AU663655B2

AU663655B2 - Apparatus and method for producing cornices

Info

Publication number: AU663655B2
Application number: AU67529/94A
Authority: AU
Inventors: Ronald Keith Pollock
Original assignee: USG Boral Building Products Pty Ltd
Current assignee: Knauf Gypsum Pty Ltd
Priority date: 1993-07-16
Filing date: 1994-07-15
Publication date: 1995-10-12
Anticipated expiration: 2014-07-15
Also published as: AU6752994A

Description

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AUSTRALIA

Patents Act 1990 P/00II RegSaWao 3.2 663655 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

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c C rC C C Crtt eC, C tC C CC CCgg Name of Applicant: Actual Inventor: Address for service RONALD KEITH POLLOCK RONALD KEITH POLLOCK in Australia: CARTER SMITH BEADLE 2 Railway Parade Camberwell Victoria 3124 Australia Invention Title: APPARATUS AND METHOD FOR PRODUCING CORNICES Details of Associated Provisional Application: Australian Patent Application No. PL9994 filed 16 July 1993 The following statement is a full description of this invention, including the best method of performing it known to us .c 2 oo me I TITLE: APPARATUS AND METHOD FOR PRODUCING CORNICES The present invention relates to an apparatus and a method for continuously producing ornate cornices.

Cornices are elongate members, usually of curved crosssection, that are applied for decorative effect, generally to the corner between a ceiling and the walls of rooms. Cornices may be plain or ornate, with ornate cornices having patters formed in the surfaces that face into the room. Cornices are elongate members and hereinafter throughout this specification, the word "cornice" is to be understood to be any elongate member.

Cornices are generally manufactured from plaster or other cementitious composition which is initially pourable and sets to a solid. For convenience, the term "plaster" will 15 hereinafter be used to refer to any cementitious composition.

Plain cornices, commonly called "Scosher" cornices, are machine made and are produced in continuous fashion. In making Scosher cornices, a web of paper is fed from a roll into a number of lifting guides. The lifting guides are shaped such 20 that the edges of the web of paper are upturned and the middle of the web of paper has a curve placed in it, which curve is concave downwardly. The web of paper has a generally shape cross-section cnce it has passed through the lifting guides.

Plaster is subsequently poured into the top of the web of paper and the edges of the web are folded over the upper surface of the plaster. Adhesive tape is applied to the edges of the paper and acts to close the upper part of the web and to wholly enclose the plaster within the web and tape. After allowing sufficient time for the plaster to set, the cornice is cut to length.

Ornate cornices are generally made by hand in batch fashion. Production of ornate cornices involves adding a plaster mix to a mould, allowing the plaster to set and removing the cornice from the mould. Backing paper is neither required nor used. This method of production of ornate cornices is time-consuming, has a low production rate and leads to an expensive product.

Attempts have been made to continuously manufacture ornate '1

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4 AN:04:13331.C 4 July 1994 rI J'4 3 cornices cornice.

wear and by using rollers to imprint the pattern onto the However, the rollers suffered from very high rates of such continuous processes have not found widespread use.

In a first aspect, the present invention provides apparatus for the continuous production of ornate cornices by supplying a plaster mix to a continuously moving web of material, said apparatus comprising web feeding means for continuously feeding the web of material, moistening means for moistening the moving web of material to soften the material, shaping means for shaping the moving web of material into a desired cross-section shape, at least one press for forming a S" pattern in the moving web of material, the at least one press s including upper and lower members moveable relatively towards and away from each other, said upper and lower members being moved relatively towards each other to engage the moving web of material to form a pattern on the web of material, the at least one press being mounted to move along with the web of material when the at least one press engages the moving web of material, plaster supply means for supplying plaster to the moving web of material, folding means for folding over the edges of the web I of material, and means to cause the edges of the web of material to be held in place.

In one embodiment of the apparatus of the present invention, the at least one press is operative to form the complete pattern in the web of material prior to the plaster 4 mix being supplied to the web.

In another embodiment of the apparatus of the present invention, the at least one press is located in the apparatus J after the means to cause the edges of the web of material to be held in place such that the pattern is formed in the web of material after the web has been supplied with plaster and the edges of the web of material held in place., In yet a further embodiment of the present invention, the 35 apparatus has a plurality of presses including at least a first press for applying a first pattern to the web of material prior to supplying the web with plaster and a second press for I applying a second patterno o the web of material after the web MII:04:13331.C 4 July 1994 S 17 4 has been supplied with plaster and the edges folded over and held in place.

In all cases, the press(es) should be located downstream of the moistening means. This assists in preventing breakage of the web of material during pattern formation in the web.

It will be appreciated that, in embodiments where the press is located to form a pattern in the web after the web has been supplied with plaster and taped, the pattern should be formed before the plaster has set to any appreciable extent.

The web of material preferably comprises a web of paper or cardboard. Grades of paper or cardboard known to be suitable S for use in the continuous production of plain cornices are suitable for use in the present invention. The web of paper or cardboard is preferably supplied from a roll of the paper or eoe• S 15 cardboard.

The web feeding means preferably comprises a pair of cooperating rollers that engage the web and move the web therethrough. The speed of the rollers may be controllable to any desired speed to thereby control the speed of the web through the apparatus. More than one pair of rollers may be used to supply the web, if desired.

Preferably, the shaping means is arranged such that the cross-section shape of the web of material is gradually altered 2 to the desired cross-section. As will be appreciated, the web of material has an essentially flat cross-section when it is fed from the roll and the shaping means gradually alters the cross-section shape of the web to the desired cross-section.

The shaping means may include a shaping guide that includes a continuous shaping surface across which the moving web of material moves. The continuous shaping surface preferably has a continuously changing cross-section and this acts to change the cross-sectional shape of the web of material as the web of material moves across the surface to a desired cross-section as the web of material leaves the shaping surface.

/3 5 Alternatively, the shaping means for shaping the moving web of material into a desired cross-sectional shape may include one or, more preferably, a plurality of lifting guides.

The plurality of lifting guides are arranged to gradually alter AN:04: 13331.C 4 July 1994

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1R the cross-section of the moving web to the desired crosssection. Lifting guides are well known to persons skilled in the art and further description will not be provided at this stage.

The shaping means may further include one or more creasing rollers for placing one or more creases into web of material as the web passes over or through the creasing rollers. Creasing rollers may be used if it is desired to put one or more creases into the web of material (for example, if it is desired to produce a cornice having one or more longitudinal creases or ridges therein as part of the ornate pattern of the cornice).

The one or more creasing rollers are preferably located before "t the shaping guide or lifting guide(s). The creasing roller(s) may be located after the shaping guide or lifting guide(s), but S 15 it is somewhat more inconvenient to roll creases into the shaped web of material.

The desired cross-section of the web preferably includes upturned edges. Preferably, the middle portion of the web is also curved, concave downwardly, such that the web has a generally shaped cross-section. The cross-section referred to is the end-on cross-section of the web.

.t The apparatus of the present invention also includes site moistening means which supplies moisture to the web. The web, t t such as a web of paper, absorbs the moisture, which acts to soften the web and assists in preventing tearing or breakage of the web during subsequent pattern formation in the press or presses. The moistening means is preferably a water spray adapted to spray a very fine mist of water onto the moving web of material. The fine mist of water impinges upon the moving web of material and the material will at least partly absorb the water. Any moisture that is not absorbed by the material when the web enters the first die is forced into the material by the action of the die.

Alternatively, the moistening means may comprise steaming means for supplying steam to the moving web of material.

The amount of moisture supplied to the moving web of material should be adequate to soften the material to ensure that the web does not tear or break when a pattern is imprinted A:04:13331.C 4 July 1994

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*4tt 4 4* t ~4- S S V 54' 5 therein by the first die.

Furthermore, the moistened web of material should retain sufficient strength to enable it to retain the plaster after the plaster is added. Accordingly, over-wetting of the web of material shou.Ld be avoided.

The moistening means may be located before the shaping means or after the shaping means. In fact, the only requirement for the moistening means is that it be located before the first press.

As mentioned above, the press or presses may be positioned either before or after the plaster supply means. If more than one press is used, presses may be positioned all before, all after both before and after upstream and downstream) of the plaster supply means.

The primary function of the press or presses is to form a pattern in the moving web. The pattern formed in the moving web is transferred to the plaster supplied to the web and is imprinted onto the plaster upon setting of the plaster. The pattern is, of course, formed on the portions of the web that correspond to the part of the cornice that is visible when the cornice is affixed in place in a room.

The press or presses used in the apparatus of the present invention are operable to form the pattern in the web without tearing or breaking the web. The press or presses -include 25 upper and lower members that may be moved relatively towards and away from each other. Each of the upper and lower, members may comprise unitary members, or they may include two or more separate parts. Some more specific embodiments of presses used in the present invention will be described in greater detail in later sections of this specification.

The press or presses are used to impress a pattern onto the moving web of material. In order to prevent breakage of the web, the press or presses must be mounted such that the press or presses is able to move along with the moving web when the web is engaged by the press.' If thle P,,ress(es) was not so mounted, the web would break. whenever the press(es) engaged the moving web. In a preferred embodiment, each press is mounted on rails and supported by bearings. When the Press closes and V14 a v~ :4 [1 I;i-S A:04:13331.C 4 JulY 1994 7 4.

a 9 4r 9 engages the moving web, the press is moved essentially sideways at the same speed as the web. Movement of the press may be achieved by any convenient means, such as a hydraulic cylinder.

Once the press has engaged the moving web for sufficient time to form a pattern in the web, the press is opened and is moved back to its original position, e.g. by the hydraulic cylinder, where it is again closed to engage the moving web. Thus, the press is in reciprocating motion, moving in the direction of movement of the web when it is in contact with the web and moving in the opposite direction when it is open.

The extent of sideways movement of the press may be controlled in any convenient manner, with trip switches being preferred. The movement of the press should be controlled to ensure that a substantially continuous pattern is formed on the web.

The plaster supply means supplies a flowable plaster mix to the moving web. The plaster mix preferably comprises a pourable mix of plaster (gypsum) and water. The plaster supply means preferably comprises a plaster holding means for holding the plaster mix and delivery means for delivering the plaster mix at a controlled rate to the moving web. The plaster holding means preferably includes mixing means to ensure that the plaster mix is well mixed. The plaster holding means, in a preferred embodiment, is configured as a continuous mixer in which gypsum and water are added and thoroughly mixed together.

The delivery means may be any suitable device, such as a nozzle or a valve, for delivering the plaster mix to the moving web at a controlled rate. The delivery of plaster to the moving web is controlled in order to obtain a consistent thickness of plaster on the moving web.

Once the plaster mix has been supplied to the moving web, the web passes through folding means which act to fold over the upturned edges of the web. The folding means may comprise one or more rollers arranged to contact the edges of the web of material and to fold down the edges. Alternatively, the folding means may comprise one or more lifting guides that fold over the edges of the web of material. The folded over edges of the web lie on top of the plaster and act to fully enclose it i 1

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44. 1 4 cc 9, 9,94 9 9, 9,i 9,r or partially enclose the plaster. The edges f the web of material are then treated to rprain the edges in place. In one embodiment, which is currently the preferred embodiment, the means to cause the edges of the web to be held in place comprise taping means for applying adhesive tape to the edges of the web of material to hold the edges of the web of material in place. In this embodiment, the folded-over edges of the web of material may overlap. Alternatively, there may be a gap between the folded-over edges, with the adhesive tape extending from one edge, across the gap and to the other edge. The adhesive tape holds the edges of the web in place and seals the plaster in the web.

The tape may be a gummed tape and is preferably supplied from a roll. The tape is passed to a roller that applies the 15 tape to the edges of the moving web. The taping means may be of any configuration known to the skilled person and will not be described in further detail.

Conveniently, the taping means includes a roller that acts to fold over the edges of the web and applies tape to the folded-over edges.

Once the moving web, filled with plaster, has been taped, the plaster is retained within the web. The web may be pressed (if required) to apply a pattern thereto without plaster being exuded from the web.

25 In another embodiment, the folded-over edges of the web of material overlap and the mreans to cause the edges of the web of material to be held in place include means for applying adhesive to an edge of the web of material and means for pressing one edge of the web of material onto the other edge whereby the adhesive applied to an edge joins the edges together. In this embodiment, it is preferred that the means for folding over the edges of the web of material folds over the lower edge and subsequently folds the upper edge over the lower edge after adhesive has been applied to one of the edges.

Again, the edges of the web are held in place and the plaster is sealed within the web.

As discussed above, the press or presses may be located before the plaster r pply means, after the plaster supply neans 1 -i p: fM:04:13331.C all- 4 July 1994 0 I teV-

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-9or both before and after the plaster supply means.

After the complete pattern has been formed on the web and the web has been taped, the plaster is allowed to set to its first set point where it is solid but soft and the cornice is cut to length. Cutting the cornice to length at the first set point of the plaster reduces wear on the cutting apparatus and minimises dust formation during cutting.

The apparatus preferably includes cutting means for cutting the cornice to length, which cutting means is mounted to move along with the moving web during cutting. The cutting means is preferably a cutting saw. Mounting the cutting means so that it moves a-'ong with the web during cutting ensures that ia clean cut is obtained and assists in preventing unwanted breakage of the cornice. Lateral forces on the cutting means are also minimised.

In a further aspect, the present invention also provides a method for the continuous production of ornate cornices comprising providing a web of material, feeding the web of material to shaping means to shape the web of material into a 20 desired cross-sectional shape, supplying plaster to the moving web of material, folding over the edges of the web of material and applying adhesive or adhesive tape to the edges to retain the edges in place, wherein a pattern is formed in the moving i web of material by passing said web of material through at i least one press which includes upper and lower members that are relatively movable towards and away from each other, the upper and lower members being moved relatively towards each other to engage the moving web of material to form a pattern thereon, i said at least one press being movable along with the moving web of material when the at least one press engages the moving web i of material, said at least one press returning to its original I si! position after releasing the moving web of material, said at least one press repeatedly engaging a section of the moving web of material to form a pattern on that section, releasing said section of the moving web of material and engaging a further section of the moving web of -material, said pattern being formed on the moving web of material after the moving web of, material has been moistened.

M:204:13331.C, 4 July 1994 :1.

"i i- 4. a..l 10 In one embodiment of the second aspect of the present invention, the pattern is formed on the web prior to the plaster being supplied to the web. In another embodiment, the pattern is formed on the weL after the plaster has been supplied to the web. In yet another embodiment, the pattern is formed on the web by presses located both before and after the plaster supply means.

A preferred embodiment of the present invention will now be described in more detail with reference to the following Figures in which: FIGURE 1 shows a side elevational view of an apparatus according to the present invention; FIGURE 2 shows a side sectional view of the inlet end of a shaping means used in the apparatus shown in FIGURE 1; FIGURE 3 shows a sectional view of the outlet end of the shaping means shown in FIGURE 2; FIGURE 4 is a perspective view of the shaping means shown in FIGURES 2 and 3; 20 FIGURE 5 shows a side elevation view of a further embodiment of the present invention; FIGURE 6 shows the cross-sectional profiles of lifting guides A to H used in the apparatus of FIGURE FIGURE 7 FIGURE 8 FIGURE 9 FIGURE 10 FIGURE 11 FIGURE 12 FIGURE 13 shows the cross-sectional profiles of lifting guides I and J used in the apparatus of FIGURE shows a side elevation of another embodiment of the present invention; shows a side elevation of another embodiment of the present invention; shows creasing rollers suitable for use in the embodiment shown in FIGURE 9; shows a schematic diagram of a press suitable for use in the present invention; shows a schematic diagram of an alternative press; shows a schematic diagram of another Id :i i

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material after it has passed through the shaping means; and FIGURE 15 shows the general cross-section of the web of material after it is supplied with plaster and the edges taped.

Referring to FIGURE 1, apparatus 10 includes a vertical support 12 having an axle 14 mounted thereon. A roll of backing paper 16 is supported on axle 14. A web 18 of the backing paper is fed from the roll 16 via pairs of co-operating rollers 20 and 22. The pairs of rollers 20 and 22 form part of S. the web feeding means of the apparatus. The web 18 passing from rollers 22 is sprayed with a fine mist of water from spray nozzle 23 and subsequently passed into shapin means 24.

In the embodiment shown in FIGURE 1, shaping means 24 comprises a shaping guide having a continuous shaping surface.

FIGURES 2 and 3 show the entry end shape and the exit end shape 2 of the shaping guide. As can be seen from FIGURE 2, the entry end of the shaping guide has a gently arcing cross-sectional shape. The cross-sectional shape of the shaping guide i continuously changes shape along the shaping guide, with the exit end shape being as shown in FIGURE 3. As can be seen, the Stc exit end has a generally shaped cross-section. FIGURE 4 shows a perspectiva view of shaping guide 24.

After leaving shaping guide 24, the web of paper has a cross-sectional shape that is essentially the same as the cross-sectional st ape of the exit end of the shaping guide 24. i With reference to FIGURE 3, the web of paper 18 leaving shaping guide 24 has upturned edges 18A and 18B and a curved midsection 18C.

The web of paper is passed into a first press 30. This first press includes a top punch 32 and a bottom die 34. The apparatus shown in FIGURE 1 is used to make an ornate cornice that includes a pattern formed on the centre part of the cornice and a double edged pattern formed near the edges of the cornice. Press 30 is used to produce the double edge pattern in the web of paper. FIGURE 14 shows a cross-sectional view of S:4:13331.C 4 July 1994

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12 the web of paper after the double edge has been produced in the web of paper.

Press 30 includes hydraulic cylinder 36 that acts to move top punch 32 upwards and downwards. By moving top punch 32 downwards, web 18 is engaged between top punch 32 and bottom die 34 and the double edge pattern is thereby formed in web 18.

In one embodiment shown in FIGURE 11, bottom die 34 is mounted on springs and the die sheet is shaped to support the centre of the paper, as is shown in FIGURE 11. With reference to FIGURE 11, the bottom die 34 includes die sheet 34A having a top surface 34B shaped to support the web of paper. Springs 34C attach the die sheet 34A to the mounting portion 34D. In use of press 30, hydraulic cylinder 36 is activated to lower top press 32 onto bottom press 34. This engages web 18 and forms the first part of the double edge pattern on the web of paper. The action of hydraulic cylinder 36 causes springs 34C to compress and subsequently spring back and this causes the second part of the edge to be formed in the web of paper. The double edge pattern requires that the press 30 include a spring loaded portion. This ensures that formation of the double edge pattern in the web of paper does not cause tearing of the web of paper. Trials by the present applicant have Ehown that attempts to make the double edge pattern with a single acting 2 t press caused tearing of the paper. t In an alternative embodiment shown in FIGURE 12, press 30 4 includes bottom die 35 and top die 37. Both bottom die 35 and i top die 37 are three-piece dies respectively including separate die pieces 35A, 35B, 35C and 37A, 37B, 37C. Outside die pieces 35C may be spring mounted and centre die piece 35A may be solid mounted. Alternatively, all die pieces 35A, 35B, 35C of bottom die 35 may be spring mounted.

As it will be appreciated, the web of paper 18 is i continuously moving through the apparatus 10. In order to prevent breakage of the web of paper 18 during operation of press 30, the press 30 is mounted such that it can move along Swith the web of paper 18 whilst the paper is engaged between top punch 32 and bottom die 34. In particular, press ~includes mounting legs 38 and 40 that are slidably mounted on ,M04:1333l.C 4 July 1994 S' *q iS 13 rail 42. Mounting legs 38 and 40 may be mounted on rail 42 by any suitable means known to a skilled person, for example, on bearings or nylon bushes. Leg 38 is connected to hydraulic cylinder 44 which controls the sideways movement of press In operation, when top punch 32 and bottom die 34 are closed, a signal is sent 'by control means (not shown) to hydraulic cylinder 44 which opens and causes press 30 to move sideways in the direction shown by arrow 46 at the same speed as the speed of the web of paper 18. When the press 30 has been in contact with the web of paper 18 for sufficient time to form the pattern on the web of paper (and accordingly has travelled a given distance sideways in the direction of arrow 46) trip 7 switches (not shown) cause top punch 32 and bottom die 34 to open and also send a signal to hydraulic cylinder 44 to move the press in the direction of arrow 48 in order to return the press to its original position. Once the press has returned to its original position top punch 32 and bottom die 34 are again closed to engage the web of paper 18. Operation of press 30 is controlled such that the desired pattern is formed on the web 18. This pattern may be a continuous pattern or it may be an intermittent pattern. In the case of formation of a double *"as edge by press 30, the pattern is formed as a substantially continuous pattern throughout the entire length of the moving ii web. The primary function of press 30 is to form a pattern in i a t 25 the web 18. However, it will be appreciated that the press h engages with the moving web and moves sideways along with the moving web 18. This also acts to assist in maintaining t movement of the moving web throughout the apparatus After passing through press 30, plaster is supplied to the moving web 18 by means of plaster supply 50. The plaster supply 50 preferably is a continuous plaster mixer that has an outlet nozzle, valve or orifice that allows for a constant flowrate of plaster from the plaster supply 50. The flowrate of plaster onto the moving web 18 is controlled such that a substantially constant thickness of plaster is placed upon moving web 18. Preferably, the flowrate of plaster onto web 18 can be regulated to ensure that a constant thickness of plaster is placed on the web, even if the speed of the web passing I AMP: 04 13331.C 4 July 1994 Aw 14 through the machine is varied. The plaster sits on the moving web and is retained in place by the upturned edges 18A and 18B.

Once the plaster has been placed on the moving web sizing roller 56 acts to fold over upturned edges 18A and 18B of the web 18. Adhesive tape is supplied from a roll of such tape 54 and is placed over the edges 18A and 18B of the web with the assistance of roller 56. The adhesive tape retains the edges of the web in place and also acts to enclose the plaster within the web. The general cross-sectional profile of the paper after it has been taped is shown in FIGURE 15. Tape generally extends in the area marked by reference numeral E The web containing the plaster is subsequently passed to S second press 58 which is used to form a further pattern on the central part 18C of the moving web 18. Press 58 includes top punch 60 and bottom die 62. Top punch 60 is reciprocated upwardly and downwardly by means of hydraulic cylinder 64.

As with press 30, press 58 is mounted on rails and adapted for sideways movement when the press engages the moving web.

The details of the mounting of press 58 are essentially similar to the mounting arrangement of press 30 and will not be described in further detail.

The bottom die of press 58 may comprise a three-part die member (refer to FIGURE 13) that includes outer parts 62A and 62C and an inner part 62B. In operation of press 58, the lower edges of the web of paper 18 are held by outside parts 62A and 62C of the bottom die 62. Top punch 60 is subsequently lowered to engage and hold the back of the web of paper 18 and then centre press 62B is raised upon into the middle of the bottom of web 18 to impress a pattern onto that part of the web.

Bottom die 62 does not need to be spring loaded as formation of a decorative pattern, for example, a flower pattern, is unlikely to cause breakage of the web.

Operation and control of press 58 is similar to the operation and control of press 30, with the exception that a three-part bottom die member is used. As with press 30, press 58 closes to engage the moving web 18. and moves sideways with the motion of moving web 18. When the top punch and bottom die are opened, press 58 is returned to its original position where SMtOC13331.C 4 July 1994 15 it again is closed to engage the web and move sideways with the moving web.

The complete pattern has now been applied to the moving web/cornice and production of the cornice is essentially complete. After allowing sufficient time for the plaster mix to attain its first set point, at which stage the plaster mix is solid but still relatively soft, cutting means 66 is used to cut the cornice to the desired length. Cutting means 66 is also mounted such that it moves along with the moving cornice during cutting in order to ensure that a clean cut is achieved and also to avoid unnecessary wear on the cutting means.

J *i Referring now to FIGURE 5, another embodiment of the apparatus of the present invention will be described. In the embodiment shown in FIGURE 5, many parts are in common with the embodiment shown in FIGURE 1 and, for the sake of brevity, discussion of the like parts will be omitted. The parts commor to the embodiments of FIGURE 1 and FIGURE 5 have been given like reference numerals.

In FIGURE 5, shaping means 24 of FIGURE 1 has been replaced with a series of lifting guides 124. In particular, a series of eight lifting guides (denoted by letters A to H in FIGURE 1) are used to gradually alter the cross-sectional shape of the web of paper 18. The cross-sectional shape of lifting S:t guides A to H are shown in FIGURE 6.

I 25 The web of paper leaving lifting guide section 124 passes through a pair of co-operating rollers 26 that assist in i driving the web of paper 18 through the apparatus. The web 18 then passes through another lifting guide configured the same as lifting guide H which ensures that the web of paper 18 retains its desired cross-sectional shape after passing through the pair of rollers 26. Steamer 28 subsequently applies steam to web 18. The web of paper absorbs the steam, which softens the paper.

The web of paper subsequently passes through first press 30 to form a double edge pattern on the web of paper. The operation of press 30 is identical to that of press 30 in i FIGURE i.

After passing through press 30, plaster is supplied to web M 4:13331.C 4 July 1994 1 1 1 1 1 1 1 1 1 1 Iirting guile section 52, which includes lifting guides I and J. FIGURE 7 shows the cross-section of lifting guides I and J.

Lifting guides I and J act to fold over upturned edges 18A and 18B of web 18. Adhesive tape is supplied from roll 54 and is placed over edges 18A and 18B with the assistance of roller 56.

The web containing the plaster is subsequently passed to second press 58 and then to cutting apparatus 66.

The embodiment of FIGURE 8 shows a further variation of the present invention and is very similar to the embodiment shown in FIGURE 5. For convenience, like numerals between FIGURES 5 and 9 refer to like features of the apparatus.

The embodiment of FIGURE 8 differs from the embodiment of 15 FIGURE 5 in that only a single press 70 is used to form the pattern. It will be noticed that this press is arranged to form a pattern on the web of paper after the web has been filled with plaster and closed by adhesive tape.

FIGURE 9 shows a further embodiment of the invention and this embodiment is generally similar to that shown in FIGURE 1.

However, in the apparatus shown in FIGURE 9, creasing rollers 21 are used to place creases or folds into the web. Creasing rollers 21 are shown more clearly in FIGURE 10. In this f FIGURE, the web of paper 18 passes between roller 212 and 214. I Rollers 214 are mounted on axle 215. Rollers 214 include raised surfaces that place creases into the web of paper.

It will be readily appreciated that the apparatus shown in the accompanying FIGURES is susceptible to many variations. In particular, the number of presses used and the location of the A 30 presses in the apparatus may be varied quite considerably. The accompanying FIGURES show apparatus incorporating one or two presses, but more may be used if desired.

Similarly, it will be appreciated that the press used to form the pattern on the moving web may be located before the web is filled with plaster and thut no stamping of the web may be required after plaster filling. The number and location of the presses used in the present invention may be varied considerably, with t he major requirement being that the presses A:04.:13331.C 4 July 1994 1 1 0 1 49 1 variations in the layout of the feeding rollers 20 and 22, with more or less rollers being used for feeding. Furthermore, if lifting guides are used, the number of lifting guides may be varied considerably and the cross-sectional shape of the web of paper following passage through the lifting guides may also vary over a wide range. However, it is preferred that, in the production of cornices, the web of paper 18 leaving lifting guide section 24 does have upturned edges.

Those skilled in the art will appreciate that the t i f l invention described herein is susceptible to variations and modifications other than those specifically disclosed. It is to be understood that the invention is considered to encompass all such variations and modifications that all within its spirit and scope.

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Claims

1. An apparatus for the continuous production of ornate cornices by supplying a plaster mix to a continuously moving web of material, said apparatus comprising web feeding means for continuously feeding the web of material, moistening means for moistening the moving web of material to soften the material, shaping means for shaping the moving web of material into a desired cross-section shape, at least one press for forming a pattern in the moving web of material, the at least one press including upper and lower members moveable relatively towards and away from each other, said upper and lower members being moved relatively towards each other to engage the moving web of material to form a pattern on the web of material, the at least one press being mounted to move along with the web of material when the at least one press engages the moving web of :material, plaster supply means for supplying plaster to the moving web of material, folding means for folding over the edges of the web of material, and means to cause the edges of the web of material to be held in place.

2. The apparatus as claimed in claim 1 wherein the at least one press is operative to form a complete pattern in the web of material prior to the plaster mix being supplied to the web.

3. The apparatus as claimed in claim 1 wherein the at least one press is located in the apparatus after the means to cause the edges of the web of material to be held in place such that the pattern is formed in the web of material after the web has been supplied with plaster and the edges of the web of material held in place.

4. The apparatus as claimed in claim 1 wherein the j apparatus has a plurality of presses including at least a first press for applying a first pattern to the web of material prior u to supplying the web with plaster and a second press for applying a second pattern to the web of material after the web has been supplied with plaster and the edges held in place. f 5. The apparatus as claimed in any one of claims 1 to 4 wherein the web feeding means comprises one or more pairs of J co-operating rollers that engage the web and move the web M:04:13331.C 4 Yuly 1994 taping means includes a roll of adhesive tape arranged to be fed to a taping roller that applies the adhesive tape to the edges of the web of material.

18. The apparatus as claimed in any one of claims 1 to wherein the means to cause the edges of the web of material to be held in place include means to apply adhesive to an edge of the web, and means for pressing one edge of the web of material onto the other edge whereby the adhesive applied to an edge joins the edges together.

19. The apparatus as claimed in claim 1 wherein the folding means is incorporated into the means to cause the edges of the web of material to be held in place.

20. The apparatus as claimed in any one of the preceding claims further including cutting means for cutting the cornice to a desired length.

21. A method for the continuous production of ornate cornices comprising providing a web of material, feeding the web of material to shaping means to shape the web of material into a desired cross-sectional shape, supplying plaster to the i moving web of material, folding over the edges of the web of material and applying adhesive or adhesive tape to the edges to retain the edges in place, wherein a pattern is formed in the i tc moving web of material by passing said web of material through at least one press which includes upper and lower members that are relatively moveable towards and away from each other, the upper and lower members being moved relatively towards each other to engage the moving web of material to form a pattern thereon, said at least one press being moveable along with the moving web of material when the at least one press engagas the moving web of material, said at least one press returning to its original position after releasing the moving web of material, said at least one press repeatedly engaging a section of the moving web of material to form a pattern on that section, releasing said section of the moving web of material and engaging a further section of the moving web of material, said pattern being formed on the moving web of material after the moving web of material has been moistened. 4 *'1333' 1 1 1. 4 Ju ly 19 1 J :04:13J31.C 4 July 1994 19 therethrough. 6. The apparatt.s as claimed in any one of the preceding claims wherein the shaping means is operative to gradually alter the cross-sectional shape of the web of material to a desired cross-section. 7. The apparatus as claimed in claim 6 wherein the shaping means comprises a shaping guide that includes a continuous shaping surface across which the moving web of material moves. 8. The apparatus as claimed in claim 7 wherein the continuous shaping surface has a continuously changing cross- 0 section. 9. The apparatus as claimed in claim 6 wherein the shaping means includes a plurality of lifting guides. 15 10. The apparatus as claimed in any one of claims 6 to 9, wherein the shaping meansl further includes one or more creasing rollers. 11. The apparatus as claimed in any one of the preceding claims wherein the or each press is slidably mounted on rails to facilitate sideways motion of the or each press. 12. The apparatus as cl.imed in any one of the preceding claims wherein the plaster supply means includes at least one plaster holding tank and delivery means for delivering plaster from the plaster holding tank to the moving web of material. 13. The apparatus as claimed in claim 12 wherein the delivery means comprises a valve or a nozzle. 14. The apparatus as claimed in any one of the preceding claims wherein the folding means includes one or more rollers arranged to contact the edge of the web of material and to fold down the edges. The apparatus as claimed in any one of claims 1 to 13 wherein the folding means comprises one or more lifting guides that fold over the edges of the web of material. 16. The apparatus as claimed in any one of the preceding claims wherein the means to cause the edges of the web of material to be held in place comprise taping means for applying adhesive tape to the edges of the web of material to thereby i hold the edge: of material in place. I 21 *0 00 0 *00 9

22. An apparatus for producing ornate cornices substantially as hereinbefore described with reference to the accompanying drawings.

23. A method for producing ornate cornices substantially as hereinbefore described with reference to the accompanying drawings. DATED: 15 July 1994 CARTER SMITH BEADLE Patent Attorneys for the Applicant: RONALD KEITH POLLOCK 0000 00 0 V go 4 a H iF p ii AN!04:13331.C 15 July 1994 *A An .ratus for producing ornate cornices comprising feed rollers (20,22) to feed a web of material, such as backing paper, from a roll (16) of the material. Moistening means such as a fine water spray, moistens the web of material to soften the web. Shaping means (24) subsequently shape the moving web into a desired cross-section profile. The shaped web then passes to a first press (30) that forms part of a pattern onto the web of material. Press (30) mounted on rail (42) to enable the press to move along with the moving web when the press engages the web to prevent breakage of the web. Movement of press (30) is controlled by hydraulic cylinder (44) and a suitable control arrangement. After leaving press plaster slurry is supplied to the web from plaster supply 15 tank Taping roller (56) folds over the edges of the web and places adhesive tape onto the edges from roll of tape (54). This holds the edges in place. The web and plaster may then pass through a second press (58) to imprint further pattern onto the web. The cornice is cut to length by saw (66). i AN:04:13331.C 15 July 1994 i ooo a J 1