Improvements in and connected with Embossing and Printing.
Year: 1889

page_text: Date of Application, 20th Sept., 1889
Complete Specification Left, 21st July, 1890-Accepted, 20th Sept., 1890
PROVISIONAL SPECIFICATION.
Improvements in and connected with Embossing and Printing.
I RICHARD CHARLES of 7 Hurlingham Buildings New Kings Road Fulham in the
County of Middlesex, General Designer do hereby declare the nature of this
invention to be as follows:-.
This invention relates to certain improvements in and connected with embossing
and printing, and has for its objects, first the preparation of the model to be embossed
or printed and secondly the construction of the embossing rollers. Hitherto models
for designs to be embossed have been prepared by hand on the actual rollers, and the
rollers for embossing such designs on materials such for example as leather wall-
papers, velvets, and the like have been constructed by a long and laborious process of
casting engraving etc. By my invention I greatly simplify the preparation of the
aforesaid models and the construction of the rollors and by saving time and labor
greatly reduce the cost of producing the same.
In carrying my invention into practice I first cause the design which it is desired
be ombossed to be cut out in cardboard, brass, or any suitable material to form an
open work stencil of the required dimensions. Upon this stencil I place a sheet of
lead or other, suitable soft metal and firmly secure the two together. They are then
passed between two machine rollers suitably placed apart to give the desired pressure,
and .covered with a soft pliable material such as india rubber the result being that the
soft lead or metal is pressed through the open stencil work so that when the lead sheet
is removed the stencilled design is clearly raised upon its surface.
After being suitably pressed and before being removed from the stencilled design
the lead or other metal model is worked tip by hand to any degree desired so that all
lines will be clear and sharp.
Then the stencil plate is fixed with some secure adhesive matter round a wood
roller of the requisite diameter corresponding to the repeat of the said design.
Then the lead sheet having the raised design corresponding in the stencil plate is
to be reinserted into the stencil and forced to the proper fitness by hand both the
two corresponding edges being brought closely together. To solidify the raised
ornament on the lead and also to retain it in a corresponding cylinder form tho size of
the wood roller a layer of brown paper is to be pasted with strong gum on to the
back of raised design. Both the leaden ornamented sheet and the paper lining are to
be left on the roller until the paper becomes thoroughly dry and hard.
Then the said cylinder to be detached out of its position by detaching the two
repeating edges away from the stencil which must remain on the roller thus detaching
the cylinder by the aid of expansion of it, and so by this means it is freed from the
composite roller of wood and stencil.
It is then placed within a specially constructed cylinder of a corresponding diameter
made of tin or such like inaterial with the raised side inside or as it were on the
inverted side. This special cylinder is so constructed that it can be opened at will in
the direction of its length its edges overlapping each other, and it is provided with
suitable clumps or clasps to securely fasten when closed. Great care inust be taken
to properly adjust the lead model within the special cylinder and any means may be
used to secure the proper adhesion of the inside of the cylinder and the outer side of
the lead or other metal model when rolled.
It will then be ready to take either an electro or a plaster impression the latter for
casting in a sand mould, or another devised method of using a fireclay internal and
When secured it is then
external moulds incasing the lead model between the two.
placed in a hot oven so as to dissolve the lead model thus leaving a vacuum into
which molten brass or bronze is to be poured which will then form a corresponding
casting after the lead model.

page_text: If for printing an engraved plate or plates or a duplicate in electro from it must be
substituted for the ornamented lead and stencil plates.
Concentrically within the aforesaid special cylinder after the lead model has been
properly adjusted and electroed or otherwise another plain cylinder or core of smaller
dianeter is to be placed so that a space or mould is left between its outer surface
and the surface of the electroed sheet which as before stated is firmly secured to the
outer cylinder. Into this space is poured moulten metal suitable for the purpose and
the whole is left to cool and set in the usual manner.
The outer cylinder is then opened by means of its clamps or fasteners and the
electroed or first model removed leaving a clear and inverted impression of the design
on the surface of the united metal roller which will be found to have shrunk on the
inner cylinder or core which had been properly prepared for the purpose and the
embossing roller is complete and can be used in the usual manner.
If desired the lead or other metal model made in accordance with the first part of
my invention may be used flat to take electro types or casts instead of being rolled
and placed inside the specially constructed cylinder described and likewise for
printing as aforesaid.
Dated this Twentieth day of September 1889.
RICHARD CHARLES.
COMPLETE SPECIFICATION.
Improvements in and connected with Embossing and Printing.
I RICHARD CHARLES, of 7 Hurlingham Buildings, New Kings Road, Fulhain in
the County of Middlesex, General Designer, 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 certain improvements in and connected with embossing
and printing and has for its objects firstly, the preparation of the model from the
design to be embossed or printed (by which model I mean an accurate copy of any
given design in suitable form and material for reproduction) and secondly, the
construction of the embossing roller, that is to say, the manufacture from the said
model of a permanent roller bearing upon its surface in practically indestructible.
metal or inaterial a facsimile of the given design. Hitherto models for designs to be
embossed have been usually prepared by hand on the actual rollers, and the rollers
for the purpose of embossing such designs on materials such for example as leather,
wall paper, velvets and the like have been constructed by a long and laborious process
of casting engraving, etc.
By my invention I greatly simplify the preparation of the aforesaid models and the
construction of the rollers and by saving time and labour greatly reduce the cost of
producing the same.
In carrying any invention into practise I cause a copy of any design which is to
be transferred to a roller for embossing or printing to be prepared and fixed to a
cylindrical core: I vary the method of doing this according as high or low relief is
required or to suit special cases. For high relief I copy and cut out the design in
card board brass or any suitable sheet material to form an open work stencil of the
required dimensions. To this stencil I apply a sheet of soft inaterial suitable for the
purpose (which I call the model sheet and which I will presently define) and I force
it into the openings of the said stencil by means of a rotary pressing machine in the
following manner:
I take a cylindrical wood core of a diameter corresponding to the required
"repeat" of the given design; the core may be solid or it may be cut into two parts
with a sliding mortice and tenon key piece intervening in the known manner; upon
the core I fix the said stencil plate, and I use a rotary pressing machine. These
machines usually have two squeezing rollers geared together between which any
required work is passed, but for applying the design sheet to the circular stencil I

page_text: uso the said wood core covered as described with its stencil plate for the upper roller
of the usual machine pair, and I cut a groove in it parallel with its axis into which I
fix one side or end of the model sheet. The two rollers are suitably spaced apart
and the lower one is covered with a soft pliable material such as india rubber. On
revolution of both rollers the model sheet is wound round the circumference of the
upper one and at the same time pressed into and through the openings of the stencil
work and the free end is secured either in the same groove or by nails bands or in
any suitable and convenient manner. Thus the given design is clearly indented in
repoussee" upon the surface of the model sheet. The roller is then removed from
the rotary machine, and before the model sheet is removed from the stencil plate it is
tooled by hand and worked up after the manner of engraving to any degree of
figuration and enrichment desired so that all linos will be clear sharp and
characteristic of the original style. Where lower relief is required I dispense with
the stencil aforesaid and I apply to a cylindrical core of wood or other suitable
substance similarly constructed a model sheet of thin workable material such as lead
or copper, and I fix it as above described or in any suitable manner. To the model
sheet I apply a copy of the required design and I incise the design by hand labour,
or I may stamp it on by suitable dies, so that it is reproduced in low relief on the
surface of the said model sheet. In both the above cases whether a stencil plate is
used or not the model having an accurate representation of the given design
concave and of required depth on its surface is complete, and I then proceed by one
or other of the methods hereinafter fully explained.
In further describing my invention, I will refer to the accompanying drawings
which are merely intended as diagrams and in which similar letters are used to lenote
similar parts.
Figure 1 is a broken view of a model constructed as first above described (before
passing through the pressing machine) in which m is the cylindrical core, s the stencil
plate affixed thereto, c the model sheet one end of which is secured into the groove,
and for brevity I will hereinafter refer to these the parts m, s, c, constituting the model
by the letter M. After passing through the machine the design is indented upon the
sheet c as described.
Either for high or low relief from models prepared as above described I construct
the permanent embossing or printing rollers, and I may accomplish this by several
alternative processes according to the nature of individual cases.
By process No. 1 first hereinafter described I cast the permanent roller from the
model sheet after the removal of the stencil and core above specified and backed up
with lead or composition.
In alternativo process No. 2 second hereinafter described I fix the prepared model
sheet on a suitable core and take a inould thereof in fluid material which afterwards
sets and I melt out the design sheet which must therefore be of wax, gutta percha or
the like, and I cast direct in the space left.
Or by process No. 3 third hereinafter described I employ the electro deposition
process in which case the model sheet is of lead gutta percha or any material not
affected by the electrolytic process. I will describe these three processes in detail :-
According to casting process No. 1 I use the apparatus shown in vertical sections
Figures 2 and 4 and in Figure 3, which is a plan of Figure 2 with cap removed.
a is a special cylinder made of cast iron or steel, or it may be of composition, bored
out and split or constructed in two or more segments so that it can be opened at will
in the direction of its length by means of screws flanges and bolts such as are
illustrated at a¹ to securely fasten it. This cylinder (which I call the "casting
cylinder") is mounted on a bed plate b preferably in a groove b¹ and concentrically
within it I insert the aforesaid completed model M which in this case would have a
copper model sheet c and I fix it firinly in a central position by a pin 62 on the bed
plate fitting into a hole in it, or by other suitable ineans, an annular space x of
suitable width say to inch thus intervenes between the outer side of the model M
and the plain inner wall of casting cylinder ..
b
I then apply to the top of the annular space a specially constructed tunnel cap i

page_text: with slots for the flow of metal and having a similar holding pin b to that above
described to hold the top end of the model firmly and centrally, and I pour thereinto
melted lead or other suitable material y until the space is full and this metal forms a
backing to the model sheet c. If I use a composition backing the model sheet may be
of lead.
'?'
When the backing y is cool or set as the case may be the cylindrical core m with
its stencils are first removed and for them is substituted a plain iron cylinder r
(Figure 4) of smaller diameter. This cylinder r is the foundation of the completed
embossing roller R and may be cast with spokes and centres for the reception of a
spindle as illustrated Figures 4 and 5, or made solid as desired for ultimate use. This
cylinder is or inay advantageously be roughened or grooved on its surface to enable
the permanent metal to adhere or key on to it. When fixed in position as in Figure 4
an annular space al of suitable width, say inch, intervenes between the outer surface
of roller and the inner surface of the modol sheet c which with its adhering lead or
backing y remains firmly secured inside the casting cylinder a. Into this space by
a cap as before I then pour moulten metal such as " Babbett," "Type" or other
metal or alloy suitable for the purpose and the whole is left to cool and set in the usual
manner. The introduced metal or alloy when cool shrinks on and becomes firmly
keyed to the cylinder ». The casting cylinder a is then removed the backing y and
inodel sheet c are slit up and the roller is taken out having attached to its surface the
metal which bears a clear impression of the design on its surface; the embossing
roller R Figure 5 is now complete and ready for use. I find it advantageous to coat
the surface with electro in the usual manner for subsequent use.
When it is required that the permanent roller should fit on to existing shafts or
mandrils according to my invention I adopt the following means illustrated in Figure 9.
I apply to and fix fast upon such existing shaft or mandril La tapered or coned
sleeve l, which may be circular octagonal or otherwise externally, as a foundation for
my permanent metal. Instead of using the cylindrical core r as described I use a
tapered core to which the metal will not adhere and which I afterwards remove, and
then slip the permanent metal upon the aforesaid tapered sleeve I fixed to the shaft or
mandril and key up all tight. According to casting process No. 2, referring to
Figures 6 and 7 I use a cylindrical core m of such a composition as is hereinafter
indicated, or it may be of the usual casting loom or sand, and apply thereto a conting
of beeswax w or other material suitable for the purpose and capable of melting by
heat, upon which I work by hand the given design; or I may work the design on a
flat wax sheet, or cast it on and then wind it round the core m in which case a backing
of suitable fabric must be interposed; then I placo and fix the whole centrally in an
outer cylinder of suitable material and analogous to the casting cylinder a above
described, and of such diameter as to afford an intervening annular spacer of sufficient
width, say one and a half inches, and this space I fill with a fluid material of a
refractory nature which will set hard. For this purpose I have found that a mixture
of three parts of fine fireclay dust and one part of plaster of Paris is good, but I do not
confine myself to any particular composition. I make it of about the consistency of
Then I
cream pour it in and let it set when I remove the outer casting cylinder a.
subject the whole to a temperature sufficient to melt out the wax model w and the
representation of the design is thus left upon the inner walls of the introduced com-
position, then by a cap t as before described I fill in the space hitherto occupied by the
model but now left empty, with the brass copper or other metal or alloy selected for
the permanent roller. In order to free the inetal I break up the inner and outer
composition moulds, and the permanent metal shell is then completed and may be
mounted as set forth or in any convenient manner.
It will be noticed that by this process I dispense with the internal iron cylinder r.
According to the electro deposition process No. 3 for producing a permanent roller,
the model sheet c is of lead or gutta percha or other material suitable for the purpose
and it is applied to the model as illustrated in Figure 1. I split it and remove the
core m and the stensils and 1 place the model sheet in an electro bath and allow it to
remain there until a sufficient thickness of deposit is obtained on its inner surface.

page_text: For reproducing models from the flat I make my transfer in gutta percha and I roll
it up to the required diameter and place it in the casting cylinder, having previously
inserted thereinto a lining of perforated tin. To insure the transfer is well bedded in
so as to adhere to the perforated tin I apply hydraulic pressure by means of a sinooth
surfaced india rubber water bag m furnished with end plates n a central screwed
spindle n¹ and a fly nut n² such as illustrated in Figure 8. By inserting this and
gradually expanding it, pressure is evenly and gently transmitted to all parts of the
transfer which causes it to adhere to the perforated tin backing; when the bag is
removed the compound tin and transfer is removed from the outer cylinder and taken
to the electro-bath. When a sufficient thickness is deposited thereon I remove the
cylinder from the bath and coat its inner surface with tin, and the permanent roller is
constructed from this electro cylinder as first hereinabove set forth.
It will thus be seen that according to my invention I am enabled to manufacture
permanent rollers for embossing or printing from any kind of designs whether flat
circular or otherwise.
Having now particularly described and ascertained the nature of this inven-
tion and in what manner the same is to be performed I declare that what I
claim is :-
1. The hereinbefore described methods of preparing models from given designs for
use in the manufacture of permanent embossing or printing rollers (a) by the use of
a cylindrical core m stencil s model sheet c and pressing machine, (b) by the use of a
cylindrical core m and model sheet upon which the given design is incised or
stamped substantially as set forth.
2. The manufacture of permanent embossing or printing rollers according to the
direct casting process No. 1 hereinbefore set forth with reference to Figures 1 to 5.
3. The inanufacture of permanent embossing or printing rollers according to the
melting out and casting process No. 2 hereinbefore set forth in reference to Figures 6
and 7.
4. The manufacture of permanent embossing or printing rollers according to the
electro-deposition processes undor heading No. 3 hereinabove set forth.
5. The improvement connected with embossing and printing consisting in the
method of ensuring the required adhesion of a plastic model sheet to a perforated tin
backing in a cylinder by the use of an hydraulic bag substantially as and for the
purposes set forth.
6. The means of manufacturing and fitting permanent metal rollers to existing
shafts or mandrils substantially as set forth in reference to Figure 9.
Dated this 21st day of July 1890.
J. C. CHAPMAN, F.I.P.A.,
70, Chancery Lane, London, W.C., Agent for Applicant.