TMPROVEMENTS IN DISHES OF PAPER AND OTHER MATERIALS, AND IN THE METHODS OF AND APPARATUS FOR MANUFACTURING THE SAME.
Year: 1878

page_text: LETTERS PATENT 10 John Henry Johnson, of 47. Lincoln's Inn Fields, in the
County of Middlesex. Gentleman, for the Invention of TMPROVEMENTS IN
DISHES OF PAPER AND OTHER MATERIALS, AND IN THE METHODS OF AND
APPARATUS FOR MANUFACTURING THE SAME. A communication from abroad
by Lucien Fisher, the younger, of Chicago, State of Illinois, Chalmers Ingersoll,
of Beloit, State of Wisconsin, and Henry Alonzo House, of Bridgeport, State of
Connecticut, all in the United States of America,
Seated the 27th September 1878, and dated the 3rd July 1878.
PROVISIONAL SPECIFICATION left by the said John Henry Johnson at
the Office of the Commissioners of Patents on the 3rd July 1878.
JOHN HENRY JOHNSON, of 17, Lincoln's Inn Fields, in the County of Middlesex,
Gentleman. * IMPROVEMENTS IN DISHES OF PAPER AND OTHER MATERIALS, AND IN
THE METHODS OF AND APPARATUS FOR MANUFACTURING THE SAME."
A communi-
cation from abroad by Lucien Fisher, the younger, of Chicago, State of Illinois,
Chalmers Ingersoll, of Beloit, State of Wisconsin, and Henry Alonzo House, of
Bridgeport, State of Connecticut, all in the United States of America.
This Invention relates to cheap strong dishes of thin non-friable material, such
as veneer, paper, or paper combined with other materials, and the Invention consists
of dishes made of such materials, in the modes of making the same, and of apparatus
used in the manufacture.
In carrying out the said Invention various materials may be employed in the
manufacture of the improved dishes, as paper, veneer, or compound materials, such
for example, as paper and veneer, paper and fabric, or veneer and fabric combined,
or compositions, such for example, as paper pulp or papier mache combined with
earthy matters, gums, and the like. Whatever may be the material employed, it is
first reduced 10 a sheet of the proper dimensions, and then pressed or imoulded as
berein-after described.

page_text: The purpose to which the dish is to be applied, the degree of finish required, and
the allowable cost of manufacture will determine the material to be employed.
For cheap plain articles. paper when not advanced in price has been found to
present the greatest advantages, but in some instances veneers may be used with
but little increase of expense. In such cases it is sometimes desirable to impart
greater strength by combining two or more sheets of veneer cemented together by
glue or other suitable cement, with the grain of one sheet at an angle to that of
the other, thereby preventing the splitting or cracking to which a single sheet is
liable.
It has been found that greater strength and durability may he secured, and
better and more finished articles obtained with but little increase in cost by
making the dish from combined paper and veneer, or of paper or veneer and muslin,
or other suitable fabric. Thus, a sheet of paper or fabric and a single sheet of
veneer may be cemented together, or veneer may be secured on both sides of a
sheet of paper or fabric, or sheets of paper or other fabric may be cemented to the
opposite sides of a sheet of veneer.
In the manufacture of articles of such materials, either the paper, or fabric, or the
veneer may form the inner face, as circumstances render most expedient and
desirable. In most cases however the fabric or veneer should be inside, as paper is
apt to be softened by lard, butter, or other semi-fluid or liquid contents of the dish.
and peel or scrape off when the contents are withdrawn. Thus, apart from the
additional strength and finish, the inner resistant lining is of great utility.
With most materials, especially when paper or veneer is employed, the sheet
before being moulded is subjected to a preliminary treatment by steaming or
wetting (hot or cold) to reduce it to as soft a condition as possible, without
rupturing it or impairing the uniformity of its thickness, which it is most desirable
to preserve. While in this condition the sheet is laid upon the face of a die above
a recess coinciding in form with the shape of the article to be moulded, and a
counter die is depressed, moulding the sheet, which is then dried while in shape,
either in the mould or after removal in a suitable drying chamber.
Heretofore, sheets of paper have been stamped between dies so as to form articles.
with edge flanges or sides, but in all such cases the moulds used have been plain.
and the pressure has been depended on to remove the irregularities resulting from
the folding or wrinkling of the surplus material, when the sides are turned up and
the articles produced have been deficient in strength and liable to lose their form
under the effects. of pressure or moisture. Irregular dies have not been employed
from their presumed liabilities as heretofore made, to distend and break the soft
pulpy sheet over their permanent edges. It has however been ascertained that the
softened paper may be stamped with as much facility as metal by the use of moulds.
duly proportioned to impart regular folds and shape to the surplus material
resulting from turning up the sides of the sheet.
According to this Invention dies are employed having corrugations increasing in
prominence or depth towards the upper edge, and proportioned so as to form in the
dish corresponding corrugations of such dimensions as to take up without dis-
tending or wrinkling the exact amount of material, which would otherwise form
irregular folds or wrinkles on turning up the edges of the sheet to form the sides or
flanges of the dish. When thus proportioned the dies may be operated with as
much facility on the soft sheets as upon metal forming dishes, which are not
impaired by the presence of irregular unsightly folds or wrinkles, and which having
corrugations are not weakened at any point by the distension of the material.
The corrugations further impart increased rigidity to the sides of the dish, and
strengthen the same.
Longitudinal rigidity may be given by folding over the edge of the material to
form an edge flange, which may be flat, or curved, or arched. The latter form being
preferable as it imparts increased strength, and the corrugated portions may he also
strengthened by carrying this flange round and following the edges thereof.
In place of increasing the depth of the corrugations towards the top of the dish,

page_text: the increasing surplus of material towards the upper edge may be absorbed by an
increased number of corrugations.
The dish may be corrugated at the end, or corners, or at the sides, and the
corrugations may vary in shape, position, and dimensions with the form and
character of the dishes, the inclination of the sides and other circumstances.
In order to facilitate the manufacture and to avoid loss of time in drying the.
dishes after moulding as well as to produce dishes of superior quality, the sheets
may be subjected to combined heat and pressure simultaneously in the following
manner:
A lower die and an upper die are employed which are suitably secured to the
frame and pluuger of a press, so that they may be brought together and separated.
The lower die consists of a chest and cap bolted thereto, inclosing a chamber to
which superheated steam is admitted through suitable openings. The cap has a
recess conforming in shape to the external form of the dish to be made, and at the
edge of this recess is a lip for a purpose herein-after described. At the bottom of
the recess is a depression to receive a plate secured to a rod extending through a
hollow standard of the die. a spring coiled around the rod tending to maintain the
rod and plate in an elevated position."
The upper die consists of two sectious, the under section being a shell coinciding
externally with the form of the recess in the cap of the lower die, and sliding on
hollow studs projecting from the upper section through openings in the shell, and
having enlargements at the lower ends to limit the downward movement of the
shell. which is recessed to receive the said enlargements.
In each stud slides a spring pin, the end of which projects downward below the
shell, and springs coiled round the studs tend to maintain the shell at the limit of
its downward motion.
The upper section is provided with an edge flange, which when the upper die is
brought into the lower die, overlaps the lip formed on the cap.
The shell is perforated throughout its entire extent, and in the upper section are
formed openings.
The face and edge of the upper die are covered by a sheet of felt or equivalent
material, which is secured by a continuous band clamping the edges against the
edge of the upper section.
The dies being in position superheated steam at a suitable temperature is
admitted to the enclosed chamber. the felt is applied to the upper die, and a sheet
of moistened paper or any of the materials specified is placed upon the lower die,
and the dies are brought together.
The dies are preferably formed with corrugations, which take up the excess of
material as the paper is folded up at the edges to form the sides of the dish as
before described.
When the shell has reached the limit of its downward movement, the edge of the
paper will extend above the lip before-mentioned, so that as the plunger descends,
carrying further down the upper section. a flange on the latter will fold the edge
over the lip, and form a flange at the edge of the dish. for the purpose herein-before
mentioned.
The heat of the die almost instantaneously vaporizes the moisture in the paper
or other material, as the latter is compressed to its new form. The steam escapes
freely through the perforations in the shell, and through openings in the upper
section, the felt absorbing any moisture that remains, so that the paper is instantly
dried, and the dish is set in its form the instant it is moulded. The result of these
operations is not only to expedite the manufacture of the dish, but to give it a form
which can only be changed by destructive pressure. for it has been found that
when paper is moulded as above described, the dish formed is stiff, yet elastic, and
will by its own elasticity recover its form when any but destructive pressure is
applied.
It is important that the body of the dish be clamped between the moulds before

page_text: the upper section or follower begins to turn down the flange, as otherwise there is
danger of clamping the flange before the body is formed, and tearing the material.
As the plunger recedes, the springs secondly mentioned maintain the shell in
its place until the follower rises from the flange, and the heads of the studs strike
the bottom of the shell, when the latter will also be elevated, the dish being kept
in contact therewith by the follower plate, which is forced upward by the spring
first mentioned.
When the plate reaches the limit of its movement. the spring pins will detach
the dish from the upper die, and leave the dish upon the plate from which it
may be removed prior to the moulding of-another dish from another sheet in like
manner.
The felt covering is an important adjunct in this process, as it not only helps
to dry the material and prevent the same from being stained by the upper die,
which is sometimes rusted by the moisture, but it further prevents the edges of
the die from cutting the paper, especially if folding over the Bange, and imparts a
neat and smooth finish to the inside of the dish.
The form of the dies depends upon the shape of the dish to be made, and will
vary with the character thereof, the lower or upper die in some cases being made
in several sections, operating successively or alternately as circumstances may
demand.
Other means may be employed for beating the dies and for imparting the desired
movements to the shell, and the followers and the upper die may be heated, and the
perforations may be made in the lower die.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said John Henry Johnson in the Great Seal Patent Office on the 30th
December 1878.
JOHN HENRY Johnson, of 47, Lincoln's Inn Fieids, in the County of Middlesex,
Gentleman. IMPROVEMENTS IN DISHES OF PAPER AND OTHER MATERIALS, AND IN
THE METHODS OF AND APPARATUS FOR MANUFACTURING THE SAME."
A communi-
cation from abroad by Lucien Fisher, the younger, of Chicago, State of Illinois.
Chalmers Ingersoll, of Beloit, State of Wisconsin. and Henry Alonzo House, of
Bridgeport. State of Connecticut, all in the United States of America.
The said Invention relates to cheap strong dishes of thin non-friable material,
such as vencer, paper, or paper combined with other materials, and the Invention
consists of dishes made of such materials, in the modes of making the same, and of
apparatus used in the manufacture.
in the Drawing, which forms part of this Specification, Figures 1 to 4 represent
sections of materials from which dishes may be made.
Figure 5 is a sectional view representing improved dies which are used in the
manufacture of the dishes.
Figure 6 is a side elevation; and Figure 7, a plan shewing one form of dish.
Figure 8 is a partial sectional elevation shewing an improved apparatus for
manufacturing the dishes.
Figure 9, the same as Figure 8, in a different position, the upper die being in
section, and Figure 10 is an inverted plan of the upper die.
Various materials may be employed in the manufacture of the improved dishes
as paper, veneer, or compound materials, such, for example, as paper and veneer,
paper and fabric, or vencer and fabric combined, or compositions, such, for example
as paper pulp or papier maché combined with earthy matters, gums, and the
like.
Whatever may be the material employed it is first reduced to a sheet of the
The
proper dimensions, and then pressed or moulded as herein-after described.
purpose to which the dish is to be applied, the degree of finish required, and the
For
allowable cost of manufacture will determine the material to be employed.
cheap plain articles paper, when not advanced in price, has been found to present
the greatest advantages, but in some instances veneers may be used with bui. little
increase of expense.
In such cases it is sometimes desirable to impart greater
strength by combining two or more sheets of vencer a, a, Figure 1. cemented
together by glue or other suitable cement with the grain of one sheet at an angle to
that of the other, thereby preventing the splitting or cracking to which a single
sheet is liable.
It has been found that greater strength and durability may be secured, and betier
and more finished articles obtained with but little increase in cost by making the
disc from combined paper and veneer, or of paper or veneer and muslin, or other
suitable fabric. Thus a sheet of paper or fabric and a single sheet of veneer
may be cemented together, as shown in Figure 2. or veneers a, a, may be secured
on both sides of a sheet of paper or fabric, as represented in Figure 3. or sheets b.b.
of paper or other fabric may be cemented to the opposite sides of a sheet a of
veneer, as shewn in Figure 4.
In the manufacture of articles of such materials, either the paper, or fabric, or the
veneer may form the inner face, as circumstances render most expedient and
desirable. In most cases, however, the fabric or veneer should be inside. as paper
is apt to be softened by lard, butter, or other semi fluid or liquid contents of the
dish, and peel or scrape off when the contents are withdrawn. Thus apart from
the additional strength and finish the inner resistant lining is of great utility.
With most materials. especially when paper or veneer is employed, the sheet
before being moulded is subjected to a preliminary treatment by steaming or

page_text: wetting (hot or cold) in order to reduce it to as soft a condition as possible without
rupturing it or impairing the uniformity of its thickness, which it is most desirable
to preserve. While in this condition the sheet is laid upon the face of a die A.
Figure 5, above the recess y, coinciding in form with the shape of the article to be
moulded, and the counter die B is depressed, moulding the sheet, which is then
dried while in shape either in the mould or after removal in a suitable drying
chamber.
Heretofore sheets of paper have been stamped between dies so as to form articles
with edge, flanges, or sides, but in all such cases the moulds used have been plain,
and the pressure has been depended on to remove the irregularities resulting from
the folding or wrinkling of the surplus material when the sides are turned up and
the articles produced have been deficient in strength, and liable to lose their form
under the effects of pressure or moisture. Irregular dies have not been employed
from their presumed liabilities as heretofore made to distend and break the soft
pulpy sheet over their prominent edges. It has, however, been discovered that the
softened papers may be stamped with as much facility as metal by the use of moulds
duly proportioned to impart regular folds and shape to the surplus material resulting
from turning up the sides of the sheet.
According to the present Invention therefore dies are employed having corruga-
tions e, e, increasing in prominence or depth towards the upper edge, and
proportioned so as to form in the dish corresponding corrugations & of such
dimensions as to take up without distending or wrinkling the exact amount of
material which would otherwise form irregular folds or wrinkles on turning up the
edges of the sheet to form the sides or flanges of the dish. When this proportioned
the dies may be operated with as much facility on the soft sheets as upon metal.
forming dishes D, which are not impaired by the presence of irregular unsightly
folds or wrinkles, and which having corrugations are not weakened at any point
by the distension of the material.
The corrugations further impart increased rigidity to the sides of the dish and
strengthen the same.
Longitudinal rigidity may be imparted by folding over the edge of the material
to form an edge flanger, which may be flat, or curved, or arched, as shewn in
Figure 6, the latter form being preferable, as it imparts increased strength, and the
corrugated portions d may be also strengthened by carrying this flange round and
following the edges thereof, as shown.
In lieu of increasing the depth of the corrugations towards the top of the dish
The increasing surplus of material towards the upper edge may be absorbed by an
increased number of corrugations.
The dish may be corrugated at the end or corners, or at the sides, and the cor-
rugations may vary in shape, position, and dimensions, with the form and character
of the dishes, the inclination of the sides, and other circumstances.
In order to facilitate the manufacture and to avoid loss of time in drying the
dishes after moulding, as well as to produce dishes of superior quality the sheets
may be subjected to combined heat and pressure simultaneously, an apparatus for
effecting this result being shown in Figures 8, 9, 10.
A represents the lower, and B the upper die, which are suitably secured to the
frame and plunger of a press, so that they may be brought together and separated.
The lower die consists of the chest and cap p bolied thereto, inclosing a
chamber a, to which superheated steam is admitted through the openings 6. The
cap has a recess y. conforming in shape to the external form of the dish to be
made, and at the edge of this recess is a lip ¿, for a purpose herein-after described.
At the bottom of the recess y is a depression . for the reception of a plate C, which
is secured to a rod D extending through a hollow standard D' of the die, a spring d
coiled around the rod D. fending to maintain the rod and plate in the elevated
position shewn in Figure S.
a shell
The die B consists of two sections, the under section being
coinciding externally with the form of the recess y, and sliding on hollow studs c

page_text: projecting from the section of through openings in the shell, and having enlarge-
ments el at the lower ends to limit the downward movement of the shell, which is
recessed to receive the said enlargement.
In each stude slides a spring pin g, the end of which projects downward below
the shell, and springs n coiled round the studs tend to maintain the shell at the
limit of its downward motion.
'
The section f is provided with an edge flange m, which when the die Bis
brought into the lower die A overlaps the lip i
The shell is perforated throughout its entire extent, and in the section f are
openings. The face and edge of the die B are covered by a sheets of felt or
equivalent material, which is secured by a continuous band 7 clamping the edges
against the edge of the upper section f.
Assuming that the dies are in the position shown in Figure 8. superheated steam
at a suitable temperature is admitted to the chamber a, the felt is applied to the
die B. and a sheet of moistened paper, or any of the material specified, is placed
upon the lower die, and the dies are brought together.
The dies are preferably formed with corrugations, which take up the excess of
material as the paper is folded up at the edges to form the sides of the dish, as
before described.
When the shell has reached the limit of its downward movement the edges of
the paper will extend above the lip 7. Figure 9, so that as the plunger descends.
carrying further down the upper section ƒ. the flange a will fold the edge # over
the lip and form a flange at the edge of the dish, for the purpose set forth.
The heat of the die A almost instantaneously vaporizes the moisture in the paper
The steam escapes
or other material as the latter is compressed to its new form.
freely through the perforations in the shell and through the openings h, the felt
absorbing any moisture that remains, so that the paper is instantly dried and the
The result of these operations is
dish is set in its form the instant it is moulded.
not only to expedite the manufacture of the dish, but to give it a form which can
only be changed by destructive pressure, for it has been found that when paper is
moulded as above described the dish formed is stiff, yet elastic, and will by its own
elasticity recover its form when any but destructive pressure is applied.
It is most important that the body of the dish be clamped between the moulds
before the section or follower / begins to turn down the flange #, as otherwise there
is danger of clamping the flange before the body is formed, and tearing the
material.
As the plunger recedes the springs # maintain the shell in its place until the
follower rises from the flange # and the heads el strike the bottom of the shell, when
the latter will also be elevated, the dish being kept in contact therewith by the
follower plate C. which is forced upward by the spring 7.
When the plate C reaches the limit of its movement the spring pins y will detach
the dish from the upper die and leave the dish upon the plate, from which it may
be removed prior to the moulding of another dish from another sheet in like
mauner.
The felt covering is an important adjunct in this process, as it not only helps, to
dry the material and prevent the same from being stained by the upper die, which
is sometimes rusted by the moisture, but it further prevents the edges of the die
from cutting the paper, especially in folding over the flange », and imparts a neat
and smooth finish to the inside of the dish.
The form of the dies depends upon the shape of the dish to be made, and will
vary with the character thereof, the lower or upper die in some cases being made in
or alternately as circumstances may
several sections. operating successively
demand.
Other means may be employed for heating the dies and for imparting the desired
movements to the shell and the followers, and the die B may be heated and the
manfarations may he made in the die A.

page_text: Having now described and particularly ascertained the uature of the said
Invention, and the manner in which the same is or may be used or carried into
effect, I would observe in conclusion that 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. A dish moulded of a single sheet, consisting of one or more layers of
veneer, or veneer and paper or fabric, substantially as herein-before described.
Second. A dish moulded of one sheet of paper, with sides having regular
corrugations and of uniform thickness, substantially as herein-before described.
Third. A dish moulded of a compound sheet of paper and veneer or fabric,
substantially as herein-before described.
Fourth. A dish of paper having an inner lining of cloth, veneer, or other material
which will not be disintegrated by the contents, as herein-before described.
Fifth. The dish of paper or equivalent material with corrugated sides, and with a
flange or rib following the edge of the corrugations, substantially as herein-before
described.
Sixth. As an improvement in the manufacture of dishes of paper or equivalent
material, the process described consisting in softening the material by moisture, sub-
jecting the same to moulds constructed to bend up and corrugate the sides without
irregular wrinkles, or distensions, and then drying the same in the form thus
imparted. substantially as herein-before described.
Seventh. The mode of forming dishes of paper or equivalent material by sub-
jecting dampened sheeis thereof to simultaneous heat and pressure between dies
which impart the required form, substantially as herein-before described.
Eighth. The combination in a machine for moulding paper dishes of dies A, B,
one of which is heated and the other perforated, substantially as and for the purpose
herein-before described.
Ninth. The covering of felt or other material combined with a paper moulding
die. substantially as and for the purpose herein-before described.
Tenth. The flanged follower f. having a movement independent of the section f'.
in combination with the die A and its lips i. substantially as herein-before
described.
Eleventh. In a dish moulding apparatus the follower C combined with the die A.
substantially as and for the purpose herein-before described.
Twelfth. In a dish moulding apparatus the spring pins g combined with the
die B. substantially as and for the purpose herein-before described.
In witness whereof. T. the said John Henry Johnson, have to this my Specifi
cation set my hand and seal, the Thirtieth day of December. One thousand
eight hundred and seventy-eight.
J. HENRY JOHNSON. (t.s.)