US2011439A - Apparatus for the manufacture of cementitious sheets - Google Patents

Description

Aug. 13, 1935. R DORN r v 2,011,439

APPARATUS FOR THE MANUFACTURE OF CEMENTITIOUS SHEETS Filed April 28, 1952 5 Sheets-Sheet 1 w &

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ATTORNEYS Aug. 13, 1935. RODORN .5! AL APPARATUS FOR THE MANUFACTURE OF CEMENTITIOUS SHEETS Filed April 28, 1932 3 Sheets-Sheet 2 lNVEN TORS Zena Born BY Afar/1n lVtZltls K @7/ ATTO RN EY$ Aug. 13, 1935. R. BORN ET AL APPARATUS FOR THE MANUFACTURE OF CEMENTITIOUS SHEETS Filed April 28, 1952 3 Sheets-Sheet 5 a .8 m MW m 7 7 W; m 1

. 3 d y T 5 A m/ 0 m M NM 4 1 m :2 W i w M Q fl 7 a f 4 g Patented Aug. 13, 1935 APPARATUS FOR THE MANUFACTURE OF CEMENTITIOUS SHEETS Rene Born and Martin Willis, New Orleans, La. I Application April 28, 1932, Serial No. 607,971

14 Claims.

This invention pertains generally to apparatus for theformation of sheets and particularly to apparatus for the formation of sheets from pulps.

In our copending application Serial No. 607,970, now Patent No. 2,004,935, dated June 18, 1935, there is shown and described a novelcementitious sheet and a process for making-the same. The invention herein relates to apparatus adapted to be used in carrying out .the aforementioned process.

Referring to the drawings in which like reference characters are appended to like parts in the various figures,

Figure 1 is an elevation of apparatus for carrying out the above-mentioned process;

Figure 2 is a plan view thereof;

Figure 3 is a perspective'view of a matrix showing a layer of pulp thereon;

Figures 4, 5 and 6 are broken sections of finished sheets;

Figure 7 is an elevation partly in section of a hopper and of parts adjacent thereto;

Figure 8 is a plan view of the hopper, and

Figure 9 is a detail of an'adjustable eccentric.

-Referring more particularly to the drawings, at I in Figures 1 and. 2 is shown a' conveyor illustrated as being of the driven roller type. However, any other suitable type of conveyor, whether endless or not, may be substituted therefor.

Resting on the conveyor I0 is a matrix I I having an upper surface I2 with a shape substantially identical with that of the sheet to be manufactured.

At I3 is shown a hopper containing pulp I4. Hopper I3 has an opening I transversely there- 'of of a length'equal to the desired width of the layer I6 of pulp which is formed by'pulp I4 passing through the opening I5. The hopper shown is of the type more particularly described and claimed in our co-pending application Serial No. 706,814, now Patent No. 2,004,936, dated June 18, 1935.

Pulp I4 may be of a consistency so as to flow by gravity through the opening I5 but is preferably of lesser water content. This will require some special means to cause the pulp to flow through the opening I5 because of the stifferand viscous consistency. Such means may comprise a vibrating hopper, a form of which will be more particularly described hereinafter or any other suitable device such as one adapted to'extrude the layer I6 through a die conforming to the desired opening I5 by means of pressure on the pulp I 4 with or without heat. I v

If the pulp contains a fibre, such as pulp made from hydraulic cement, asbestos fibre and water, the fibre'upon passing through the narrow opening I 5 will become substantially oriented into planes more or less parallel with the surface of 1 the layer I6'formed by the opening I5. We find substantial orientation is obtained with layers up to three quarters inch in thickness.

The matrix I I is positioned and moved relative to the layer I6 so that the'end of layer I6 contacts the right end of matrix I I, as'seen in Figure 1, the matrix II preferably moving to the'right on conveyor ID at a speedconforming more or less closely to the speed at which the layer I6 issues from the opening I5 so that the layer I6 will be laid out on the matrix II without undue stretching or buckling.

The layer I6 will conform to the surface I2 of matrix II whether such surface I2 is fiat, corrugated or of any other configuration, forming thereon a sheet layer of substantially uniform cross sectional thickness throughout.

Depending upon thetype of means employed for depositing layer I6, this layer may have a certain slight surface unevenness or waviness.

To remove any such irregularity, we may provide a roller I8 adapted to lightly touch the upper surface of the layer I6 throughout its width, the roller l8having a contour conforming to that of the layer I6. The roller I8 preferably is driven so that its surface moves oppositely to that of the layer I6 and at a substantially greater speed. The roller I 8 is essentially a smoothing roller and its contact with the layer Ifi should not be such as to cause pulp to accumulate on the front side of the roller. I8.

Any other means might be substituted. for the roller I8 such as a shoe adapted to lightly contact the upper surface of the layer I6. I g

It might be pointed out here that itis not necessary to expel any water from the layer I6 at this point. Expelling of water is accomplished by means of a press 25 having an upper matrix or die 26 conforming to the upper surface 1 of the layer I 6 anda lower matrix or die 2'l'for.

holding the matrix II. To expel watenmatrix 21 together with the matrix H and the sheet thereon are raised by means of the piston and cylinder arrangement shown at 30,'the upper sur- "face of the layer I6 coming in contact. with the matrix 26 and being substantially uniformly contacted thereby throughout its surface so that the water is expelled without substantially disturbing the previous structural'relationship of the sheet l6 or substantially displacing the par.-

the manufacture of laminated sheets, it being merely necessary toduplicate the hopper l3, as

illustrated at 2|, or to add any additional number offhoppers depending upon the number of laminations desired. As shown, the roller l8 has been duplicated at 23.

Any additional layers such as the layer 20 posited upon layers IE will conform to thereon-j figuration of the layer IS in all respects similarly to the manner in which the layer l6 has con;

formedto the matrix II. Due to the semi-fluid character of the layers of pulp and'the care-with which the second layer is deposited upon the first, there may be a slight and inconsequential shift of material so that one layer might'be very slightly thicker at one pointth'an at another. However,

"such slight shift in material is wholly incidental and in' no way departsfrom the spirit of the invention. a r

Orientation of the fibres greatly increases the tensile strengthof the layer per unit of fibre content. a

' By variation of fibre "content in each layer the tensile strength acrossa sectionof a sheet may be varled in accordance withdemands. For instance; if the load is'on one face of thesheet the layer adjacent the. load will be under compression'and the layer opposite the load will be under tension. The layer under compresion may, thereforefhave'less' fibre in View of the higher compressive strength of materials of this type; This will increase its resistanceto the elements.

It is very'simple to provide. means for .study- ,ing the division line between theadhering laminations by merely providing any suitable device such as illustrated at H! for depositing-a thin filmoistfipesof coloring matter ll on the layer I6.before'applicationof the layer 20 thereto; We

find that avery suitable coloring substance can be madeby mixing 90% dry hydraulic cement and -10% red'iron oxide. It is, of course, understood :that any other substance might be substituted z'the'refor inasmuch'as the function of this coloring matter is merely to show. the .division line between the adhering laminations to identify the -processby means of which the sheet hasbeen manufactured; If: more than two laminations comprisethe'sheet, it is,. of course, understood that, if desired, any, additional number of color depositing devices may be added.

The manufacture of sheets by means ofv com .bining'laminationsaffords an opportunity to efficiently incorporate reinforcement members during the :steps .of superimposing the layers. For, instance, in the manufacture of corru- "gated sheetspparticularly those used for roofing I purposes wherein the ,vales are placed under ten- :sion and the crests under compression, inasmuchas the compressive strength of this type of mateirlalif is substantially greater than the! tensile strength it is desirable .to reinforce the Vales;

.This may be done by; laying longitudinalrodsin the vales between the hoppers|3 and 2I-. -These longitudinal rods, of course, arelnot reshapedin thepress but already they-.wil1'have in the finished product. ItjiS,:Qf course, possible to also insert rods inthe crests if j-desiredior insert rods in the, crests only lt is R also possible .to employ any, other,formg,of' rein- The reduction inv forcing, member 46.

shafts 56 and 51.

have theshape which ,Q Shaft 51- is journaled in forcement alone or in addition to the rodssuch are examples. Such mesh would be preformed to conform to the upper surface of the layer I6 '50 that no reshaping would be necessary in the press 25 or otherwise. For instance, if the sheet.

is to be corrugated, the mesh would also be corrugated.

After the desired number-of. laminations have been superimposed withlor without coloring mat- ,ter and/or reinforcements, the composite mass is-placed within the press 25 and the water ex npe lled in the same manner as above set forth.

3 'Ihe'matri-x I I is then' withdrawn and the sheet is stripped therefrom or permitted to cure on the matrix as desired,

While the invention has been described in connection with a single matrix, it is, of course, un-

derstood that the matrices II will succeed each other on the conveyor In. In fact, the matrices I I may be arranged on the conveyor II] with abutting ends so that the layers of pulp may be 'deposited continuously,-the cutting of the layers between the matrices taking place justbefore introduction of each matrixinto=the press 25.

Other means may be substituted for the press 25for expelling water from the sheets.

may be substituted. It willbe seen-that the layer 3| has conformed to'the corrugations.

In Figure 4 we have shown a sheet 32'corn-' prising upperlaminatio'n 33 and lower lamination 34. The line35 shows the colored dividing line between the layers 33 and 34,1the inclusion; of:

which is, of course, optional.

In Figure 5 we have .shown a sheet 3ljcompri'sing'upper lamination 38 an'dilower lamination 39.

40 is the dividing line between the two laminations. "At- 4| .we:.-have shownirodspositioned. in

the Vales between laminations138'and'39 for reinforcement purposes. It is, .aof course, understood that 'thelamina- .tions join into; a unitary sheetv and strongly adhereto the reinforcing members 4|. i

.. -In Figured we haveshown a sheet com- .prisingupper lamination 44 and lower laminationj45. We have alsoshown a corrugatedr'eticular reinforcing member 46 positioned between the laminations 44 and '45. The; laminations, of

course, adhere ,to each other.

, and to the rein- In Figures 7 and 8 we have shown a vibrating hopper.- .Thi'sfl hopper comprises" oppositely arranged reciprocating sidewalls 50 and 5|;shown ,arran'gedin the form of a V with an opening 52 at;thejvertex. Side walls 50 and 5l areshown arranged between stationary end walls 53, the

,side walls 50 and 5|, being-supportedin guides 51 securedto the end walls 53.;

Mounted on the frame i4;9 ;ar'e two transverse Shaft55is shown drivenby a motor 58 through reduction gearing 59 and belt or chain 60; Shaft 5]is illustrated as driven from shaft 56. by means offachain 6 v A Shaft 56 isjournaled -'in slidable blocks 62 blocks 52 being adjustable by means ofgscrews-fit to move the'side; wall with respectto theside wall SI-to adjustthe opening52.

blocks 65, being, ad-

justablebymeansof screws 56 for the purpose of moving side wall 5! with respect toside wall 50 to adjust the opening 52.

' Side wall 50 is mounted'on spaced eccentrics shaft 51.

i6] ina manner so that the eccentrics 61. recipro- ,wall 5| by means of vadjusting chain 6| on sprocket 'H on shaft 56 and on sprocket 12 on The adjustment is preferable one in which side walls 55 and 5| reciprocate in unison, that is, synchronously. It is, of-,course,xunderstood that the length of chain 6| will vary ac- ;cording to the adjustment at 63 and 66.

The variation in size of the opening 52 and the movement of the side walls 55 and 5| about the opening 52, due tothe reciprocationof sidewalls 55; and 5| not only causes the pulp 13 to flow through the opening 52 in layer form but also tends to cause any fibre in the pulp to become oriented into planes substantially parallel to the surfaces of the layer of pulp formedat the opening 52. 1

As shown, the opening 52 has a longitudinal dimension more or less equal to the Width of the matrix H.

The cross sectional contour of the layer of pulp may be varied by variation in the lower edge of side wall 5| and/or side wall 55. This will prove of advantage in forming corrugated sheets with thickened crests and vales such as described and claimed in copending application Serial No. 447,150 of Martin Willis and Frederick Schroder.

Side wall so in Figure 7 is illustrated as being somewhat longer than the side Wall 5| at the opening 52. The side wall 59 thus acts somewhat as abase toward which the side Wall 5| may operate in the formation of a layer, both side walls acting to advance the layers through the opening 52: However, any other arrangement of the ends of side walls 55 and 55 may be made.

The layer I 6, issuing from the opening 52, may be more or less undulatory in character in a lengthwise direction. If desired, a roller 15 may be provided for smoothing the layer it. The action of roller 75 is merely smoothing in character and roller '55 ordinarily will no more than lightly touch the surface of the layer 6. Roller 75 preferably rotates in a direction opposite to the movement of the layer it on matrix H and should preferably have a somewhat increased peripheral speed. Roller 75 may be made adjustable vertically by means of screws It.

The chute, shown at H, pertains to a device for keeping the pulp l3 at a uniform height in the hopper and otherwise does not pertain to this invention.

Another means for timing the reciprocation of a side wall 55 with respect to the reciprocation of side wall 5| is by use of an adjustable cam. Such a cam, however, is more useful for varying the length of the stroke of the reciprocating side walls. One form of adjustable cam is disclosed in Figure 9 in which an eccentric rim portion T8 is made adjustable with respectto an'eccentric hub portion 19 mounted on a shaft 863. The adjustment may be accomplished by providing the hub portion 19 with a plurality of spaced grooves 8| which are adapted to cooperate with a complementary groove 82 in the rim portion F8 to form a key-way for a key 83. It is, of course, understood that any other form of adjustable cam may be employed. By moving rim portion '58 with respect to hub portion 79 the length of the stroke of the side wall may be varied as will be understood by persons skilled in the art. Any necessary adjustment as to synchronization may then be made by adjusting chain 6|.

It is, of course, understood that any other means maybe employed for driving shafts 56 and 57 and for connecting the shafts together so as to synchronize the movements of side walls 50 and 5|.

The particular description herein has been merely for the purposes of illustration and many modifications and/or substitutions may be made in the parts particularly described without departing from the spirit of the invention. The claims herein are intended to be limited only by the prior art.

1. Apparatus for forming a sheet from pulp comprising a rigid matrix having the contour and extent of the finished sheet, and means independent of said matrix for forming pulp into a layer and applying said layer upon said matrix.

2. Apparatus for forming a sheet from: pulp comprising a matrix in the form of the finished sheet movable in a substantially horizontal direction having an operative surface of corrugated contour, and meansfor depositing a corrugated layer of pulp upon said matrix as said matrix moves past said means.

3. Apparatus for forming a sheet from pulp comprising a rigid matrix having the contour and extent of the finished sheet and having an operative surface conforming to the desired shape of the sheet, and means independent of said matrix for forming pulp into a layer and depositing said layer upon said matrix.

4. Apparatus for forming a laminated sheet comprising a formed matrix having a contour conforming to the desired shape of the sheet, means independent of said matrix for forming pulp into a layer and depositing said layer upon said matrix, and means for similarly depositing a second layer of pulp upon said first layer.

5. Apparatus for forming a laminated sheet comprising a formed matrix having a contour and means for moving said matrix relative to said hopper.

7. Apparatus for forming a laminated sheet comprising a formed matrix having the contour and extent of the finished sheet, a plurality of spaced hoppers, means for moving said matrix consecutively under said hoppers, said hoppers adapted to successively issue layers of pulp therefrom and deposit it upon said matrix.

8. Apparatus for forming a laminated sheet,

comprising a rigid matrix, means independent of said matrix for forming pulp into a layer and depositing said layer upon said matrix, and means for smoothing the surface of said layer.

9. Apparatus for forming a sheet comprising a corrugated perforated matrix movable in a substantially horizontal direction, and means for depositing a corrugated'layer of pulp upon said matrix as said matrix moves past said means.

IO/Apparatus for forming a sheet comprising a rigid formed matrix having the-contour and extent of the finished sheet, said matrix also having an upper surface of a shape desired in the sheet, means independent of said'matri'x for forming pulp into a layer and depositing said layer upon said matrix, and a press having a matrix of a shape desired in the sheetv and adapted to receive said first mentioned matrix thereon and substantially uniformly compress said layer to express water therefrom and to consolidate said layer.

' l1. Apparatus for forminga laminated sheet comprising a rigid formed matrix having the contour and extent of the finished sheet, said matrix also having an upper surface of a shapedesired in the sheet, means independent of said matrix for forming pulp into a plurality of'l'ayers and superimposing said layers upon said matrix, and

a press having a matrix of a shape desired in the sheet and-adapted to receive said 'first mentioned matrix thereon and substantially uniformly compress said superimposed layers to consolidate said layers and express Water therefrom.

express water therefrom.

construction-having the contour and extent of the finished sheet and also having an operative surface of a shape desired in the sheet, means independent of said matrix' for forming pulp into a plurality of'layers'and superimposing said layers upon said matrix, and a press having a matrix of a shape desired in the sheet and adapted to receive said first mentioned matrix thereon and substantially uniformly compress said superimposed layers to consolidate said layers "and -14. Apparatus for forming a laminated sheet comprising a rigid formed matrix of filter-bed construction having the contour and extent of the'fi'nishe'd sheet and-also having an operative surface, of a shape desired in the sheet,- means independent of said matrix for forming pulp into "a plurality of layers and. superimposing said layers upon said matrix, means for depositing coloring matter on said pulp and a press having a matrix with an operative surface of the shape desired in'the sheet, said last mentionedsurface adapted to receive said first named matrix thereon and cooperate with said first mentioned surface to substantially uniformly compress said superimposed layers to consolidate said layers and express water therefrom.

- NE N: V

MARTIN WILLIS.

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