IMPROVEMENTS IN THE MANUFACTURE OF ARTIFICIAL STONE, AND IN MACHINERY AND APPARATUS CONNECTED THEREWITII
Year: 1876

page_text: LETTERS PATENT to John Henry. Johnson, of 47, Lincoln's Inn Fields, in the
County of Middlesex, Gentleman, for the Invention of "IMPROVEMENTS IN THE
MANUFACTURE OF ARTIFICIAL STONE, AND IN MACHINERY AND APPARATUS
CONNECTED THEREWITII." A communication from abroad by William Harrold
Smith, of Philadelphia, Pennsylvania, United States of America.
PROVISIONAL SPECIFICATION left by the said John Henry Johnson at the
Office of the Commissioners of Patents on the 16th May 1876.
JOHN HENRY JOHNSON, of 47, Lincoln's Inn Fields, in the County of Middlesex,
Gentleman "IMPROVEMENTS IN THE MANUFACTURE OF ARTIFICIAL STONE, AND
IN MACHINERY AND APPARATUS CONNECTED THEREWITH." A communication from
abroad by William Harrold Smith, of Philadelphia, Pennsylvania, United States of
America.
The object of this Invention is to convert a mixture of granulated or pulverized
mineral ingredients into artificial stone by subjecting the same while in a condition
described hereafter to impact in moulds.
In carrying out this Invention any granulated or pulverized stone, or fine or
coarse sand, or any mineral substances may be used, the degree of fineness to which
they should be reduced depending partly upon the texture of the artificial stone to
be made, and partly on the character of the mineral ingredients.
In connection with the comminuted mineral, lime or any of the ordinary mineral
cements of commerce may be used, the proportions of the ingredients being varied
as their character and the texture of the desired stone may suggest.
When lime is used as one of the ingredients sufficient water should be thrown on
to a mass of the lime to reduce it to a powdered condition, after which the powdered
lime should be passed through a sieve having, say, about eighteen meshes to the
inch.
If any of the ordinary mineral cements of commerco are employed, no preliminary
treatment is necessary other than that which they received in preparing them for
the market.
Sound blocks of artificial stone have been produced. by mixing together two parts
of granulated or pulverized marble chips and one part of the lime, and subjecting
the mixture to the process herein-after described. Blocks have also been made of

page_text: pulverized slag or scoria and the ordinary cement of commerco, and of fino sand and
lime, coarse sand and cement, and of pulverized sandstone and lime, different pro-
portions of the ingredients being used.
In carrying out this Invention a metal mould of the desired size and shapo is
made, and in connection with this mould is used a die arranged to the die, being
preferably constructed in the manner herein-after described.
In the process of treating the mixture there are two branches, the first being the
preliminary preparation of the material, and the second the condensation of the
material by impact in the mould.
The first branch consists in imparting to the pulverized or granulated materials a
proper degree of dampness, on which success depends, for without a strict observance
of the rules relating to this preliminary branch of the process the second branch will
be of no avail.
The mixture should not be made plastic, but should be reduced to such a condition
by the addition of a small proportion of water that on pressing a mass in the hands
the particles will barely cohere, or if they do cohere temporarily, will resumo their
granular condition on receiving a slight touch of the finger.
The desired quantity of material having been deposited in the mould, and the die
adjusted in the latter on the material, the whole is placed on the anvil of a steam
hammer. The mass in the mould should not be subjected to violent impact in the
first instance, but to a comparatively slight pressure or a few light blows, after
which the heaviest blows may be imparted. This violent impact has such a solidi-
fying effect on the material that after the removal of the block from the mould and
exposing it to the air for about a week, the block will be in a condition to be used
for building purposes. During this exposure of the block water should be poured
over it, or it should be dipped in water from time to time.
When the Invention is applied to the production of simple quadrangular blocks of
artificial stone for building and other purposes, the moulds and dies are constructed
by preference in the following manner:-The die consists of a heavy quadrangular
block of cast iron, on each of the four sides of which are a series of vertical grooves
communicating with horizontal grooves, which are formed on cach side of the block
near the bottom of the game. The lowermost portion of the block below the hori-
zontal grooves is slightly less in width and breadth than the body of the block, for
a purpose herein-after explained. To the top of the block is secured in any suitable
manner a central vertical bar for receiving the blows of a hammer, and to the under
side of the block may be secured a plate of steel. The vertical bar should be made
of wrought iron, and is by preference furnished at the top with a cap or plate of
copper to receive the blow of the hammer.
The mould consists of four substantial plates or slabs of cast iron, fitted together
and secured by bolts, or in any other suitable manner. The interior of the mould
has a series of vertical grooves arranged on each side, and extending from top to
bottom, and each side of the interior of the mould is lined with a plate, by preferenco
of steel, which is secured by bolts, each plate being perforated with a series of
vertical rows of small holes communicating with the above-mentioned grooves.
The body of the die fits accurately, but so as to be moved freely within the
mould, but the lower rib of the die below the horizontal grooves is, as before
remarked, a trifle less than the interior of the mould, so that when the die is in the
latter there shall be narrow spaces on the four sides between the rib and the side3
of the mould, and these spaces communicate through the holes in the lining with the
vertical grooves of the mould, and also with the vertical grooves of the die.
In using the above described appliances the mould is placed on a suitable anvil,
or on a plate resting on the anvil of a steam hammer, and within the mould is
placed as much of the granular material prepared in the manner described as the
desired thickness of the block of artificial stone to be produced may suggest, after
which the die is lowered into the mould, and bearing on the material compresses the
same to a slight extent; comparatively light blows may now be struck on the
vertical bar, and finally the heaviest blows.

page_text: During the preliminary pressure to which the material is subjected tho air within
the mass finds a freo vent between the edge of the rib of the die into the channels
formed by the horizontal grooves, thence through the vortical grooves of the die and
vertical grooves of the mould. This free expulsion of the air from the granular
mass is of importance, especially during the preliminary operations the mass,
and it is also important that free vents should be afforded during the hammering
operations.
The vents in the mould may in some cases bo dispensed with, as, for example,
in making blocks of a comparatively small size, the vents being formed in the die
alone.
After the material has been subjected to the desired hammering, the block may
bo forced from the mould by the aid of the mechanism heroin-after explained, and
the blocks may bo piled up and exposed to the atmosphere, and subjected to the
water treatment above explained.
A number of slabs or bricks may be formed simultaneously by the employment
of a cellular mould constructed and arranged in the manner next herein-after
described.
The outer portion of the mould consists, as in the former instance, of four sub-
stantial plates firmly bolted together, these plates being preferably lined, with their
plates of steel having perforations communicating with vertical channels, as in the
former case.
The interior of the mould is separated into compartments by partitions extending
entirely across the mould, and other partitions arranged at right angles to and
extending between the first-mentioned partitions. The mould may contain, for
example, 24 compartments as viewed from the top, but each compartment is sepa-
rated into, say, four cells by removablo transverse partitions, so that there are in all
96 cells for the formation of as many building blocks.
Each of the first-mentioned partitions consists of two plates and intervening bars
so arranged as to leave a series of vertical passages with which perforations in tho
plates communicate. The partitions secondly mentioned are constructed in a similar
manner.
The removeable transverse partitions each consist of two plates grooved, so that
when the two grooved faces are placed together, and the plates rivetted together,
each partition will contain passages for the escape of air, and perforations in the
plates communicate with these passages.
The die used in connection with this cellular mould consists of a substantial plate,
to which are secured as many bars as there are compartments in the mould, each
bar being arranged to fit snugly but slide freely in one of the compartments, and
each bar, which is in reality a die, having vertical grooves, horizontal grooves, and
a rib arranged in the same manner and for the same purpose as those in the die first
herein-before described.
In using this cellular mould it is placed on the anvil or on a plate resting on the
anvil, the transverse partitions being in the first instance absent. Into each com-
partment is then deposited a determinate supply of the granular material, and on
the latter is placed in each compartment one of the transverse partitions, then above
the latter another determinate quantity of the material, and so on until the mould
with its 96 cells charged with granular material is ready for the die, which is
adjusted to the uppermost cells, and then subjected to the repeated heavy blows of
a steam hammer until the material in the cells has been sufficiently condensed, when
the contents of the mould, consisting of 96 building blocks with transverse partitions,
are forced from the mould in the manner herein-after described.
Similarly, moulds and dies for forming slabs, such, for instance, as may be used.
for paving purposes or for facing buildings in imitation of marble or other stone,
may be constructed, such moulds and dies differing in no way from those last
described excepting as regards the size of the compartments and the absence of
horizontal partitions.
According to one mode, which is by preference employed, of constructing the baso

page_text: of the mould, the base consists of a heavy plate with a projection beneath, or other
provision for attachment to the anvil of a steam hammer. In the upper surface of
this plate is let a thin plate, by preference of steel, and either the under surface of
this plate or the upper surface of the plate beneath is grooved so as to form a
number of passages, with which communicate small perforations in the other plate,
so that when the material in the mould is subjected to impact the air dislodged
from the interstices of the material may find vent through the perforations and
passages.
The dies may be each fitted with a corrugated plate beneath, so as to impart a
corrugated face to the artificial stone.
It will be evident that moulds may be made for the formation in the manner
described of blocks, slabs, and the like of different forms, and a variety of other
objects; and that the Invention may be applied to the formation of slabs and the
like, with figures in relief or intaglio.
As an example of one of the many applications of the Invention, pipes may be
manufactured by the use of the mould and dies next herein-after described.
The mould consists of a substantial base having an annular projection on which
rests an inner tubular portion or core, whilst an outer tubular portion rests on the
base. In the outer face of the core are made a series of grooves, and in the inner
face of the outer portion a series of similar grooves, and to this portion is fitted a
thin perforated lining, the core being confined within a thin perforated tube. An
annular space is provided between the perforated lining and perforated tube for the
formation of the body of the pipe, and to this space is adapted an annular die, which
is grooved in the same manner as the dies herein-before described.
When a pipe with a socket at one end for receiving the plain end of an adjoining
pipe is required, the mould is made accordingly, and if the interior of the socket has
to be recessed for receiving a gasket, a ring is used for the formation of the recess,
the ring being in sections, each of which has steady pins adapted to slots in the
annular projection of the base. After the granular material has been hammered in
the mould through the medium of the annular die, the mould with its contents and
with the sectional ring is elevated above the base, the said ring is then withdrawn,
one of its sections having been first removed, which permits the lateral withdrawal
of the other sections, and the pipe is forced from the mould by means of the die.
In carrying out these operations two parallel elevated tracks are employed, which
are so combined with turntables as to admit of a truck being readily transferred
from one to the other. The hammer and anvil are arranged in connection with one
track, and the ejecting machine, herein-after described, in connection with the other.
On the former track runs a truck, which carries the mould and presents it beneath
the hammer. After the latter has performed its duty, the truck with the mould is
transferred to the adjoining track, and moved to a position where the ejector can
force the contents of the mould on to a truck which is adapted to a narrow track.
situate below the rails of the other track, the truck secondly mentioned after
receiving the contents of a number of moulds being wheeled away to a point where
the blocks can be conveniently handled and piled.
The mils of the elevated track, in connection with which the hammer is arranged,
are supported by standards secured at suitable intervals to a foundation, to which is
also secured the framework of a steam hammer, the latter being similar to ordinary
steam hammers excepting the features herein-after described.
The platform of the truck which carries the mould is composed by preference of
wrought-iron girders, to which are secured hangers forming the bearings of the axles,
the latter having the usual flanged wheels.
The moulds herein-before described are furnished with trunnions, the bearings of
which are capable of sliding in guides in standards secured to a plate carried on the
platform, the whole forming a structure which is supported by the truck, but which
can be raised and lowered on the same. The mechanism for this purpose may consist
of racks secured to the said movable structure and controlled by pinions, which are
retained by suitable pawls.

page_text: On the under side of the bearings bear the short arms of levers, by depressing the
long arms of which the bearings and the mould suspended therein may be readily
elevated, the levers, the long arms of which are connected together, being secured so
that the mould can be retained in its elevated position.
The mould, which is provided with a plate on the bottom, having received its
proper charge of granular material, is traversed with the truck along the track to a
proper position beneath the ram of the steam hammer, and is then lowered on to tho
anvil plate by releasing the long arms of the levers. The dic, which is suspended
by links to the ram of the steam hammer, is now lowered into the upper portion of
the mould so as to rest upon tho material in the same, after which the links aro
detached from the vertical rod of tho die, and four rods are caused to descend in the
manner herein-after described, and to bear hard with their lower ends on the top of
the mould, so as to effectually steady the same on the anvil plate. After the
desired number of blows have been imparted by the rum on the rod of the dic, the
steadying rods and rain of the hammer are elevated, and the die is raised clear of
the anvil plate by the levers, when the truck with the mould and its contents may
be wheeled along the track to the ejecting mechanism.
The upper portion of each steadying rod is threaded and adapted to a nut formed.
in the hub of a bevil wheel, which turns in bearings on a frame secured to the
framework of the steam hammer, and all four wheels are geared together by addi-
tional wheels and shafts, the gearing being under the control of an endless clinin
adapted to a chain pulley on one of the shafts.
The ejecting mechanisin is arranged in the following manner:-A receiving truck
is employed as before mentioned, the wheels of which are adopted to the rails of tho
narrow track before referred to. A platform is connected to this truck by two pairs
of weighted arms, the arms of each pair crossing each other, and the upper ends of
the arms being jointed to slide adapted to transverse guides on the under side of
the platform. The tendency of the weight on the arms is to elevate the platform,
and this tendency may be increased or diminished by the adjustment of the weights.
After the granular material has been hammered in the mould, as herein-before
described, the truck which carries the said mould is wheeled to a position beneath a
steam cylinder carried by a plate, which is connected by, say, four substantial rods
to another plate situate beneath the rails and standards. After the truck with its
mould has been adjusted to its proper position, supporting rods are introduced
between the movable structure which carries the mould and brackets on tho
standards, so that the racks and pinions which support this structure as well as the
truck itself may be relieved from the pressure imparted by the direct action of
the steam on the piston in the cylinder and through the ejecting plunger in forcing
the material from the mould.
As the moulded material leaves the mould it bears on the platform of the receiving
truck, which is situate below the mould truck, and this platform will yield to the
action of the plunger, so that the moulded block will leave the mould without any
sudden jar, which might disturb its integrity.
A suitable slide valve is provided for regulating the admission of steam to and
its discharge from the cylinder.
From the valve chest extend two pipes, the former communicating with the upper
end of the cylinder, and the latter with the lower portion of the same. The valvo
is connectod to an operating lever, which is also connected by a rod to another lover
arranged relatively to an adjustable arm clamped to a rod attached to the piston in
such a manner as while admitting of the valve, and consequently the movements of
the hammer, being mainly controlled by the operator of the lever, that the adjustablo
arm by coming in contact with the lever arranged relatively thereto shall move the
valve so as to prevent the descent of the ram beyond a given point.
If preferred, the ejection may be effected by the die and steam hammer employed
in performing the hammering operation.
The dies should be furnished with a comparatively soft material for the hammer
to strike against, such, for example, as a bar of wrought iron surmounted or not

page_text: with copper or with other comparatively soft metal or alloy, or even hard wood
may be used to receive the blow.
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 9th
November 1876.
JOHN HENRY JOHNSON, of 47, Lincoln's Inn Fields, in the County of Middlesex,
Gentleman. "IMPROVEMENTS IN THE MANUFACTURE OF ARTIFICIAL STONE, AND
IN MACHINERY AND APPARATUS CONNECTED THEREWITHL." A communication from
abroad by William Harrold Smith, of Philadelphia, Pennsylvania, United States of
America
The said Invention has for its object converting a mixture of granulated or pul-
verized mineral ingredients into artificial stone by subjecting the same while in a
condition herein-after described to impact in moulds.
In carrying out the said Invention any granulated or pulverized stone, or fine or
coarse sand, or any mineral substances may be used, the degree of fineness to which
they should be reduced depending partly upon the texture of the artificial stone to
be made, and partly on the character of the mineral ingredients.
In connection with the comminuted mineral, lime or any of the ordinary mineral
cements of commerce may be used, the proportions of the ingredients being varied
as their character and the texture of the desired stone may suggest.
When lime is used as one of the ingredients sufficient water should be thrown
on to a mass of the lime to reduce it to a powdered condition, after which the
powdered lime should be passed through a sieve having, say, about eighteen meshes
to the inch.
If any of the ordinary mineral cements of commerce are employed, no preliminary
treatment is necessary other than that which they received in preparing them for
the market.
Sound blocks of artificial stone have been produced by mixing together two parts
of granulated or pulverized marble chips and one part of the lime, and subjecting
the mixture to the process herein-after described. Blocks have also been made of
pulverized slag or scoria and the ordinary cement of commerce, and of fine sand
and lime, coarse sand and cement, and of pulverized sandstone and lime, different
proportions of the ingredients being used.
wish it however to be understood that I neither desire to claim nor to limit
myself to any specific mineral ingredients or cements, or to any specific proportions
of the same, the Invention being directed to the preparation and treatment of mix-
tures composed partly of granular or granulated or pulverized mineral substances
with limes or cements.
A metal anould of the desired size and shape is made, and in connection with this
mould is used a die arranged to fit closely but slide freely in the mould, both the
latter and the die being preferably constructed in the manner herein-after described.
The process of treating the mixture consists of two branches, the first being the
preliminary preparation of the material, and the second the condensation of the
material by impact in the mould.
The first branch consists in imparting to the pulverized or granulated materials a
proper degree of dampness, on which success depends, for without a strict observance
of the rules relating to this preliminary branch of the process the second branch will
be of no avail.
The mixture should not be made plastic, but should be reduced to such a condition
by the addition of a small proportion of water that on pressing a mass in the hands
the particles will scarcely cohere, or if they do cohere temporarily will resume their
granular condition on receiving a slight touch of the finger.

page_text: The desired quantity of material having been deposited in the mould, and the dio
adjusted in the latter on the material, the whole is placed on the anvil of a steam
hammer. The mass in the mould should not be subjected to violent impact in tho
first instance, but to a comparatively slight pressure or a few light blows, after
which the heaviest blows may be imparted. Quadrangular blocks nine inches
square and three inches thick have been produced after a few preliminary light
blows, by from five to eight blows of a hammer weighing 2,500 lbs., and falling a
distance of eighteen inches, the pressure of steam used in the cylinder of the hammer
being 60 lbs. per square inch. This violent impact has such a solidifying effect on
the material that after the removal of the block from the mould and exposing it to
the air for about a week, the block will be in a condition adapted to be used for
building purposes. During this exposure of the block water should be poured over
it, or it should be dipped in water from time to time.
Having thus described the process generally, for the manufacture of artificial stone
according to the said Invention, I shall now proceed to explain more fully tho
machinery and apparatus employed in carrying the said process into effect, and for
that purpose shall refer to the several Figures on the five Sheets of Drawings here-
unto annexed.
Moulds and dies which are preferred for conducting the above process are illus-
trated by Figures 1, 2, 3, 4, and 5 (Sheet 1 of the Drawings), Figure 1 being an
inverted plan view of the dic; Figure 2, a side view of the same; Figure 3, a vertical
section of the mould; Figure 4, a plan view of the same; and Figure 5, a detached
sectional view of part of the mould drawn to an enlarged scale. These appliances
are used for making simple quadrangular blocks of artificial stone for building and
other purposes.
.
The dio consists of a heavy block A of cast iron, on each of the four sides of
which are a series of vertical grooves a, a, communicating with horizontal grooves b,
which are formed on each side of the block near the bottom of the same. The
lowermost portion d of the block below the grooves b is slightly less in width and.
breadth than the body of the block, for a purpose herein-after explained. To the
top of the block is secured in any suitable manner a central vertical bar B for
receiving the blows of a hammer, and to the under side of the block may be secured
a plate a¹ of steel. The bar B should be made of wrought iron, and is preferably
furnished at the top with a cap or plate of copper to receive the blow of the
hammer.
The inould consists of four substantial plates or slabs C, C¹, O", C1, of cast iron,
fitted together and secured by bolts e in the manner shown in Figures 3 and 4, or
in any other manner which may be considered appropriate. The interior of tho
mould has a series of vertical grooves f arranged on each side, and extending from
top to bottom, and each side of the interior of the mould is lined with a plate h, by
preference of steel, which is secured by bolts c¹ in the manner too clearly shown in
the Drawing to need description, each plate being perforated with a series of
vertical rows of small holes ff communicating with the above-mentioned grooves fi
the relation of which holes and grooves to each other will be best understood by
reference to the enlarged sectional view, Figure 5.
The body of the die A fits accurately, but so as to be moved freely within the
mould, but the lower rib d of the dio below the horizontal grooves b is, as beforo
remarked, a trifle smaller than the interior of the mould, so that when the die is in
the latter narrow spaces shall be left on the four sides between the ribs d and the
sides of the mould, which spaces communicate through the holes f' in the lining h
with the vertical grooves f of the mould, and also with the vertical grooves a of
the die.
In using the above described appliances the mould is placed on a suitable anvil,
or on a plate resting on the anvil of a steam hammer, and into the mould is
introduced as much of the granular material prepared in the manner herein-beforo
described as the desired thickness of the block of artificial stone to be produced may:

page_text: suggest to be necessary, after which the die is lowered into the mould, and bearing
on the material compresses the same to a slight extent; comparatively light blows
may now be struck on the bar B, and finally the heaviest blows.
During the preliminary pressure to which the material is subjected, the air within
the mass finds a free vent between the edge of the rib d of the die into the channels
formed by the horizontal grooves b, thence through the vertical grooves a of the die
and vertical grooves f of the mould. This free expulsion of the air from the granular
mass is of especial importance, particularly during the preliminary operations on the
mass, and it is also important that free vents should be afforded during the ham-
mering operations. It is this free escape of the air in fact which prevents the
formation of laminated and easily fractured blocks.
It may be here remarked that it is not in all cases necessary to form vents in the
moulds. For example, in making blocks of a comparatively small size, the vents may
be formed in the die only. Nor is it necessary in all cases to line the moulds with
plates, although that arrangement is preferred.
After the material has been subjected to the desired hammering, the block may
be forced from the mould by the aid of the mechanism herein-after explained, and
the blocks may be filled up and exposed to the atmosphere, and subjected to the
water treatment herein-before referred to.
Figures 6, 7, 8, and 9, Sheet 1, illustrate a cellular mould in which a number of
slabs or bricks may be formed simultaneously; and Figures 20 and 21, Sheet 3,
shew the die for this mould.
The outer portion of the mould consists, as in the former example, of four sub-
stantial plates C, C), C", C, firmly bolted together by bolts e, which plates are by
preference lined with thin plates of steel, having perforations f¹ communicating
with vertical channels f, as in the former case.
The interior of the mould is separated into compartments F by partitions D
extending entirely across the mould, and partitions E extending between the said
partitions D, so that the mould contains in the present example 24 compartments as
viewed from the top, but each compartment is separated into four cells by removable
transverse partitions G, so that there are in all 96 cells for the formation of as many
building blocks.
Each partition D consists of two plates i, i, and intervening bars j, so arranged as
to leave a series of vertical passages, with which perforations in the plates com-
municate. The partitions E are constructed in a similar manner.
The mode of making the transverse partitions will be best understood by
referring to the detail views Figures 8 and 9, cach partition consisting of two
plate i, i, each of which is grooved, as shown at 2 in Figure 8, so that when the
two grooved faces are placed together and the plates rivetted together, each par-
tition will contain passages 3 (Figure 9) for the escape of air, and perforations in
the plates cominunicate with these passages.
The die used in connection with this cellular mould is shown in Figures 20 and
21, Sheet 3, and consists of a substantial plate H, to which are secured as many
bars Has there are compartments in the mould, each bar, which in reality con-
stitutes a die, being arranged to fit closely but slide freely in one of the compart-
ments, and having vertical grooves a, horizontal grooves b, and a rib d arranged in
the same manner and for the same purpose as those in the die shown in Figure 2,
Sheet 1.
In using this cellular mould it is placed on the anvil or on a plate resting on the
anvil, the transverse partitions being in the first instance absent. Into each com-
partment is then deposited a determinate supply of the granular material, and on
the latter is placed in each compartment one of the partitions G, then above the
latter another determinate quantity of the material, and so on until the mould with
its 96 cells charged with granular material is ready for the die (shown in Figures 20
and 21), which is adjusted to the uppermost cells, and then subjected to the repeated
licavy blows of a steam hammer until the material in the cells has been sufficiently

page_text: condensed, when the contents of the mould, consisting of. 96 building blocks with
transverse partitions G, are forced from the mould in the manner herein-after
described.
Figures 32, 33, and 34, Sheet 4, show moulds and dies for forming slabs, such, for,
example, as may be used for paving purposes or for facing buildings in imitation
of marble or other stone, this mould and die differing in no way from those last
described excepting as regards the size of the compartments and the absence of
horizontal partitions.
In the
Figure 34 is an enlarged sectional view illustrating more fully the combination
of the partitions with the mould, and the method of constructing the same.
This
will be readily understood from the foregoing without additional explanation..
Figures 29, 30, and 31; Sheet 4, show the mode which is preferred of constructing
the base of the mould. This base consists of a heavy plate J with a projection e¹
beneath, or other provision for attachment to the anvil of a steam hammer.
upper surface of this plate is let a thin plate J, by preference of steel, and either.
the under surface of this plate or the upper surface of the plate J beneath is grooved
so as to form a number of passages, with which communicate small perforations f
in the plate J, so that when the material in the mould is subjected to impact the
air dislodged from the interstices of the material may find vent through the perfora-
tions and passages.
21
Figure 39, Sheet 5, shows a die with a corrugated plate B¹ beneath, so as to
impart a corrugated face to the artificial stone.
It will be evident that moulds may be made for the formation in the manner.
described of blocks, slabs, and the like of different forms, and a variety of other
objects; and that this Invention may be applied to the formation of slabs and the
like, with figures in relief or intaglio.
As an example of one of the many applications of the Invention, the pipes shown
in Figures 28 (Sheet 4) may be referred to. Figures 24, 25, 26, and 27 (Sheet 4)
show the mould and dies for the formation of these pipes..
The mould consists of a substantial base K, having an annular projection m, on
which rests the inner tubular portions or core K' of the mould, the outer tubular.
portion K¹ of the same resting on the base K. In the outer face of the core K' are
made a series of grooves f, and in the inner face of the outer portion K" a series of
similar grooves f¹, and to this portion is fitted a thin perforated lining n, the core
being confined within a thin perforated tube n¹. An annular space is left between
the perforated lining n and perforated tube n¹ for the formation of the body of the
pipe, and to this space is adapted the annular die L, which is grooved in the same
manner as the dies herein-before described.
When a pipe with a socket at one end for receiving the plain end of an adjoining
pipe is required, the mould is made accordingly, as will be clearly understood by
reference to Figure 24, and if the interior of the socket has to be recessed for
receiving a gasket, a ring M is used for the formation of the recess, the ring being
constructed in sections, as shewn in Figure 26, and each section having steady
pins 1 adapted to slots 2 in the annular projection m of the base. After the granular
material has been hammered in the mould through the medium of the annular die,
the mould with its contents and with the sectional ring M is elevated above the
base, after which the said ring is withdrawn, one of its sections M', Figure 26, being
first removed, which permits the lateral withdrawal of the other sections, and the
pipe is forced from the mould by means of the die.
A general view of the manner which is preferable of conducting the above opera-
tions may be obtained by reference to the diagram, Figure 23, Sheet 3.
Two parallel elevated tracks are provided, one composed of the rails
9.9, and the
other of the rails q', q', and these tracks are so combined with turntables q₁, q, q", q",
that a truck can be readily transferred from one to the other. N represents the
location of the hammer and anvil, and N¹ that of the ejecting machine herein-after
described; P is a truck which carries the mould, and presents it beneath the
hammer. After the latter has performed its duty, the truck with the mould is

page_text: transferred to the adjoining track, and moved to a position where the ejector can
force the contents of the mould on to a truck Q, which is adapted to a narrow track
composed of rails 7, 7, situate below the rails of the other track, the truck Q after
receiving the contents of a number of moulds being wheeled away to a point where
the blocks can be conveniently handled and piled.
Sheet 5 illustrates the hammering appliances, Figure 35 being a front view;
Figure 36, a side view; and Figures 37 and 38, plan views.
Ir Figures 35 and 36 q, q, represent the rails of one of the above-mentioned
elevated tracks, these rails being supported by standards t, t, secured at suitable
intervals to a foundation, to which is also secured the framework of a steam hammer,
the latter being similar to ordinary steam hammers excepting in the features herein-
after described.
P is the platform of the truck, preferably composed of wrought-iron girders, to
which are secured the hangers P1, P1, forming the bearings of the axles, the latter
having the usual flanged wheels.
The moulds C (herein-before described) are furnished with trunnions, x, of
which 8, 8, are the bearings adapted to guides in standards 8, 8, secured to the
plate &, the whole forming a structure which is supported by the truck, but which
can be raised and lowered on the same. The mechanism for this purpose consists
in the present example of racks t¹, t, secured to the said moveable structure, and
controlled by pinions ", which are retained by suitable pawls.
On the under side of the bearings 8, 8, bear the short arms of levers u, u, by
depressing the long arms of which the bearings and the mould suspended therein
may be readily elevated, the levers, the long arms of which are connected together,
being secured so that the mould can be retained in its elevated position.
The mould, which has a plate on the bottom, having received its proper charge of
granular material, is traversed with the truck along the track to a proper position
beneath the ram of the steam hammer, and is then lowered on to the anvil plato
by releasing the long arms of the levers u. The die A, which is suspended by
links to the rain of the steam haminer, is now lowered into the upper portion of
the mould so as to rest upon the material in the same, after which the links are
detached from the rod B, and four rods R are caused to descend in the manner
herein-after described, and to bear hard with their lower ends on the top of the
mould, so as to effectually steady the same on the anvil plate. After the desired
number of blows have been imparted by the ram on the rod B of the die, the
steadying rods R and ram of the hammer are elevated, and the die raised clear of
the anvil plate by the levers u, when the truck with the mould and its contents
may be wheeled along the track to the ejecting mechanism.
The upper portion of each steadying rod R is threaded and adapted to a nut
formed in the hub of a bevil wheel R, which turns in bearings on a frame S¹
secured to the framework of the steam hammer, and all four wheels are geared
together by additional wheels and shafts too clearly illustrated in the Drawing to
need description, the gearing being under the control of an endless chain m³ adapted
to a chain pulley on one of the shafts.
The ejecting mechanism is illustrated in Sheet 2, Figure 10 being a front view;
Figure 11, a side view; Figure 12, a plan view of the same; and Figure 13, a
detached view of a portion thereof.
Qis the receiving truck, the wheels of which are adapted to the rails 7, 7, of the
above-mentioned narrow track. A platform T is connected to this truck by two
pairs of weighted arms T, T", the arms of each pair crossing each other, and the
upper ends of the arms being jointed to slides v, v, adapted to transverse guides on
the under side of the platform. The tendency of the weights on the arms is to
elevate the platform, and this tendency may be increased or diminished by the
adjustment of the weights. After the granular material has been hammered in the
mould as above described, the truck P, which carries the said mould, is wheeled to
a position above the truck Q, as shewn in Figures 10 and 11, and beneath a steam
cylinder U carried by a plate Z, which is connected by four substantial rods V to a

page_text: plate W situated beneath the rails ?, r, and standards t. After the truck P with its
mould has been subjected to its proper position, supporting rods X, X, are introduced
between the moveable structure which carries the mould and brackets on the
standards t, t, so that the racks and pinions which support this structure as well as
tho truck itself may be relieved from the pressuro imparted by the direct action of
the steam on the piston in the cylinder and through the ejection plunger in forcing
the material from the mould.
As the moulded material leaves the mould it bears on the platform T of the
truck Q, and the platform will yield to the action of the plunger, so that the
moulded block will leave the mould without any sudden jar, which might disturb
its integrity.
:
Figure 14, Sheet 3, is a sectional view of the ejecting cylinder; and Figures 15,
16, 17, 18, and 19 are detached views of the valve for regulating the admission of
steam to and its dischargo from the cylinder.
It will not be necessary to describe this valve minutely, as it is fully illustrated
in the Drawing.
From the valve chest W₁ extends two pipes Y and Y, the former communicating
with the upper end of the cylinder, and the latter with the lower portion of the
same. The valvo is connected to the operating lever 2, which is also connected by
a rod 3 to a lever 4. A rod 5 attached to the piston extends upwards, and to this
rod is clamped an adjustable arm 6. Although the valve, and consequently tho
movements of the hammer, are mainly controlled by the operator of the lever 2, the
adjustable arın 6 by coming in contact with the lever 4 will move the valve so as to
prevent the descent of the ram beyond a given point.
Although it is preferred to use the ejecting mechanism, especially in manu-
facturing blocks of artificial stone on a large scale, it should be understood that this
machinery is not indispensible, as the ejecting of the compressed blocks may bo
accomplished by the same die and steam hammer which performed the hammering
duty.
It may be observed that the dies should be furnished with a comparatively soft
material for the hammer to strike against. In the present example a bar of wrought
iron is shown as the medium through which the blows are struck, but this may be
surmounted or not with copper or with other comparatively soft metal or alloy, or
even hard wood may be used to receive the blow.
Having now described and particularly ascertained the nature 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. The mode or process herein set forth of manufacturing artificial stone, that
is to say, by subjecting granulated or pulverized mineral substances while in the
damp condition described and while in a mould, first, to comparatively slight pressure
or light blows, and then to heavy blows, as herein-before described.
Second. The within described die, having vertical grooves a and horizontal
grooves b, and below the latter ribs & proportioned in respect to the main body of
the die, as hercin-before described.
Third. The within described mould composed of plates having vertical grooves
and lining plates having perforations communicating with the said grooves.
Fourth. The cellular mould composed of external plates and partitions D and E
having internal passages, all substantially as herein-before described.
Fifth. The removable partitions G, each composed of two plates with air passages
between them, and each adapted to one of the compartments of the cellular mould,
as herein-before described.
Sixth. The anvil block J, its plate J, and passages between the two.
Seventh. The pipe mould consisting of the grooved internal portion K¹ and per-
forated cover, and the grooved outer portion K" with the perforated lining.
Eighth. The combination of the said pipo mould with the annular die L.

page_text: Ninth. The combination of the said pipe mould with the sectional ring M.
Tenth. In combination with a mould and die for forming blocks of artificial stone
of a súperimposed pad of soft metal or equivalent material for receiving the blows
of a hammer.
Eleventh. The combination of the mould and its trunnions with the truck P and
sliding bearings for the said trunnions.
Twelfth. The truck P and vertically adjustable platform 81 carrying the mould.
Thirteenth. The combination of the mould and its anvil supports with the ver-
tically adjustable steadying rods R.
Fourteenth. The combination of the mould with the steam driven ejecting
ram B¹.
Fifteenth. The combination of the mould ejecting ram and yielding platform T
with the truck Q.
Sixteenth. The combination of the truck P carrying the mould with a truck Q
below for receiving the contents of the said mould.
In witness whereof, I, the said John Henry Johnson have to this my Speci-
fication set my hand and seal, the Seventh day of November, One thousand
eight hundred and seventy-six.
J. HENRY JOHNSON. (L.S.)