US3202025A

US3202025A - Tool for producing fissures in mineral felt

Info

Publication number: US3202025A
Authority: US
Inventors: Lorien A Carlson; John J Kozacik
Original assignee: Wood Conversion Co
Current assignee: Wood Conversion Co
Priority date: 1959-09-28
Filing date: 1959-09-28
Publication date: 1965-08-24
Anticipated expiration: 1982-08-24
Also published as: GB913268A

Description

llg- 24, 1965 L. A. CARLSON ETAL 3,202,025

TOOL FQR PRODUCING FISSURES IN MINERAL FELT fFiled sept. 28, 1959 2 sheets-sheet 1 VFiled sept. 28, 1959 Aug- 24, 1965 L. A. CARLSON ETAL 3,202,025

TOOL FOR PRODUCING FISSURES IN MINERAL FELT 2 Sheets-Sheet 2 United States Patent O The present Ainvention relates to impression-forming punches, tools or dies for forming fissures in mineral felts,

for example, to produce iissured tile.

Travertine has long been a decorative wall material, which is commonly imitated in board-form tile installed on walls and ceilings. Such tile is available as porous liber felts of approximately l to 25 pounds per cu. `ft., the fibers being all vegetable, or all mineral or mixtures thereof.

Various methods to form fissures into the tile or onto panels to be cut into tiles, have been employed, and methods for one kind of tile are not necessarily applicable to other kinds of tile. Some methods are practiced during the formation of the board material, and others are practiced on finished board and on tile cut therefrom.

In such porous board having a high content of mineral fibers, which are fragile, fissures may be formed by crushing inwardly alregion of board to appear as a fissure, thus breaking off the fibers and leaving a cavity from which fiber remnants are easily removed, as by blowing or suction. p

Fissures to imitate travertine, or otherwise to have an acceptable decorative effect, must be irregular in outline, wall surface and depth, and be present in assembled tile in a variety of different forms. Hence, in producing tile for such assemblies `a variety of fissure-forming tools is required.`

The present invention provides a simple and inexpensive method of producing tools to form such irregular fissures.

It is one object of the invention to provide such a tool in the form of a punching die, which `may be used to form a fissure of a corresponding character, or which may be used as a master or pattern for casting integral dies which produce fissures of the same character.

In the artistry of `designing fissures for decorative effect many forms of `dies are made and discarded in reaching a group of acceptable fissures. It is, therefore, important in developing dies for commercial production that a simple and inexpensive method be available. The present invention provides such a method for making an initial form useful to form such fissures, say in development of a line of tile. When such an initial form is `acceptable for commercial production, it is such that it may be released from active use to form fissures and used as a pattern or master for casting any number of dies for commercial production.

The simplicity of the method is illustrated by reference to the drawings, in which:

FIG. 1 shows a foundation in the form of a wooden board, with marked outlines for fissures.

FIG. 2 shows the board of FIG. 1 with packed pins driven variously into it Within the outlines and projectcylinder carrying projecting punch portions, shown in cross-section as it punches a tile.

FIG. 7 is a modified form somewhat similar to FIG. 3 with which a stripper plate may be used.

FIG. 8 is a view in crosssection of the form shown in FIG. 7, and similar to the View shown in FIG. 5.

In FIG. l, a wooden board 10 is provided, preferably slightly larger than the tile for which it is to be used. On it the general outline of fissures is indicated for the purpose of illustration, four

such outlines

11, 12, 13 and 14 being shown, generally elongated in the same direction.

Into the board 1t) Within the outlined areas are driven pins in closely packed formation at various angles.` Common nails may be used to supply the pins, and at a suitable stage of the process, the heads of the nails are cutoff, preferably at various angles and in a manner to leave varying lengths of the nail shanks projecting above the face of board 10. The ends of the pins and the Shanks of the outermost pins predetermine the character of a fissure which may be rnade.

In FIG. 2 the pin-filled areas are designated 11', 12', 13 and 14', in a manner merely to indicate the presence of pins, the detail being shown in FIG. 3.

In FIG. 3, a plurality of pin Shanks 16 is shown, some in cross-section and some in elevation, with Shanks at various angles departing from normal positions to the face lllab of board 1t), and with ends 17 at various angles with respect to a right-angled cross-section.

A form such as FIG. 2 may be used to punch lissures into a tile having a suiiicient content of :mineral fibers to be crushed by the advancing dies 11 to 14. g

When in the course of development endeavor lissures are accepted for commercial production, the experimental die ofFIG. 2 is set aside for use as a master or pattern. From it a casting mold is made, which may be a sand mold, and a cast made, represented by a metal casting illustrated in FIG. 4, in which the base Ztl and the

projections

21, 22, 23 and 24 are integral. The minute irregularities evident in FIG. 3 may or may not be reproduced, according to the precision of the casting method, a suitable reproduction being illustrated by the crosssection of FIG.` 5, corresponding to the section in FIG. 3. The general contour of the master is reproduced in the cast, `and substantially the same character of fissure is produced by both.

Although the invention has been illustrated and described above by reference to a flat platen or base 10 in FIG. 1 and 20 in FIG. 4, the base may be a cylinder. Originally, it may be wood to receive pins or nails aS described, and in casts there may be

arcuate metal plates

25, 26 and 27, with projecting dies 28, over a drum 29, as shown in FIG. 6.

In FIG. 6, a bed plate 30 has a mineral fiber tile 31 moving on it under the cylinder, forming fissures by a process which may be continuous.

It is preferred to punch rather than to roll in the fissures, since this method permits simultaneous formation of punched sound-absorbing holes. the fissure-forming die of FIG. 3 or FIG. 5, has long single pins normal to the base, which first punch a hole iu the body before the ssure-forming die makes its forming contact.

Such optional punching pins are indicated by the nu meral 34 in FIG. 3 and 35 in FIG. 5. Pins such as 35 in a cast die like that of FIG. 5 are preferably not cast with the die, but are inserted in drilled holes in the cast of the fissure-forming die.

When the ssure-forming platen is used for punching in the fissures, as distinguished from rolling them in as illustrated in FIG. 6, the basel() may also have elsewhere in its area than over the fissure-forming dies, a multi amaze To do this j plicity of pins to make sound-absorbing holes in the unssured area of a tile. Such pins are illustrated by pins 36 in FIG. 5, of which only a few are indicated in FIG. 4 to avoid confusion in the drawing.

Consequently, the resulting die to form fissures is one with or without a multiplicity of pins normal to the base for the purposes described, anywhere over the area of the die.

Experience with punching mineral tile with dies for forming fissures and punched holes has led to a modiiication of Vthe forms shown above. Especially when punching pins are present there is great friction between the entire die and the tile making it diicult to Withdraw the die from the tile. The friction may be so great in some cases that holding the tile at the edges to Withdraw the die results in rupture of the tile. T o avoid this possibility, the die is applied through a stripper plate having openings which pass the projecting elements of the die, such that the stripper plate presses on substantially all of the unaffected face of the tile to hold it while the die is withdrawn.

To accommodate a die of the present invention for use with such a stripper plate, the projecting elements of the die which are intended to penetrate the tile, are connected to the tile base by intervening portions, of which all or part reside within the two faces of the stripper plate when the die is deepest in the tile. It is preferred that the connecting parts be such as to accommodate stripper plates of various thicknesses. As a result, a single die may be moved in functioning on tile through a stripper plate against stops which may be adjusted in position to vary the space between the die base and a given stripper plate. By this means, a die may be used to form different fissures according to its depth of penetration into the tile.

FIG. 7 represents in cross-section a structure similar to that in FIG. 3 wherein a wooden base 40 receives nails or pins 41 in a mass thereof to form a fissure, as described for FIG. 3. The dotted lines 42 represent the location of a stripper plate having an opening through which the die-mass formed by nails or pins 41 projects to variable extents permitted by a variable space 44 between the face 45 of the die base and a face 46 of a stripper plate.

FIG. 8 is a view like that of FIG. 5 showing in crosssection a casting made by use of the form of FIG. 7 as a pattern. 1t shows an integral fissure-forming die with die base 50, projecting die part 51, including a peripheral Wall 52 substantially perpendicular to the planar face 53 of the die base 50 by reason of said wall and said face forming an angle of at least 90. The dotted lines 54 represent the location of a stripper plate with opening 55 of contour matching the contour of the fenced-in portion, but preferably slightly larger for freedom of movement.

Numeral 56 represents one or more pins for punching acoustic holes, which may be inserted into the casting after its formation, as described in reference to FlG. 5.

From the foregoing it is to be understood that the invention is not limited to the illustrative embodiments shown in the drawings, and that all other forms and modifications are contemplated as falling within the scope of the invention as expressed in the appended claims.

We claim:

1. A die for forming fissures in mineral felts which die comprises a solid platen base having a planar face to overlie a mineral felt to be lissured, an elongated fissureforming mass carried by and projecting from said face, said mass being rigid with respect to said base and having a substantially perpendicular peripheral wall of irreguiar contour extending from said face, said Wall and said face forming an angle of at least the shape of the mass being that of a number of closely packed pins projecting to various extents outwardly from said face.

2. A die according to claim 1 in which said mass is composed of closely packed pins projecting to various extends outwardly from said face.

3. A die according to claim 1 in which said mass projecting from said face is solid.

4. A die according to claim 1 in which a punching pin extends from said mass beyond the outermost extent of said mass and in the same direction as said mass extends from said face.

References Citedvby the Examiner UNITED STATES PATENTS 224,665 2/80 Edison 83-30 346,580 8/86 Cobb.

3 89,112 9/88 Setchell 41-24 1,471,472 10/23 Anderson 22--195 1,591,572 7/26 Stimson.

1,794,194 2/31 Meyercord et al. 41-24 2,064,322 12/ 36 Ruppert 41-24 2,332,360 10/ 43 Wakefield 16?.-144 2,371,061 3/45 Milano 76-107 2,518,838 8/50 Tempe 82-660 y 2,611,434 9/52 Mugler.

2,716,909 9/55 Rupert 76-107 2,724,919 11/55 Leyendecker 41-24 2,968,838 1/61 Hicks 76-107 3,013,626 12/61 Brown et al. 162-114 3,013,937 12/61 Brown et al. 162-114 3,017,947 1/ 62 Eckert 162-114 ANDREW R. JUHASZ, Primary Examiner. JAMES S. BAILEY, CARL TOMLIN, Examiners,

Claims

1. A DIE FOR FORMING A FISSURES IN MINERAL FELTS WHICH DIE COMPRISE A SOLID PLATEN BASE HAVING A PLANNAR FACE TO OVERLIE A MINERAL FELT TO BE FISSURED, AN ELONGATED FISSUREFORMING MASS CARRIED BY AND PROJECTING FROM SAID FACE, SAID MASS BEING RIGID WITH RESPECT TO SAID BASE AND HAVING A SUBSTANTIALLY PREPENDICULAR PERIPHERAL WALL OFF IRREGULAR CONTOUR EXTENDING FROM SAID FACE, SAID WALL AND SAID FACE FORMING AN ANGLE OF AT LEAST 90*, THE SHAPE OF THE MASS BEING THAT OF A NUMBER OF CLOSELY PACKED PINS PROJECTIN TO VARIOUS EXTENTS OUTWARDLY FROM SAID FACE.