Year: 1889

page_text: I, FRANK BENONA HOWARD a Resident of the City of Montreal in the District of
Montreal and Province of Quebec Canada Manufacturer of Hollow Ware 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:-
My-Invention relates to improvements in the moulds, dies and apparatus by which
pulp is pressed into shape for the purpose of forming it into slabs or masses having
regular or irregular surfaces configurated or ornamented such as sign boards and
other advertising plaques having raised or impressed letters or words upon their
surface or surfaces, with or without other ornaments; also to form imitations of
carved wood and articles for various purposes; and the object of this part of my
invention is to obtain more perfect impressions from the said dies or moulds than have
been heretofore obtained, also to enable higher relief to be formed in the dies or
moulds and upon the impressions in pulp made therefrom, and my invention also
relates to the manner of forming the said dies for compressing the pulp into shape
to form the same much more readily and cheaply than by any of the means at
present in use.
I attain these objects by the means illustrated in the accompanying drawings in
which similar letters of reference and numerals indicate like parts and :-
८८
Figure 1 is a side elevation of a mould and plunger as attached in a press for
compressing pulp. Figure 2 is a longitudinal vertical section of the plunger and
mould taken at about the line x. Figure 4, also a section of the die C. taken at about
the line. Figure 3-Figure 3 is a plan of a die, as shown, this is arranged to form
the word Pulp" in relief. Figure 4 is a plan of the upper side of the plunger.
Figure 5 is a plan of the upper side of the frame or mould in place upon the drainage
bed, also showing the die Cin place in the mould with portions of the various lying
parts removed to show the construction and arrangement (in plan) more clearly.
Figure 6 is a plan of a portion of the underside of the plunger-Figure 7 is a section
on line Figure 5 of the drainage bed-Figure 8 is a longitudinal section of the die
provided with surfaces at various heights of relief showing the manner of forming
the drainage to the same, also showing the pulp as having been compressed therein,
•

page_text: this section is taken at or about the line x Figure 9-Figuro 9 is a plan of the die
shown in Figure 8-Figure 10 is an illustration of the difficulties that are overcome
by part of my improvements. Figure 11 is a longitudinal section taken at about the
position of the line a Figure 4. of the plunger and mouldas arranged to form embossed
surfaces or impressions on both sides of the pulp that is pressed therewith―
Figures 12. 13. 14. 15. 16. 17 and 18 are details of construction of the die-plate a¹ for
imparting letters figures and ornaments &c. &c. to the pulp.
Before describing my Invention I think it advantageous to the more clear and
easy understanding of the following description of my improvements to make a
few remarks upon the difficulties or defects which 1 have overcome, they are as
follows:
In the apparatus which I have heretofore used the plan has been to form a die and
place it in the upper part of the mould or plunger, and to form the lower part of the
mould in such a manner that the whole of the drainage will take place from the back
or lower part of the pulp being pressed, thus compressing the pulp a up into an
upper matrix or die bas shown in Figure 10. by this means portions of water cand
sometimes both air and water are locked in, in the recesses of the die, particularly
when such recesses are made of considerable height or depth to cause a high relief
and no amount of force or pressure would cause generally the water to be removed,
as the tighter the pressure the more firmly is the water locked in, and if for some
reason it does at times make its escape, it causes channels or grooves in the surface
of the pulp, similar to the tracks made by sand eels on the sea shore. My object is
with other improvements in the construction of the die proper to overcome the above
mentioned difficulties and enable perfectly formed projections or relief to be made of
any desired height.
d is the head of the press in this case stationary, and e is the platen of the press
which is arranged to move up and down but if desired the reverse arrangement of
the two may be made.
To the head of the press d is attached by bolts and nuts d' a plunger f and on the
platen e is placed a drainage bed n and drainage plate g upon which is placed a frame
or mould of suitable size and form to fit closely about the plunger for whatever
form the said plunger may be made, as shown in the drawings, it is rectangular but
it may be of any regular or irregular shape desired.
The plunger fas shown by Figures 1. 2 and 6 consists of a casing i having pro-
jections, preferably of the form of a frustrum of a cone, but other forms may be
used if desired. Within the plunger is a perforated or drainage plate 7 and undor
this is a diaphragm of fine wire cloth m. Within the centre part of the casing i is
formed a chamber r to which is connected a pipes by means of this the air can be
exhausted from the space or chamber t about the projections k.
"2
a² are outer marginal edges which serve as scrapers to the mould, and are
provided with a chamfer a. The drainage bed n consists of a bed provided with
ridges O, and at one or both sides, has a channel p, having any desired number of
drainer pipes g.
e is a diaphragm of wire cloth as shewn, placed within the mould h, but if desired
it may be made as large as or larger than the outer edges of the mould, which will in
such case rest upon it; the said wire cloth will be of a mesh of about forty to the inch
upon this is placed the die, or dies- proper C, these consist each of a die plate a¹
the manner of forming which will be hereinafter described) an exact matrix of the
raised work, relief or projections, as also the impressions, that are to be imparted to
the surface of the body or mass of pulp that is pressed, a diaphragm of wire cloth b¹
of a mesh of from about sixty to one hundred and fifty to the inch, according to the
smoothness of the surface required on the tops of the elevations or relief formed on
the pulp being pressed; also a perforated plate c¹ (see Figures 2 and 8) these three
parts viz-die-plate a diaphragm of wire cloth and perforated plate care all
equal in plan dimensions and are all secured together by soldering applied about or
between their outer edges or by any other means such as screws &c. &c., and when so
united to form one piece, they are in this Specification called the die C.

page_text: It is to be understood that when depressions are to be formed in the pulp corre-
sponding projections will be formed upon the die-plate a' as will be seen by Figure 8
as the centre piece d' is in the nature of a projection, and causes a corresponding
rocess or depression in the pulp.
As shown in Figures 2 and 3 the die C, is arranged for forming the word "Pulp"
in relief all of one height. The section of the die C, shown in Figure 2, is taken on
line, Figure 3. In Figures 8 and 9 a die is shown arranged for forming the
letters A. B. of one height of relief and a corner ornament of different heights of
relief.
Whenever the pattern or letters &c. are such that a central or detached portion d¹
(see Figures 8 and 9) will be required or formed, as in the letter P, in the word
pulp," or in the letters A and B such detached or central portion is attached on the
wire cloth by solder, or in any other desired manner, to be in the proper relative
position with the other parts of the letter or pattern.
To form projections of various heights as shown by Figures 8 and 9 if the part is
a central portion e' arranged to give various heights of relief, I attach it on the wire
cloth 6, the same as the parts d' but in this case I provide it with perforations and
wire cloth f¹ upon its upper surfaces as shown, the pieces of wire cloth being
attached to the portion e¹ by fine soldering at the edges, the whole being of the height
and configuration desired to form the required relief in pulp.
In Figure 8, three heights of relief are shown, 1. 2. 3, from which will be under-
stood how any desired number of heights may be formed. The wire cloth on the
elevation 2, is not required, nor are the perforations Z, that are shown connected with
it, but I prefer to provide them in cases where very free drainage is desired the wire
cloth on the elevation 3 and the perforations Z, connecting therewith are required
because without them a portion of water may be locked in, as hereinbefore described
and shewn in Figure 10. If the piece e¹ is not a center piece; but is on one or more
of its sides integral with the plate a¹ (as shewn in Figure 18) and the connection is
sufficiently strong, it need not be soldered to the wire cloth, but will be provided with
perforations and wire cloth at the required heights of relief, which will be understood
from the drawings and foregoing description:
My improved method of forming the die-plate-a-shewn-at-Figures 12 to 17-
inclusively; as is a piece of soft wood board being in thickness equal to the height of
the highest relief to be formed in the pulp, and of suitable size in length, width and
desired boundary configuration, this is shewn in Figure 12 as being rectangular with
straight sides. 65 is a piece of hard wood board being larger in size than the board a
so that it will form a lower margin c The letters, numbers, ornaments and other
designs required to be formed in pulp are (after the boards a and b, have been glued.
together) carved in the board a being cut completely through it to the plane of the
board as shewn in Figure 14, which is a transverse section of Figure 13, taken on
line x, and in Figure 15, which is a longitudinal .section on line y Figure 13 we will
take them for example to be IX L, as shown in Figure 13.
In cases when various heights of relief are used, some of the relief will not be
carved so deeply as to the plane of the board 6. The margin c is cut down to be a
small amount lower than the remaining portion of the surface of the board 65 as shown
in Figure 14. On the edges of the surface of the board a¹ is attached a marginal
beading do and the edges of the board a and beading d are trimmed off to any
desired bevel e*.
I now cover the carved side of the boards a' and 6 with a thin coat of dry material,
finely levigated plumbago, I have found as a whole to be the most suitable, then with
a thick and substantial soft body of bees wax f' I make an impression of it, the wax
being pressed upon the boards with sufficient force to insure a perfect impression as at
Figure 15. The wax impression is very carefully removed from the boards and well
and evenly thinly coated, or dusted with plumbago &c. it is next placed in an electro-
lytic bath and coated with copper in the ordinary manner of electro-plating, only tho
operation is carried to such an extent that the copper shell g will be of a sufficient
strength for the purpose hereinafter described. This shell is after having been removed

page_text: from the wax, then placed upon a hot block of metal * Figure 16 of an equal or of a
greater degree of heat than the molten metallic compound backing which is to be pro-
vided to it. The hot block will be provided with a surface arranged to properly
support the shell in a perfectly level position. The whole of the upper surface of the
shell is then covered with tinfoil, the block 5 being sufficiently hot to fuse the tinfoil,
and cause it to unite with the copper shell and coat it. Having at hand ready a fused
composition of metal, preferably of the character of " type metal" but softer, having
less antimony and tin in it, so that if the shell g³ should spring or warp when being
filled with the fluid metal, or while the same is cooling it may be sufficiently ductile to
stand being straightened without cracking, also that it may be readily cut or worked
with tools.
I fill the shell until the projections are slightly covered over with the metal, as
shown at 4, in Figure 17. The whole is then left until cold and set; after this the
die-plate a thus produced is cut down to the required size, as shown by the lines 5. in
Figure 17 thus leaving a bevelled marginal projection a on the edges of the die,
which serve the purpose of keeping the edges of the pulp from pressing on the sides
of the mould when fully compressed as will be understood from Figure 11, where a
body of pulp is represented as being fully pressed. The edges a¹ are set out with a
caulking tool against the sides of the mould and against the sides of each other when
more than one die is used in the mould at the same time, to prevent the pulp from
pressing between the die or dies and the mould or between the dies.
The back of the die a¹ is planed off to a level surface, and the parts at 4 (Figure 17)
are removed by cutting away all the material down to the dotted line, so that the
projections are thus formed into openings completely through the die a¹. The die is
then ready to have the wire cloth b' and perforated plate c' attached to it as herein-
before mentioned.
I take pulp which has been reduced by a beating engine, and mixed with water to
bring it to a soft pulpy mass, and place it in the mould / using a sufficient quantity of
it to form the article required; the mould and plunger are then moved by hydraulic
or other power to press the pulp.
The pipe s, Figure 11 is connected with any suitable air-pump or other ordinary
means by which a vacuum is formed in the chamber or space b, by this means the
drainage of water from the pulp is caused from both sides of the mass of the pulp that
is being pressed, as shown in Figures 2, 8, 11 and 18 the drainage from the lower sido
of the pulp is caused to pass through the openings and perforations in the die-plate a¹
by pressure and gravity, and as shown in Figure 11, the drainage from the upper side
of the pulp a is caused to pass through the openings in the upper die-plate a¹ by
pressure and vacuum, which said openings form the letters or other decorated work
upon the surface of the pulp.
As soon as the pulp has been sufficiently compressed the plunger and mould are
moved apart and the vacuum being continued in the chamber t it causes the plunger
to lift the compressed body of pulp out of the mould; when the plunger and mould
are sufficiently apart, the vacuum in the chamber t is destroyed, whereupon the com-
pressed pulp is easily removed from the plunger, and is then ready for the process of
drying induration, painting &c. &c. when such are desired.
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 combination in an apparatus for pressing the pulp and forming upon it
configurations as described of a press provided with a drainage bed n, drainage
plate g, wire cloth u, mould die C. with a plunger f having vacuum chamber t
perforated plate 2, wire cloth m and marginal edges a² the whole constructed
arranged and operating substantially as described.
2. The combination in an apparatus for pressing pulp and forming upon it con-
figurations as described of a press provided with a drainage bed perforated
plate . wire cloth a mould and die plate a¹ having wire cloth b¹ and perforated

page_text: plate c¹ with a plunger having vacuum chamber t perforated plate 1, wire cloth m,
the whole constructed, arranged and operating together substantially as and for
the purposes described.
3. The combination in an apparatus for pressing pulp and forming upon it
configurations, of a vacuum chamber, provided upon one side of the mould with a
die and having drainage on both sides of the body of pulp being pressed, the whole
substantially as and for the purposes set forth.
4. The combination in the construction of the die plate a¹ of the shell go with the
openings that produce the relief formed entirely through the thickness of the die
plato, and a filling or backing 9 the whole substantially as described.
5. The method of forming the die plate a', which consists in uniting two boards
together and carving in or through one of them the desired configurations, then
making an impression of the carved side of the boards, metalizing the said impression,
and then electro-plating the same and forming a shell thereon, filling the shell and
forming it into a plate and cutting it down until openings are formed completely
through the same, the whole substantially as described.
6. In a die for forming configurations on surfaces of pulp, the die plate having the
openings to produce the relief formed entirely through it substantially as described.
7. In a die for forming configurations on surfaces of pulp the combination of the
die-plate a having relief openings completely through it with a wire cloth having
centre-pieces d' attached thereon, in proper relative position to act in union with the
said die plate, the whole combined substantially as described for the purposes set
forth.
In a die for forming configurations on surfaces of pulp, a die plate having relief
openings completely through it, with a wire cloth, having pieces attached thereto of
various heights of relief or elevation, the said pieces being provided with wire cloth
and having also perforations through their body to cause a drainage from the said
heights of elevation, the whole combined and operating substantially as described.
9. In a die for forming configurations on surfaces of pulp, the die plate having
openings of relief completely through it and having chamfered edges a¹ for setting out
to prevent the passage of pulp about its edges, in combination with a wire cloth b
and mould h, the whole combined substantially as described.
Dated this 2nd day of March 1889.
ABEL & IMRAY,
Agents for the Applicant.