Improvements in Machinery for the Production of Sheets Direct from Molten Metal or Glass.
Year: 1890

page_text: Date of Application, 28th Apr., 1.890
Complete Specification Left, 7th Nov., 1890-Accepted, 10th Jan., 1891
PROVISIONAL SPECIFICATION.
Improvements in Machinery for the Production of Sheets Direct
from Molten Metal or Glass.
I, CARL MARLA PIELSTICKER, of Suffolk House, Cannon Street, in the City of
London, County of Middlesex, Engineer, do bereby declare the nature of this inven-
tion to be as follows:-
My invention relates to improved machinery and process for producing sheets
direct from the molten metal, instead of as is now usually practised, first casting large
ingots or slabs and then reducing these by repeated rollings and re-heating.
Various attempts have been made to attain this object, amongst others, by pouring
molten metal between two revolving rollers; in this process the molten metal
collecting on the top and between the two rollers, rapidly chilled and rendered it
impossible for the rollers to take hold of the mass of solidified metal and pass it
through the small space left between them.
In a modified method the molten metal was poured in a thin stream directly between
the two rollers, the latter being run at a sufficiently high speed to prevent the
accumulation of any molten metal on the top of them.
By this process, only very thin sheets could be produced owing to the stream of
molten metal coming into contact only tangentially with the periphery of the rollers,
such instantaneous contact not being sufficient to solidify the centre of any but a very
thin plate.
Moreover there exists great difficulty in so regulating the speed of the revolving
rollers as to prevent the molten metal from collecting between the rollers when they
are running at too slow a speed or to avoid the tearing or breaking of the plate when
running at too high a speed, and further since the nozzle of the crucible can only be
carried down for a certain distance between the two rollers, the molten metal has to
fall through some distance before it reaches the rollers, whereby objectionable oxidation
of the molten metal takes place.
Another method consists in pouring the molten metal between the peripheral
surface of a revolving wheel and the surface of an enclosing fixed semi-circular
segment. Here it was found that since the plate, while solidifying, did not receive
any compression, numerous faults appeared on the surface, on account of the gases
occluded in the molten metal which formed blow holes after solidification, and that
the surface of the plate in contact with the fixed segment was of an uneven and
rough appearance. The friction between the face of the wheel and the fixed segment
being excessive, it entailed an undue wear and tear between them and necessitated
considerable motive power to rotate the wheel.
In this my improved apparatus and process, I obviate all these difficulties.
The molten metal can neither collect between the rollers, should they be running
slow, nor can the continuity of the plate be broken in the event of their running
fast. The apparatus can be run at any degree of speed desirable and a thick or a
thin plate be produced presenting on both sides a smooth and finished surface.
Further as the machine can be run at any desired speed and as the molten metal
remains in contact with the peripheral surface of the roller for a distance of nearly
one quarter of its circumference, plates of considerable thickness can be produced,
the molten metal having sufficient time to solidify right to the centre.
My machinery consists of one large or receiving roller of say five feet diameter,
more or less, and of a width equal to the plate to be produced, and one or more small
or forming rollers, say of about nine inches in diameter more or less; the latter
being arranged to revolve in suitable bearings and on the upper surface of the large
roller.

page_text: Iron or other Sulciore matern and are
preferably made hollow.
A stream of water circulates through each roller, entering at one end and issuing
at the other.
The large roller is supported in bearings placed in vertical housings or side frames
and is provided with flanges at each end.
These flanges are of such a width apart as to embrace the small rollers and of a
depth greater than the thickest plate which it is proposed to roll, and are constructed
so as to run in contact with corresponding loose collars arranged to revolve freely on
the axis of the small rollers.
By this construction the molten metal flowing on to the surface of the large roller
is prevented from escaping sideways by the flanges and at the same time the surface
velocity of the small rolls is maintained at the same uniform rate as that of the large
roller.
may instead arrange for the loose collar to revolve on the axis of the large
roller and the flanges to be on the small rollers.
The bearings of the smaller rollers are fitted within corresponding slides and
furnished with screws for the purpose of adjustment.
By varying the diameter of the loose collars the small rolls can be run nearer to
or further from the large roller the diameter of the loose collars being determined
according to the thickness of plate to be made.
The first small roll may have a coating of refractory material.
Between the first and second and the second and third of the small rollers, and
parallel to the axis of the large roller a refractory or metal shield may be placed,
arranged so as to be capable of being adjusted nearer to or further from the large
roller in a similar manner to the small rolls. When these shields are made of iron
they are preferably constructed hollow and kept cool by the circulation of water inside
of them, the water entering at one end and issuing at the other.
I have found it preferable in some instances, especially when dealing with metals
of high melting point, to construct the first of the small hollow rollers of a refractory
material, and instead of cooling this roller, to heat the same by means of a blow pipe
flame introduced at one end of the cylinder. the products of combustion finding an
outlet at the other end of the same.
Immediately opposite to the first of the small rollers is a guard block of refractory
material extending right across, and parallel to the axis of the larger roller and
resting on the surface of same, the object of which is to prevent any molten metal
escaping in the wrong direction, and to afford the possibility of running the machine
at a slow speed when making thicker plates and also of accumulating a head of metal
to evenly feed the machine. This refractory block may be provided with a tubular
perforation along its whole width for the purpose of heating it by means of a blow
pipe, or otherwise.
A similar refractory block may be placed immediately in front of the first small
roller which may likewise be similarly heated as the first block. This block is so
constructed as to leave a space equal to the thickness of the plate to be made between
its under surface and the periphery of the large roller.
In order to prevent the adhesion of molten metal to the rolls I preferably coat them
with oil, plumbago, powdered lime or other similar material whilst the machine is in
operation, or I may oxidize the surfaces.
Between the two refractory blocks, or between the first refractory block and the
first one of the small rollers, a space is left for the insertion of the nozzle of a crucible,
the nozzle extending in a direction parallel to the axis of the large roller and so close
to the peripheral surface of the roller that only a space equal to the thickness of the
plate to be formed is left between the end of the nozzle and the roller.
The space between the two refractory blocks or the opening of the nozzle of the
crucible, may be closed or regulated by an eccentric roller or a wedge shaped
refractory stopper so arranged as to be operated by suitable levers or otherwise by the
attendant.
When very thin plates are to be manufactured and the metal is fed between the

page_text: refractory block and the roller I may place a small roller of say two inches in diameter
immediately in front of the first forming roller to lessen the angle formed between
the first forming and receiving rollers.
Or in lieu of the above the metal may be fed from a furnace direct either between
the two blocks or between one block and the first small roller.
In order to prevent the possibility of the metal chilling in the inlet, the spaco
between the two blocks may previously be heated by means of a blow pipe introduced
temporarily from either end.
When dealing with metals of high melting point, as for instance. steel, I prefer to
feed my machine direct from a furnace in which the metal may be kept for any length
of time in a molten condition, the furnace being divided into two parts by a wall or
bridge extending across it, in the middle of which wall or bridge is an opening which
may be closed by means of a stopper operated in any convenient manner from the
exterior of the furnace, whereby the flow of molten metal on to the machine can be
regulated as desired. The heat from the furnace serves likewise to keep the inlet of
the machine in a highly heated state. If steel is to be fed on the machine from a
crucible, I may allow the steel to run in a thick stream on to a shallow ladle provided
with a wide lip and placed across the large roller and parallel to its axis. By tilting
this trough like ladle the metal will flow over its lip on to the roller without the
danger of clogging the outflow, which would exist if a crucible with a narrow slit in
the nozzle was employed for steel.
al
In operating my machine: After heating the inlet and causing the water to
circulate through the rollers and the shields or by heating the small roller I cause the
large rollers to rotate by means of a belt, or other suitable driving mechanism, and
this in revolving causes the small rollers with which it is in contact by means of the
loose collars on its axis, to revolve in a similar manner. I then pour the molten metal
into the inlet between the two refractory blocks or between the first block and small
roller whence it flows on to the surface of the large roller in a continuous stream the
depth of which is regulated to the thickness of the required plate to be produced by
the space or opening provided between the peripheral surface of the large roller and
that of the under surface of the refractory block or that of the end of the nozzle of a
cracible or the surface of the first small roller.
The plate after having passed between the large flanged roller and the small roller
is then further solidified by passing under the following rollers where it may receive
compression. The small rollers may be caused to rotate by the passage of the plate
between them and the large roller instead of by their loose collars running in contact
with the flange.
The plate may be still further finished and reduced in thickness by other rollers
placed in close proximity underneath of or on the same level with the large
roller and also by placing one or more pairs of rollers in advance of the large
roller.
The edges of the plate are sheared off by means of a pair of circular shears or
ordinary construction and similar shears may cut the sheet in strips of the desired
width.
If the sheet is very thin it may at once be reeled off on to a reeler placed in advance
of the circular shears.
When it is desired to manufacture sheets of shorter lengths, one or more ribs may
be raised on the surface of one of the pair of rollers between which the finished and
still red hot plate passes, and parallel to its axis, the rib being high enough to touch
the under surface of the second roller forming the pair.
My machine may be applied to the manufacture of sheets of glass as well as sheets
of metal, in which case the rollers should be warmed and the sheet of glass stretched
and annealed as it leaves the last roller.
Dated this 28th day of April 1890.
C. M. PIELSTICKER.

page_text: COMPLETE SPECIFICATION.
Improvements in Machinery for the Production of Sheets Direct
from Molten Metal or Glass.
I, CARL MARIA PIELSTICKER of Suffolk House, Cannon Street, in the City of
London, and County of Middlesex, Engineer, 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 improved machinery and process for producing sheets direct
from the molten metal, instead of as is now usually practised, first casting large
ingots or slabs and then reducing these by repeated rollings and re-heating.
Various attempts have been made to attain this object, amongst others, by pouring
molten metal between two revolving rollers; in this process the molten metal collecting
on the top and between the two rollers, rapidly chilled and rendered it impossible
for the rollers to take hold of the mass of solidified metal and pass it through the
small space left between them.
In a modified method the molten metal was poured in a thin stream directly between
the two rollers. the latter being run at a sufficiently high speed to prevent the
accumulation of any molten metal on the top of them.
By this process, only very thin sheets could be produced owing to the stream of
molten metal coming into contact only tangentially with the periphery of the rollers,
such instantaneous contact not being sufficient to solidify the centre of any but a very
thin plate.
Moreover there exists great difficulty in so regulating the speed of the revolving
rollers as to prevent the molten metal from collecting between the rollers when they
are running at too slow a speed or to avoid the tearing or breaking of the plate when
running at too high a speed, and further since the nozzle of the crucible can only be
carried down for a certain distance between the two rollers, the molten metal has to
fall through some distance before it reaches the rollers, whereby objectionable oxidation
of the molten metal takes place.
Another method consists in pouring the molten metal between the peripheral surface
of a revolving wheel and the surface of an enclosing fixed semicircular segment.
Here it was found that since the plate while solidifying, did not receive any compression,
numerous faults appeared on the surface, on account of the gases occluded in the molten
metal which formed blow holes after solidification, and that the surface of the place in
contact with the fixed segment was of an uneven and rough appearance. The friction
between the face of the wheel and the fixed segment being excessive, it entailed an
undue wear and tear between them and necessitated considerable motive power to
rotate the wheel.
In this my improved apparatus and process, I obviate all these difficulties.
The molten metal can neither collect between the rollers, should they be running
slow, nor can the continuity of the plate be broken in the event of their running
fast? The apparatus can be run at any degree of speed desirable and a thick or a
thin plate be produced presenting on both sides a smooth and finished surface.
Further as the machine can be run at any desired speed and as the molten metal
remains in contact with the peripheral surface of the roller for a distance of nearly one
quarter of its circumference, plates of considerable thickness can be produced, the
molten metal having sufficient time to solidify right to the centre.
1 will now describe my invention by reference to the accompanying sheets of
drawings on which :—
Fig. 1. represents a sectional elevation of my apparatus.
Fig. 2. is an enlarged view of the adjustable bearing for the small rolls.
Fig. 3. is an end elevation of my apparatus as seen from the back.
Fig. 4. shews in detail the eccentric roller for closing the mouth of the crucible.
Fig. 5. a plan as seen from above.

page_text: fed direct from a furnace.
my apparatus constructed so as to be
Fig. 7. being a front view of the bridge across the furnace.
Fig. 8. is a transverse section through the upper portion of large roller A, showing
the arrangement of the small rollers B B¹.
Fig. 9. is a transverse section showing the arrangement of shallow ladle W and
crucible.
It will be seen that my machinery consists of one large or receiving roller A of
say five feet diameter, more or less, and of a width equal to the plate to be produced,
and one or more small or forming rollers B C D, say of about nine inches in diameter
more or less; the latter being arranged to revolve in suitable bearings b c d and on
the upper surface of the large roller A.
These rollers may be constructed of iron or other suitable material and are preferably
made hollow.
A stream of water circulates through each roller, entering at one end and issuing
at the other.
The large roller A is supported in bearings E placed in vertical housings or side
frames and is provided with flanges G at each end.
These flanges & are of such a width apart as to embrace the small rollers B CD
and of a depth greater than the thickest plate which it is proposed to roll, and are
constructed so as to run in contact with corresponding loose collars H arranged to
revolve freely on the axis of the small rollers B, C, D.
By this construction the molten metal flowing on to the surface of the large roller A
is prevented from escaping sideways by the flanges G and at the same time the surface
velocity of the small rolls is maintained at the same uniform rate as that of the large
roller. I may instead arrange for the loose collar H to revolve on the axis of the
large roller A and the flanges G to be on the small rollers, B, C, D.
The bearings b c d of the smaller rollers are fitted within corresponding slides K
and furnished with screws L for the purpose of adjustment.
By varying the diameter of the loose collars H the small rolls can be run nearer
to or further from the large roller A, the diameter of the loose collars being determined
according to the thickness of plate to be made..
The first small roll B may have a coating of refractory material.
Between the first and second and the second and third of the small rollers, and
parallel to the axis of the large roller A a refractory or metal shield M may be placed,
arranged so as to be capable of being adjusted nearer to or further from the largo
roller in a similar manner to the small rolls. When these shields M are made of
iron they are preferably constructed hollow and kept cool by the circulation of water
inside of them, the water entering at one end and issuing at the other.
I have found it preferable in some instances, especially when dealing with metals of
high melting point, to construct the first of the small hollow rollers B of a refractory
material, and instead of cooling this roller, to heat the same by means of a blow pipo
flame introduced at one end of the cylinder, the products of combustion finding an
outlet at the other end of the same.
Immediately opposite to the first of the small rollers B is a guard block of refractory
material N extending right across, and parallel to the axis of the larger roller A and
resting on the surface of same, the object of which is to prevent any molten metal
escaping in the wrong direction, and to afford the possibility of running the machine
at a slow speed when making thicker plates and also of accumulating a head of metal
to evenly feed the machine. This refractory block N may be provided with a tubular
perforation along its whole width for the purpose of heating it by means of a blow pipe,
or otherwise.
A similar refractory block N' may be placed immediately in front of the first
small roller B which may likewise be similarly heated as the first block. This block
is so constructed as to leave a space O equal to the thickness of the plate to be made
between its under surface and the periphery of the large roller A.
In order to prevent the adhesion of molten metal to the rolls I preferably cont

page_text: them with oil, plumbago, powdered lime or other similar material whilst the machine
is in operation, or 1 may oxidize the surfaces.
Between the two refractory blocks N N', or between the first refractory.block N
and the first one of the small rollers B, a space P is left for the insertion of the
nozzle of a crucible, the nozzle extending in a direction parallel to the axis of the
large roller and so close to the peripheral surface of the roller A that only a space
equal to the thickness of the plate to be formed is left between the end of the nozzle
and the roller A.
The space between the two refractory blocks N N', or the opening of the nozzle
of the crucible, may be closed or regulated by an eccentric roller or a wedge shaped
refractory stopper so arranged as to be operated by suitable levers or otherwise by
the attendant.
When very thin plates are to be manufactured and the metal is fed between the
refractory block N, and the roller B, I may place a small roller B', of say two inches
in diameter, immediately in front of the first forming roller B to lessen the angle
formed between the first forming roller B and the receiving roller A.
Or in lieu of the above the metal may be fed from a furnace R direct, either between
the two blocks or between one block and the first small roller.
In order to prevent the possibility of the metal chilling in the inlet, the space
between the two blocks may previously be heated by means of a blow pipe introduced
temporarily from either end.
When dealing with metals of high melting point, as for instance steel, I prefer to
feed my machine direct from a furnace in which the metal may be kept for any
length of time in a molten condition, the furnace being divided into two parts by a
wall or bridge S extending across it, in the middle of which wall or bridge is an
opening T which may be closed by means of a stopper U operated in any convenient
manner from the exterior of the furnace, whereby the flow of molten metal on to the
machine can be regulated as desired. The heat from the furnace serves likewise to
keep the inlet of the machine in a highly heated state. If steel is to be fed on the
machine from a crucible, I may allow the steel to run in a thick stream on to a
shallow ladle W provided with a wide lip and placed across the large roller and parallel
to its axis. By tilting this trough-like ladle the metal will flow over its lip on to the
roller A without the danger of clogging the outflow, which would exist if a crucible
with a narrow slit in the nozzle was employed for steel.
In operating my machine:-After heating the inlet and causing the water to
circulate through the rollers and the shields or by heating the smaller roller B,
I cause the large roller A to rotate by means of a belt, or other suitable driving
mechanism, and this in revolving causes the small rollers B, C, D, with which it is in
contact by means of the loose collars on its axis, to revolve in a similar manner. I then
pour the molten metal into the inlet P between the two refractory blocks N N¹ or
between the first block and small roller B whence it flows on to the surface of
the large roller A in a continuous stream the depth of which is regulated to the
thickness of the required plate to be produced by the space or opening O provided
between the peripheral surface of the large roller A and that of the under surface of
the refractory block N or that of the end of the nozzle of a crucible on the surface of
the first small roller B.
The plate after having passed between the large flanged roller A and the small
roller B is then further solidified by passing under the rollers C. D. where it may
receive compression. The small rollers CD may be caused to rotate by the passage
of the plate between them and the large roller A, instead of by their loose collars
running in contact with the flange G.
The plate may be still further finished and reduced in thickness by other rollers
placed in close proximity underneath of or on the same level with the large
roller A and also by placing one or more pairs of rollers in advance of the large
roller A.
The edges of the plate are sheared off by means of a pair of circular shears of
ordinary construction and similar shears may cut the sheet in strips of the desired width.

page_text: If the sheet is very thin it may at once be reeled off on to a reeler placed in advance
of the circular shears.
When it is desired to manufacture sheets of shorter lengths, one or more ribs may
be raised on the surface of one of the pair of rollers between which the finished and
still red hot plate passes, and parallel to its axis, the rib being high enough to touch
the under surface of the second roller forming the pair.
My machine may be applied to the manufacture of sheets of glass as well as sheets
of metal, in which case the rollers should be warmed and the sheet of glass stretched
and annealed as it leaves the last roller.
Having fully described my invention what 1 claim and desire to secure by Letters
Patent is
1. An apparatus for the production of sheets directly from molten metal, consisting
of a revolving receiving roller, and one or more forming rollers arranged around the
periphery thereof, and means for delivering material to said rollers.
2. The herein described apparatus for manufacturing sheet metal, embracing a
revolving receiving roller, one or more forming rollers arranged in succession, and
set at a distance from the receiving roller regulated by the thickness of the sheet to
be produced, and means for delivering the metal from the furnace or crucible, the
whole being so arranged that the molten metal delivered on to the receiving roller is
thereby conveyed beneath the forming rollers.
3. The combination with a receiving roller, one or more successive forming rollers
and means of delivery of molten metal from a furnace or crucible on to the receiving
roller, of a refractory guard block keeping the metal from flowing in an opposite
direction to the rotation of the receiving roller substantially as described.
4. The combination with a receiving roller, one or more successive forming rollers,
means of delivering molten metal from a furnace or crucible on the receiving roller,
and a refractory guard-block, of a refractory block placed between the guard block
and the first forming roller, a space equal to the thickness of sheet desired being left
between the under surface of this block and the periphery of the receiving roller,
substantially as described.
5. The combination with a receiving roller, one or more successive forming rollers,
and a refractory guard block, of a crucible, the end of the nozzle of which leaves a
space equal to the thickness of the plate desired between itself and the periphery of
the receiving roller, substantially as described.
6. The combination with the machinery for the manufacture of sheet metal herein-
before described, of a furnace divided by an inner transverse wall with opening therein
for the insertion of a stopper, by which the flow of metal to the receiving roller may
be regulated substantially as described.
7. The combination of the shields M with the forming rollers B. C. D. substantially
as described.
S. The loose collars H on the forming rollers B. C. D. in combination with the
flanges G, of the receiving roller A, in combination with the flanges G, of the receiving
roller A, substantially as described for the purposes set forth.
9. In combination with the receiving roller A, a first forming roller B, made of
refractory material, and means for heating the same internally, substantially as
described.
10. The combination with the machinery for the manufacture of sheet metal herein-
before described, of means for further reducing the thickness of the sheets and for
shearing and dividing the same as set forth.
11. In combination with the receiving roller A, the ladle W, arranged to operate
substantially as and for the purpose specified.
Duted this 7th dor of November 1800
C. M. PIELSTICKER.