IMPROVEMENTS IN THE MANUFACTURE OF PATTERNS USED IN THE PRODUCTION OF METALLIC CASTINGS, AND IN TOOLS OR APPARATUS TO BE USED IN THE SAID MANUFACTURE
Year: 1879

page_text: LETTERS PATENT to Thomas Butler, of Smethwick, in the County of Stafford,
Pattern Maker and Draughtsman, for the Invention of "IMPROVEMENTS IN THE
MANUFACTURE OF PATTERNS USED IN THE PRODUCTION OF METALLIC CASTINGS,
AND IN TOOLS OR APPARATUS TO BE USED IN THE SAID MANUFACTURE,"
PROVISIONAL SPECIFICATION left by the said Thomas Butler at the Office
of the Commissioners of Patents on the 19th March 1879.
THOMAS BUTLER, of Smethwick, in the County of Stafford, Pattern Maker and
Draughtsman. "IMPROVEMENTS IN THE MANUFACTURE OF PATTERNS USED IN THE
PRODUCTION OF METALLIC CASTINGS, AND IN TOOLS OR APPARATUS TO BE USED IN
THE SAID MANUFACTURE."
My Invention has reference principally to the manufacture of patterns used in
making large castings in iron, but is also applicable to the production of patterns
for castings of small size made of various metals or alloys.
My Invention further consists of the tools or apparatus herein after described to
be used in making patterns according to my Invention.
The said patterns are made of wood, and where there are ribs or other parts
situated at right angles or making other angles with one another, it is usual to
round the angle, that is, to replace it by a curved surface.
The ordinary process of making a mould for casting renders this rounding of the
angles desirable, and the casting produced is stronger in consequence of the rounding
of the angles. This replacement in patterns of the angles by curved surfaces (commonly
called angling or curving) is usually effected by cutting the wood into the required
form by ordinary cutting tools, and takes up much time and requires the use of more
wood than is necessary in making the said patterns according to my Invention.
In making a pattern according to my Invention I build up the pattern in the
required form from properly shaped pieces of wood glued or otherwise connected
together, excepting that the parts are not "angled" or "curved," that is, the right
or other angles are not replaced by curved surfaces.
In order to effect the required angling or curving I take strips of leather having
in cross section the figure of an obtused angled triangle, the two sides forming an
Price dl

page_text: obtuse angle being of about equal length. I soften the said strip of leather in
water, and cover the two sides making an obtuse angle with glue in a liquid state.
I place the said strip of leather on the angle to be rounded, its obtuse angle being
presented to the right angle in the pattern. I then pass a rounded pressing tool
along the strip of leather, and press it closely into contact with the angle in the
wood.
In this way the strip of leather is secured firmly in the angle, and the exposed
surface of the said strip is pressed into the required curvature by the pressing
tool. When the leather and glue have cooled and hardened, the pattern is ready
for use.
The angling or curving of curved and variously shaped parts which are angled
or curved with difficulty in the ordinary method of manufacture are by my improve-
ments angled or curved with great ease.
My improvements in tools or apparatus to be used in the manufacture of the said
patterns consist in constructing planes with angular cutters or blades, which being
used as ordinary planes cut from leather strips of the kind required for angling or
curving according to my Invention.
The cutter or blade may have such an angular surface as will make it cut strips
of leather having two adjacent sides inclined to each other at the required angle,
and the cutters or blades may be formed so as to cut one or two strips at the same
time.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said Thomas Butler in the Great Seal Patent Office on the 11th Sep-
tember 1879.
THOMAS BUTLER, of Smethwick, in the County of Stafford, Pattern Maker and
Draughtsman. "IMPROVEMENTS IN THE MANUFACTURE OF PATTERNS USED IN THE
PRODUCTION OF METALLIC CASTINGS, AND IN TOOLS OR APPARATUS TO BE USED IN
THE SAID MANUFACTURE."
My Invention has reference principally to the manufacture of patterns used in
making large castings in iron, but is also applicable to the production of patterns
for castings of small size made of various metals or alloys.
My Invention further consists of the tools or apparatus herein after described to
be used in making patterns according to my Invention.
The said patterns are made of wood, and where there are ribs or other parts
situated at right angles, or making other angles with one another, it is usual to
round the angle, that is, to replace it by a curved surface. The ordinary process of
making a mould for casting renders this rounding of the angles desirable, and the
casting produced is stronger in consequence of the rounding of the angles. This
replacement in patterns of the angles by curved surfaces (commonly called
'angling" or "curving") is usually effected by cutting the wood into the required
form by ordinary cutting tools, and takes up much time and requires the use of
more wood than is necessary in making the said patterns according to my
Invention.
tr
In making a pattern according to my Invention I build up the pattern in the
required form from properly shaped pieces of wood glued or otherwise connected
together, excepting that the parts are not "angled" or "curved," that is, the
right or other angles are not replaced by curved surfaces.
In order to effect the required "angling" or "curving" I take strips of leather
having in cross section the figure of an obtuse angled triangle, the two sides forming
an obtuse angle being of about equal length. I soften the said strip of leather in
water, and cover the two sides making an obtuse angle with glue in a liquid state.
I place the said strip of leather on the angle to be rounded, its obtuse angle being
presented to the angle in the pattern. I then pass a rounded pressing tool along
the strip of leather, and press it closely into contact with the angle in the wood.
In this way the strip of leather is secured firmly in the angle, and the exposed
surface of the said strip is pressed into the required curvature by the pressing
tool. When the leather and glue have cooled and hardened the pattern is ready
for use.
The angling or curving of curved and variously shaped parts which are angled or
curved with difficulty in the ordinary method of manufacture are by my improve-
ments angled or curved with great ease.
My improvements in tools or apparatus to be used in the manufacture of the said
patterns consist in constructing planes with angular cutters or blades, which being
used as ordinary planes cut from leather strips of the kind required for angling or
curving according to my Invention.
The cutter or blade may have such an angular surface as will make it cut strips
of leather having two adjacent sides inclined to each other at the required angle,
and the cutters or blades may be formed so as to cut one or two strips at the same
time.
I will now proceed to describe with reference to the accompanying Drawings the
manner in which my Invention may be performed.
Figure 1 represents in elevation, and Figure 2 in vertical section, a wooden
pattern for moulding a bench standard, drawn quarter scale, the "angling" or
curving" of the said pattern being effected according to my Invention. Figure 3
"

page_text: is a cross section of the foot part of the pattern, drawn of the full size, taken on the
line x, x, Figure 1.
a, a, are the vertical parts, and b, b, the horizontal ribs on the wooden pattern,
the said pattern being built up of pieces of wood, the junctions of the parts a, a, b,
with one another when built up not being "angled or "curved"; c, c, are the
strips of leather by which the angling or curving of the pattern is effected.
"
Figure 4 represents in elevation and a part vertical section, and Figure 5 in
cross section, taken on the line y, y, Figure 4, a pattern for moulding a standard in
which the ribs or strengthening parts are curved instead of straight, as in the
pattern, Figures 1, 2, and 3. In the said Figures 4 and 5, a is the body of the
wooden pattern, and b, 62, the ribs or parts situated at right angles to the said
body a.
For the purpose of illustrating the application of my Invention to the " angling "
or "curving" of curved surfaces, I have shown the pattern, Figures 4 and 5, with a
variety of curved parts. The strips of leather by which the angling or curving of
the angles of the pattern is effected are marked c, c, in Figures 4 and 5. The
extreme ends of the angled or curved parts c, c, in the foot of the pattern are
bevilled at e, e. The strips of leather are also bevilled at e, e, in the foot part of the
pattern represented in Figures 1, 2, and 3.
Figure 6 represents in section strips of leather which I use in carrying my
Invention into effect.
In angling or curving the angles of the wooden patterns I soften the strips of
leather, Figure 6, with water, and I cover the two sides f,f, of the leather strips
with glue in a liquid state. I place the softened strip of leather on the angle to be
rounded, the obtuse angles f, f, of the leather strips being presented to the angle in
the pattern. By means of a rounded pressing or smoothing tool the strip of leather
is pressed closely into contact with the angle in the pattern, so as thereby to firmly
secure the strip of leather in the angle.
By the pressure of the pressing tool the exterior or exposed surface of the leather
strip is pressed into the curvature represented in the sectional "angled" parts of
the patterns, Figures 1, 2, 3, 4, and 5, and the angling or curving of the angled
parts in the pattern thereby produced. After the leather has hardened and the
glued cooled the pattern is ready for use.
I do not limit myself to the breadth of the triangular strips of leather which I
use, as the breadths of the strips are varied according to the size of the right or.
other angle in the pattern to be "angled" or curved;" and although I have
only represented in the accompanying Drawing the application of my Invention to
the manufacture of patterns used for moulding standards, yet my Invention is
applicable to the angling or curving of the angle parts of patterns generally, whether
the angle parts be straight or curved.
Figure 7 represents in side elevation, and Figure 8 in plan, and Figure 9 in end
elevation, the tool or apparatus which I use for cutting strips of leather having the
sectional figure represented in Figure 6, to be used in carrying my Invention into
effect. Figure 10 represents the cutter or blade of the said tool separately in side
elevation, partly in longitudinal section, front elevation, and cross section.
a, a², is the cutter or blade of the cutting tool carried by the holder b, and worked
like an ordinary plane by means of the handle c and knob d. The acting end a² of
the cutter or blade a, a, has the angular figure best seen in the cross section of
Figure 9, that is, the sides of the said acting end a² of the cutter. are inclined to
each other at the angle represented, and the upper concave side of the said end a³,
and the bottom edge of the opening 62 in the holder b enclose a triangular space, so
that the cutter will cut strips of leather having a corresponding figure, the strip as
it is cut passing between the upper side of the end a² of the cutter or blade and the
opening at 62 in the body of the holder.
The cutting end of the blade or cutter may be so constructed as to cut two strips
of leather at the same time. In this modification the cutting end of the blade has

page_text: the figure of two of the angular ends represented in the Drawing arranged side by
side.
Having now described the nature of my Invention, and the manner in which
the same is to be performed, I wish it to be understood that I claim as my Inven-
tion,―
First. The improvements in the manufacture of patterns used in the production
of metallic castings herein before described, and illustrated in Figures 1, 2, 3, 4, 5,
and 6 of the accompanying Drawings; that is to say, "angling" or "curving" the
said patterns by the use of strips of leather of the kind described and illustrated,
the said strips being applied and attached to the parts to be "angled" or "curved
by the use of glue or other adhesive matter, and by the action of a pressing tool,
substantially as described and illustrated.
""
Secondly. The construction of the cutters or blades of the tools or apparatus
represented in Figures 7, 8, 9, and 10, for cutting the triangular strips of leather
used in angling or curving patterns according to my Invention.
In witness whereof, I, the said Thomas Butler, have hereunto set my hand
and seal, this Ninth day of September, in the year of our Lord One thousand
eight hundred and seventy nine.
0 Witness,
RICHARD SKERRETT,
Clerk to George Shaw,
Birmingham.
THOMAS BUTLER. (L.S.)