IMPROVEMENTS IN THE NETHOD OF MOULDING FOR CASTING METALS
Year: 1882

page_text: LETTERS PATENT to Edward Peyton and Charles Burley both of Birmingham
in the County of Warwick for an Invention of "IMPROVEMENTS IN THE
NETHOD OF MOULDING FOR CASTING METALS
"
PROVISIONAL SPECIFICATION left by the said Edward Peyton and Charles
Burley at the Office of the Commissioners of Patents on the 1st November
1882.
EDWARD PEYTON and CHARLES BURLEY both of Birmingham in the County of
Warwick, IMPROVEMENTS IN THE METHOD OF MOULDING FOR CASTING
METALS
"
"
The method of moulding cored or hollow work is too well understood to require
description but for the purpose of describing our new method it is necessary to say
that the cores which when laid in the mould fill up a portion of the space left in
it by the impress of the pattern and so make the casting hollow are made by
pressing sand into metal moulds called core boxes. This is done by hand and the
cores made are dried in a suitable stove or oven and afterwards placed in the mould
by hand when dry and hard
This process is imperfect for the following reasons;
1st Each core has to be made separately
2nd A number of cores all made out of the same core box and by the same
operation are liable to vary and in fact do vary in size and accuracy of shape
As the process is a manual one the cores are liable to be broken and rubbed.
When broken labor is lost especially if that happens after they are placed in the
moulds and when rubbed the weight of the casting is unnecessarily heavy.
Rubbing in point of fact is of constant occurrence and moreover it is well known
that casters who are usually paid by the weight produced, rub cores purposely.
It is obvious that the more delicate in shape the cores ought to be for the
purpose of avoiding unnecessary weight the more liable they are to injury with
consequent loss.

page_text: In practice even skillful workmen make some bad work which has to be
remelted at a loss and none can insure all the reproductions from the same pattern
being perfect especially as to uniformity of weight nor as light as they can be
made by our improved process
When good work has been cast the cores have to be removed which is a work of
some time owing to the sand adhering to the metal. In the method in use the
caster works off what is technically called an odd side that is one half of a pair
of mould boxes, upon which after the pattern is properly embedded in the
sand he places one mould box of the pair of boxes he is going to use finishes his
mould in that box and then places the other box which goes to complete the pair
upon the first and completes the mould in it.
The boxes are fitted in pairs but the two boxes of each pair only need fit one
another whereas one side of every pair fits the odd side
In describing our improved method it must be understood that we do not work
from one odd side
The moulding is done from two pairs of boxes from one pair of which containing
the pattern which we call the pattern moulds sand moulds are formed corre-
sponding to the outside of the pattern and consequently to the outside of the work
to be produced and from the other pair containing the pattern of the core or core
print which we will call the core moulds the cores are produced by moulding
Both pairs of mould boxes are fitted accurately so as to correspond and register
not only one with the other of the same pair but with the other pairs also and
when mould boxes are made in sets as is usual. All the pairs and both parts of
every pair must register with every other of the set and of course with both of the
two pairs containing respectively the pattern and the core print upon which the
moulding is done
It is obvious that the desired result cannot be obtained unless the pattern in the
pattern mould and the core prints in the core-mould-are-supported in-their-places-
with perfect accuracy with reference to one another so that when the sand moulds
formed upon them respectively come together they shall exactly correspond and be
complimentary to one another and as a result leave just the required space for the
molten metal to run into no more and no less.
The means of accomplishing the above object forms the subject matter of our
invention and we will now proceed to describe the way in which we produce the
pattern moulds and core moulds which as explained take the place of the ordinary
odd side and core boxes.
These pattern moulds and core moulds are made of plaster of Paris or other
plastic material or of iron brass or other metal or of wood or of such other material
as can be cut carved or moulded into the required shape.
We first make the pair of pattern moulds of plaster of paris or other plastic
materials. We then make a sand mould in the ordinary way, upon one of these
pattern moulds. In this sand mould we place the core print or prints and then
make the pair of core moulds of plaster of paris or other plastic material the first
made upon the sand mould and the second upon the first. We then have the two
pairs of moulds previously described viz; the pattern moulds and the core moulds.
The process is the same if the pattern moulds and core moulds are made of iron or
other metal or wood or other suitable material.
When the pattern moulds and core moulds are made they are permanent and
can be used until broken, or materially damaged. When desired they may be made
in sections, so that one section may be removed and replaced by another the
importance of which all casters well understand.
When a pair of sand moulds have been made from the pattern moulds and the
cores moulded from the core moulds one half of the pair of sand moulds produced
by moulding on the core moulds is removed leaving the core lying in the other
half fresh and perfect and the sand damp.
One half of the pair of sand moulds produced. by moulding on the pattern

page_text: moulds is then placed on this half of the core mould and both turned over thereby
transferring the cores to the sand mould without touching with the hand.
They rest on the usual bearings as casters will understand.
mould is made up and poured in the usual way
After this the
The cores are very easily removed as in consequence of the sand being damp it
does not adhere to the castings but leaves them as smooth and clean inside as out.
SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said Edward Poyton and Charles Burley in the Great Seal Patent Office
on the 1st May 1883.
EDWARD PEYTON and CHARLES BURLEY both of Birmingham in the County
of Warwick "IMPROVEMENTS IN THE METHOD OF MOULDING FOR CASTING
METALS"
The method of moulding cored or hollow work is too well understood to require
description but for the purpose of describing our new method it is necessary to say
that the cores which when laid in the mould fill up a portion of the space left in it
by the impress of the pattern and so make the casting hollow are made by pressing
sand into metal moulds called core boxes. This is done by hand and the cores
made are dried in a suitable stove or oven and afterwards placed in the mould by
hand when dry and hard.
This process is imperfect for the following reasons:-
1°. Each core has to be made separately.
2º. A number of cores all made out of the same core box and by the same
operation are liable to vary and in fact do vary in size and accuracy of shape.
As the process is a manual one the cores are liable to be broken and rubbed.
When broken labor is lost especially if that happens after they are placed in the
moulds and when rubbed the weight of the casting is unnecessarily heavy.
Rubbing in point of fact is of constant occurrence and moreover it is well known
that casters who are usually paid by the weight produce rub cores purposely.
It is obvious that the more delicate in shape the cores ought to be for the
purpose of avoiding unnecessary weight the more liable they are to injury with
consequent loss."
In practice even skilful workmen make some bad work which has to be remelted
at a loss and none can insure all the reproductions from the same pattern being
perfect especially as to uniformity of weight nor as light as they can be made by
our improved process.
When good work has been cast the cores have to be removed which is a work of
some time owing to the sand adhering to the metal. In the method in use the
caster works off what is technically called an odd side that is one half of a pair of
mould boxes upon which after the pattern is properly embedded in the sand he

page_text: places one mould box of the pait of boxes he is going to use finishes his mould in
that box and then places the other box which goes to complete the pair upon the
first and completes the mould in it.
The boxes are fitted in pairs but the two boxes of each pair only need fit one
"another whereas one side of every pair fits the odd side.
In describing our improved method it must be understood that we do not work
from one odd side.
The moulding is done from two pairs of boxes from one pair of which containing
the pattern which we call the pattern moulds sand moulds are formed corre-
sponding to the outside of the pattern and consequently to the outside of the work
to be produced and from the other pair containing the pattern of the core or core
print which we will call the core moulds the cores are produced by moulding.
Both pairs of mould boxes are fitted accurately so as to correspond and register
not only one with the other of the same pair but with the other pairs also and
when mould boxes are made in sets ns is usual all the pairs and both parts of
every pair must register with every other of the set and of course with both of the
two pairs containing respectively the pattern and the core print upon which the
moulding is done.
It is obvious that the desired result cannot be obtained unless the pattern in the
pattern mould and the core prints in the core mould are supported in their places
with perfect accuracy with reference to one another so that when the sand moulds
formed upon them respectively come together they shall exactly correspond and be
complimentary to one another and as a result leave just the required space for the
molten metal to run into no more and no less.
The means of accomplishing the above object forms the subject matter of our
invention and we will now proceed to describe the way in which we produco tho
pattern moulds and core moulds which as explained take the place of the ordinary
odd-side-and-core-boxes:
--
These pattern moulds and core moulds are made of Plaster of Paris or other
plastic material or of iron brass or other metal or of wood or of such other material
as can be cut carved or moulded into the required shape.
In carrying out our improvements we find it advantageous first to make the
pair of pattern moulds of plaster of Paris or other plastic materials. We then
inake a sand mould in the ordinary way upon one of these pattern moulds. In
this sand mould we place the core print or prints and then make the pair of core
moulds of plaster of Paris or other plastic material the first made upon the sand
mould and the second upon the first. We then have the two pairs of moulds
previously described viz; The pattern moulds and the core moulds. The process
is the same if the pattern moulds and core moulds are made of iron or other metal
or wood or other suitable material.
When the pattern moulds and core moulds are made they are permanent and
can be used until broken or materially damaged. When desired they may bo
made in sections so that one section may be removed and replaced by another the
importance of which all casters will understand.
When a pair of sand moulds have been made from the pattern moulds and the
cores moulded from the core moulds one half of the pair of sand moulds produced
by moulding on the core moulds is removed leaving the core lying in the other
half fresh and perfect and the sand slightly moist.
One half of the pair of sand moulds produced by moulding on the pattern
moulds is then placed on this half of the core mould and both turned over thereby
transferring the cores to the sand mould without touching with the hand.
They rest on the usual bearings as casters will understand. After this the mould
is made up and poured in the usual way.
The cores are very easily removed as in consequence of the sand being slightly
moist it does not adhere to the castings but leaves them as smooth and clean inside
as out
Having thus described the nature of our invention and the manner of performing

page_text: or carrying the same into practice we would have it understood that we make no
claim to any part of the process or operation of moulding separately for the
purpose of moulding for casting metals which is well known and in common use.
But what we claim is-The improved method of moulding for casting metals by
means of a set of pattern moulds and core moulds produced substantially in the
manner and for the purpose herein before fully described.
In witness whereof I the said Edward Peyton have hereunto set my hand
and seal this Twenty fifth day of April in the year of our Lord One
thousand eight hundred and eighty three.