placed between the two boxes or flasks d and e, and sand is
to be rammed first into the lower box, and the two boxes are to be turned
over, and the sand is then to be rammed into the upper box or flask. By this
means the two half moulds will be produced as is shewn at Figure 4*. The
upper half mould is to be lifted off and the pattern plate c removed, and the
upper half mould returned to its place on the lower half mould, as shewn at
Figure 6. I have not thought it necessary to describe the making of the
"gets, as the workman will perceive how they are made by the Drawings.
In this manner may. the patterns be made of a great variety of kinds when
for casting articles requiring concave and convex surfaces in the midst of or
surrounded by other surfaces in the manner shown, such other surfaces being
plain or ornamental; and if it be desired to make articles having the reverse
side convex in place of concave, then in making the pattern it will have two
convex sides in place of only one; or if the articles are required to have two con-
cave 'surfaces, then the pattern will require to be made with two concave sides.
I will now proceed to describe how hollow ware is to be cast according to
my Invention. It is well known that great skill is necessary to enable a
workman. to make sand moulds for casting hollow ware, that is, articles such
as saucepans, and other articles of a like kind, where the mouth is less than
the larger dimensions of the belly or interior of the vessel; but by employing
my Invention in making patterns and in casting moulds may be made very
readily and correctly by inferior workmen. In fact, it will require very little
previous practise in making moulds for casting hollow ware in order to enable
a workman; when working according to my Invention, to make moulds very

page_text: correctly and quickly. Figure 7 shows a plan and section of the flask and
sand mould therein for the bottom half mould for making a saucepan, the
pattern plate c being in its place, and Figure 8 shows a section of the half
mould after the pattern plate c has been removed. I would remark, that in
making moulds for hollow ware I prefer to use two pattern plates, one for eacli
half mould; and Figure 9 shows a section and plan of the flask or box, and
the upper half of a sand mould made therein, together with the pattern
plate c, and Figure 11 shows a section of the upper half mould after the
pattern plate has been removed. Figure 12 shows a section of the two half
moulds combined together, having the core therein; and I will now describe
how I make the core and place it into the mould Figure 12, so as to obtain
great correctness. For this purpose I employ a core box in two halves, as is
shown separately in section and in plan at Figure 13, and the core box is
shewri combined at Figure 14. The core box having been rammed full of
sand, the guide cover (shown separately at Figure 15, in plan, section, and
under side view), is to be placed therein, as shown at Figure 16, and then what
is called the "hedgehog " y (shewn separately at Figure 17) is to be intro-
duced and forced down by the rammer a, shown separately at Figure 17*, the
cylindrical part of the guide cover guiding the hedgehog as it descends into
the core, thus ensuring great correctness; and when the flanches of the rammer
come down on to the cylindrical part of the cover z, the hedgehog will have
been forced down into its proper position, and the core will then be complete;
the rammer is then to be withdrawn, the cover z removed, and the halves of
the core box taken away. It will be readily seen by a person acquainted with
making moulds for casting hollow ware that by employing pattern plates c, and
thus avoiding sand parting in the making of the two half moulds, and then
having recourse to the means of making a core in the manner described, 'a
workman, however little informed, will scarcely be liable to make a bad mould
and core for casting an article of hollow ware. Figure 18 shows a section
and plan of each of the pattern plates c, and it will be seen that one pattern
plate has pins or guides, and the other pattern plate c has holes to correspond,
and it will be seen in the other Figures that the flasks or boxes are similarly
made, one with pins or guides and the other with holes, so that they will come
together under like circumstances.
Having thus described the nature of my Invention, and the manner in which
the same is to be performed, I would remark that I do not confine myself to
the precise details, so long as the peculiar character of iny Invention be
retained; and I would state that although I have only mentioned two parts
of a mould being used, yet a greater number of parts may be employed,"

page_text: according to the judgment of the workman, and depending on the article to
be cast; but what I claim is, the mode of making patterns for casting articles
having concave and convex surfaces, and also articles with two convex or two
concave surfaces in the midst of and surrounded by other surfaces, the pattern
plate extending beyond the pattern, and is the means of producing the parting
surfaces of the moulds; and I also claim the means of making the core for
casting hollow ware, and the use of pattern plates extending beyond the pattern,
and being the means of producing the parting surfaces of the mould when
casting hollow ware, as herein described.
In witness whereof, I, the said Joseph Douglas, have hereunto set my
hand and seal, this Eighth day of July, in the year of our Lord One
thousand eight hundred and forty-siv