US1802878A - Machine for making multiply building board - Google Patents

Description

April 28, 1931. H, CUMFER 1,802,878

MACHINE FOR MAKING MULTIPLY BUILDING BOARD Filed June 24, 1929 5 Sheets-Sheet 1 Jh-Je 72 1'01; I

Harry J1. Can/(fer;

April 28, 1931. H. A. CUMFER 7 MACHINE FOR MAKING MULTIPLY BUILDING BOARD Filed June 24'. 1929 5 Sheets-Sheet 2 April 28, 1931.

MACHINE H. A. CUMFER 1,802,878

FOR IAKING MULTIPLY BUILDING BOARD Filed June 24. 1929 s Sheets-Sheet s Q fiii/enfor M Harv/1 (inn/Er,

April 1931- H. A. CUMFER MACHINE FOR KING MULTIPLY BUILDING BOARD Filed June 24, 1929 S'Sheets-Sheet 4 Apnl 28, 1931. H. A. CUMFER 1,802,878

MACHINE FOR MAKING MULTIPLY BUILDING BOARD Filed June 24 1929 5 Sheets-Sheet 5 lllHH F I 000 0 o o o oi;

6g 1 5 I A\ 51 6 46 .[72 249-22 tor-r liar/" 12 (inn/"e77 jig Patented Apr. 1931 UNITED STATES PATENT OFFICE HARRY A. 0mm 0]? GHIGAGO, ILLINOIS, ASSIGITOR 0F ONE-EAL? '1!) user, or can, mmcrrcu'r ncnnm iron. ammo murmur 311mm. roam) Application filed-June 24, 1929. Serial No. 378,090.

The present invention relates to improvements in a machine for the manufacture of building board, plaster board-or the like,

and has for one of its principal objects the provision of a device to which a plurality of separate sheets of material are fed, operated upon continuously and united, the resultant product issuing from the machine in a finished condition ready to be packed and marketed.

The device of the present invention has been designed particularly for the manufacture of a building board suitable for use as a plasterbase comprising essentially a flat base sheet, one surface of which is coated with an adhesive (which is also preferably a waterproofing material, such as asphalt), while a second sheet is provided with corrugations and is united to the flat base sheet through the medium of the adhesive to prowasted, and two, the upper surface of the cut-out being devoid of adhesive presents a surface having an atlinity for plaster. Thus, when the plaster passes through the aperture it will key with the corrugated sheet as well as with the base sheet through the medium of the cut-out united therewith.

Among the important objects of this in the second'luneorrugated sheet; means for completely severing the scored portions and positively attaching the cut-outs thus produced with the uncorrugated sheet, and

means for the two sheets in positive contact until the adhesive has set sufficiently to permit the composite structure to be cut into board of a size convenient for marketing.

In one preferred embodiment of. the invention, the flat base sheet preferably com prises a laminated multi-ply structure made up by uniting a pluralityof separate plies, although it is to be understood that the machine is designed to produce a board structure in which either or both the base sheet or the corrugated sheet may comprise one or a number of laminated plies. p

In its preferred operation, the machine of the present invention unites the cut-outs to the base sheet immediately opposite to the apertures thus formed in the corrugated I sheet.

Another important object of the invention is to provide means for manufacturing a fibrous structure which may be used in place of the usual laths, the plaster being applied to the corrugated surface squeezing into the apertures provided therein, thereby keying the plaster to the board. By means of the present invention the board may be manuactured economically, and due to its waterprolofing qualities surpasses the conventional lat 7 Other and further important objects of the invention as well as advantages will be apparent from the accompanying drawings and the following description.

In the drawings, Figs. 1 and 1a taken together illustrate in side elevation the machine of the present invention; i

Fig. 2 is a. top plan view of the device shown in Fig. 1, with parts broken away for clearness. Fig. 3 is a fragmentary sectional elevational view, part1 diagrammatic, illustrating particularly t e essential instrumentalities of the. machine. 1

Fig. 4 is a fra entary sectional View of the product prodii ced by the' ,machine, in contact with the corrugatmg bar chain.

Fig. 5 is a fragmentary top plan view of a. portion of the device shown in Fig. 10:.

Fig. 6 is a transverse sectional view taken on line 66 of Fi looking in the direction indicated by t e arrows.

Referring more parti ularly to the drawings 1 indicates enerally the frame of the machine, mountef on the front end of which are a plurality of horizontally disposed rollers 2 suitably positioned one above the other. The rollers 2 are adapted to guide a plurality of strips of fiber board 3 to the machine from conventional supply rolls (not shown). A tank or vat 44 positioned adjacent the lower front end portion of the frame 1 is adapted to contain an adhesive material (which is also preferabl a water roofin material), such as aspha t or the 'ke. pump 5 is positioned within the vat 4 adapted to transfer the adhesive material from the tank to the surfacesof the sheets 3, through an upstanding'conduit 6 rovided with a series of transversely extend d pipes 7 dis osed between the strips 3. The strips are t en passed through a pair of co acting pressure rolls 8 and 9, said rolls being mounted in bear blocks 10 and 11, respectively. The bearin block 11, may be fixed relative to a pair 0 guides or trunnions 12 com rising a portion of the frame 1,-Whereas the lock 10 ma be slidabl positioned be tween said gui es. The block 10 may be adjusted vertically by means of a hand wheel 13 mounted at the upper portion of the trunnions. The wheel 13 is rigidly connected to a shaft 14 which has mounted thereon adjacent its ends bevel gears 15 (Fi 2) which in turn mesh with cooperating vel gears 16 mounted upon adjustin screws 17 In passing through the rolls 8 and 9 the separate strips 3 are adhesively united, forming a laminated board 18. After passin through the pressure rolls 8 and 9, an ad 'tional uantity of adhesive 'material'is applied to t e upper surface of the board 18. The board 18 then asses through a set of doctor rolls 19 wherein the adhes ve materialis uniformly spread over the surfaces and then through a set of scrapers 20 where excess adhesive material is reinoved, the same dropping back into the vat A roller 2', similar to rollers 2, is mounted above rollers 2 upon the frame 1. A strip of fiber board 3 is ada ted to be guided by the roller 2' to an and 'ary guide roller 21, from which the strip 3 is directed to a corru atin' unit 22, comprising 3 having longitudina ribs 24 on its sur ace. 'An endless chain of pressure bars 25 is a'daptedto pass over the cylinder 23, the individual bars- 26 being ada ted to so register with the'channels formed tween the ribs 24. The cylinder 23' in contact with the bars 26 meshes with a co-acting cylinder 27, provided with a series of alternate large and small ribs 28 and 29. U n rotation 5 of the cylinders the point of contact of the two cylinders alternately presents a rib 24 juxtaposed to a rib 28, and a bar 26 to a bead 29, thus producin a corrugated sheet, as shown best at 30 in i re 4. The cylinder 23 is adjustable with respect to the cylinder 27, the bearing blocks 31 being slidable within the guides 32, the latter being actuated by means of the hand wheel 33, (Fig. 1), shaft34, and accompanying gears 35 and 36, the adjusting mechanism being similar to that associated with the pressure rolls 8 and 9.

After leaving the corrugating unit 22, the corrugated strip 30 in registration with the bar chain 25 to prevent collapse of, the

corrugations, passes to a scoring -unit 37,

which comprises a cylinder 38, having longitudinal ribs 39' formed upon its surface and a cylinder 40, having a plurality of appropriately spaced scoring dies 41 dis posed upon its surface. The scoring dies 41 comprise body members 42 (Fig. 3) vided with central apertures 43 define by knife edges. Adapted to be ositioned in the apertures 43 are resilient p ugs'44 which may be constructed of rubber, composition, or may if desired take the form 0 spring impelled plungers. In operation, the dies 41 are adapted to score, but not completely sever, the crests of the corrugated strip 30; hence, the provision of the resilient plugs 44, which prevent the knife edges from severing the fiber sheet.

In passing from the corrugating unit 22 the lower surface of the corrugated strip g 30 contacts and slides upon an inclined platform 45, positioned immediatel%below the pa th of the bar chain 25. ence, the corrugated element is held in position by the chain at the top and the p atform 45 at the bottom, thereby eliminating the possibility of "stretching said strip. After passing through the scoring unit 37, the

int of contact of the two cylinders 38 and 40 alternately presents a rib 39 on the cylinder 38 and a series of scorin members 41, then a bar 26 in contact wit the two 0 lindrical surfaces. As shown best in i i 3, the rectangular crests 46 are partia 1y cut from the bottom upwardly b the scoring members 41. Although, as s own in the specific embodiment of,the device, circular tabs are scored, I do not wish to be any suitable source of power (not shown),

such as an electric motor, power engine, or

limited to an articular configured scoring 'a cylinder 23 di the per the like. A bevel gear 49 is suitably keyed to the shaft 48 and is adapted to mesh with a bevel gear 50 rigidly connected to a spur gear (not shown) which in turn is operativel associated with the lower pressure roll 9. last mentioned spur gear is adapted to mesh with a spur gear 51 operatively connected to the upper pressure roll 8. Hence, the two pressure rolls 8 and 9 turn in synchronism with'each other.

Another bevel gear 52, also mounted upon the drive shaft 48 may mesh with a bevel gear 53, which may be rigidly connected to a spur gear 54, which inturn may drive an idler gear 55. The idler 55 may mesh with a spur gear 56 operatively connected to the scoring cylinder 40. The gear 56 may mesh with another/gear 57 connected to the upper cylinder 38 of the scoring unit. An'i ler gear 58 may be interposed between! the gear 56 and a gear 59, which latter gear is operatively connected tothe lower cylinder 27 ot the corrugating unit. The gear 59 may mesh with a gear 60 operatively connected to the up er cylinder 23 of the corrugating unit. ence, by means of the above described tgear train, the corrugating unit and crating unit operate synchronously. The spur gears '56, 57, 58, 59 and 60 may all be angularly adjustable to provide a ready means for properly timing the relative positions of the ribs, scoring elements and bars upon the cylinders 23, 27, 38 and 40 in their respective cooperative rotations. Thisfeature is important particularly with regard to corrugating unit 22 inasmuch as the two cylinders 23 and 27 may be so relatively adjusted that a suitable amount of clearance exists between the ribs on the two cylinders and the bars 26. -In other words, clearance is provided between the co-acting ribs and bars so that the sides of the corrugations formed in the sheet 3' are not gauged or cut.

The bars 26 are fastened at each end to sprocket chains 61, the bars bein spaced a e propriatelyto mesh with the ri s u on t e upper corrugating cylinder 23. he bar chain 25 is primarily driven by two. sprocket wheels (not shown) rigidly connected to the cylinder 23 and over which the chains 61 travel. The path of travel of the bar chain 25 is substantially rhomboidal, and is guided at each of its corners by a series of sprocket wheels. The sprocketwheels, as above mentioned, guide the chain 61 at the upper acute angle of travel, two sprocket wheels 63 guide the sameat the lower obtuse angle of travel,

two sprocket wheels 64 guide the same at the lower acute angle of travel, and two sprocket wheels 65 guide the .same at the upper obtuse angle of travel. Hence, a continuous path is provided for-the bar chain 25, the same being conducted by the sprocket clgain 61 over'the various wheels described a ove.

wheels 63. The .cylinder 67.are bot To prevent the bar chain 25 from breaking engagement with the corrugated sheet, when passing from the corrugating unit 22 to the scoring unit 37 and from the scoring unit to the joining unit, the sprocket chain 61 at each side of the bar chain 25 is guided parallel to the platform 45 by means of tracks 45, which may be positioned on each side of the platform 45 and parallel to the surface thereof. By this means the bar chain 25 is positively held in engagement with the corrugated sheet while the same is traveling in an inclined plane.

The corrugated sheet 30 in registration withthe bar chain 25, after assing from thescoring unit 37, changes its direction of travel and assumes a substantially horizontal path. Simultaneously upon changing direction, the lower-portion of the corrugated sheet 30 is brought into contact with theup per surface of the base sheet 18. Pressure is maintained between the two strips 30 and 18 by means of the sprocket wheels 63, holding the bar chain 25 and sheet 30 in contact with the sheet 18, which in turn is held in contact with the sheet 30 by means of avbelt 6.6 which passes over a cylinder67, positioned immediately beneath the axis of the sprocket rocket wheels 63 and adjustable relative to each other, that is, their centers of rotation; I

may be brought tdward or away from eacl llf other. hand wheels 68 and 69 for the wheels 63 and cylinder 67, re 'tively, and associated gear and screw mei hi nism similar to that de scribed in connection with the pressure rolls The adjusting mechanism com 8 and 9, the corrugating unit 22 and scoring" unit 37.

It can be readily observed that the corrugated strip 30 is fed to the point of juncture at an angle to the plane of the strip 18. This feature of the device eliminates the possibility of tearin or sliding the corrugations u on the base s eet, since no relative motion 0 the corrugated strip to the laminated board exists,-the travel of the belt 66 and a a the chain 25 being synchronized. The syn-- chronizing means comprises a sprocket wheel (not shown) rigidly connected to the sprocket wheel 64, which drives a sprocket chain 70, as shown in Fig. 1a, which in turn drives an idler sprocket wheel (not shown), and rigidly connected thereto is a spur gear 71- which meshes with another spur gear 72 rigidly connected to a rear belt pulley 73. Thus the bar chain 25 and the belt 66 are time and no relative motion of translation exists between the two. I do not wish to be limited to the specific means of synchronizing thetwo above described elements inasmuch as the invention contemplates the use of other suitable timing means.

After leaving the joining members 63 and 67, the composite board 74 travels in regisyea tration with thebar chain 25 and the belt 66 to a punching or knock out roll 75. The belt 66 in its upper travel preferably slides upon the plane surface of a table 76. Sufficient clearance is provided between the table top and the bar chain 25 to produce a slight amount of compression upon the board 74 travelling therebetween. The table is supported throughout its len h by a plural- 7, the adjust-' ity of adjustable supports ment mechanism comprising screws 78 operated by handwheels 79. By this means the proximity of the surface of the table 76 to the bar chain 25 can be regulated.

The knockout roll has disposed upon its surface studs or the like 80, which are adapted to contact the scored tabs 81 and completely sever them from the rectangular crests 46. By the same operation the tabs are forcibly applied and adhesively united to the base sheet 18 immediately below the apertures in the crests formed by completely severing the scored tabs. The roll 75 is driven in timed relation with the remaining mechanism by means of a sprocket chain-82, which operatively connects the roll 75 to the remaining rolls in an obvious manner. After leaving the knockout unit chain 25, belt 66 and board 74 held therebetween travel horizontally along the top of the table. The bar chain 25 may be held in contact with the upper surface of the board 74 by means of guides 83, in which the sprocket chains 61 are adapted to travel. Hence, by adjusting the table upwardly or downwardly a desired amount of pressure may be brought -to bear upon the board 74.

If it is desired to apply greater pressure to the bar chain a set. of pressure bars 84 may be provided. The bars may be adjustable by means of a hand wheel 85 to which is rigidly fixed a bevel gear 86 which meshes with another bevel gear 87 rigidly attached to a screw 88. The screw 88 upon being rotated is adapted to raise or lower a bearing block 89 slidably positioned in uides90. A rod 91 is journalled in the locks 89 on each side of the machine and is adapted to be raised and lowered with the blocks 89. Mounted upon the rod 91 adjacent each end thereof is one of the pressure bars 84. The bars 84 upon being lowered rest upon the top of the bar chain 25, as shown best in Fig. 6, and press the bars 26 of the bar chain tightly upon the board 74.

Upon travelling a suitable distance along the table 76 to permit the proper setting of the corrugated sheet 30 upon the laminated board 18, the bar chain 25'breaks contact with the board 74, and doubles back over the wheels 64. The board continues to travel along the table 76 and upon leaving the same may, if desired, pass over a rotary brush 92 journalled at 93 in a receptacle 94. The receptacle 94 is adapted to contain a non-adhesive substance such as talc or the like, and by means of the brush 92 a coating of the same is de osited upon the lower surface of the board 4.

The board then leaves the machine proper and passes to a conveyor (not shown) upon which it is conveyed a predetermined distance to allow' the adhesive to cool sufficiently to permit cutting of the board if such operation is desired.

It is to be noted that the machine is desifgned to corrugate while a continuous strip 0 fibrous material to be corrugated is being continuously fed at an angle to the horizontal. I have discovered that it is preferable in some cases to corru ate a continuously advancing sheet of brous material while it is travelling at an angle to the horizontal rather than to corrugate the same sheet while it is advancing in a horizontal plane.

The reason for this is that it is ex edient, when using a base sheet built up 0 a plurality of plies of individual sheets, to maintain the path of travelof the base sheet in a' straight line, inasmuch as the base sheet is generally stifier and thicker than the corrugated sheet, and, therefore, difiicult to bend. Hence, it is advisable to change the direction of travel of the corrugated sheet to conform with that of the base sheet rather than vice versa, and inasmuch as the base sheet is to move in a straight line, it is preferablethat this line be in a horizontal plane. Of course it is to be understood that this is not to be taken as a limitation of the invention, since various relative directions of feed may be utilized.

As pointed out in the objects of the invention, the machine essentially comprises means for feeding two separate strips of fibrous material, corrugating and scoring means acting on one sheet, means for uniting the corrugated and scored sheet with the second uncorrugated sheet, means for completely severing the scored portions and uniting the cut-outs thus produced to the base sheet immediately ad acent the apertures thus produced, and means for prevent ing collapse of the corrugations and maintaining the two sheets in contact until the adhesive has set sufficiently to prevent spreading or creeping.

I claim as my invention:

1. A machine comprising in combination means for uniting a continuously advancing corrugated sheet with a continuously advancing uncorrugated sheet, means acting on the corrugated sideof said united strum being united to prevent creeping of one sheet relative to the other.

2. A machine comprisin in combination, means for feeding a plura 'ty of advancing strips of fibrous material, means for corrugatmg one advancing strip, means for scormg portions of said corrugated. sheet at spacedintervals, means for adhesively unitmg said corrugated sheet with a continuo ously advancing uncorru ated sheet, means for completely severing t e scored portions of the corrugated sheet and uniting the cutouts thus produced to the corrugated sheet, and means for maintaining the corrugated and uncorrugated sheet in until the adhesive has set su ciently to prevent creepin between the two sheets.

3. A machine comprising in combination, means for feeding a continuous strip of go fibrous material at an angle to the horizontal, means for corrugating said sheet while travelling in said plane, means for scoring said advancing strip at spaced intervals, means for feeding a second strip of fibrous material in a horizontal plane, means for applying adhesive to one of the opposed surfaces of the two continuously advancing strips, means for uniting said continuously advancing strips through the medium of said adhesive, means for carrying said united structure in a horizontal plane, means for completely severing the scored portions of the-corrugated strip and positively uniting the cut-outs thus produced with the base sheet, and means for maintaining positive contact between the corrugated and uncorrugated strips until the adhesive has set su ciently to prevent creeping.

4. A machine for manufacturing plaster board comprising in combination, corrugating rolls for forming alternate ribs and depressions in a continuously advancing sheet,

scoring rolls for scoring said ribs at spaced intervals, pressure rolls for adhesively uniting the corrugated sheet to the laminated board, knockout means, comprising a cylinder, thesurface of which is provided with a plurality of spaced studs, for severing said scored .portions and positively uniting the cut-outs thus formed to the laminated board. 5. A-machine for manufacturing plaster board comprising in combination, corrugating rolls for forming alternate ribs and depressions in a continuously advancing sheet, scoring rolls for scoring said ribs at spaced intervals, pressure rolls for uniting a plurality of continuously advancing sheets to form a laminated board, a second set of. pressure rolls for adhesively uniting the corrugated sheet to the laminated board, knockout means, comprisin a cylinder, the surface of which is rovide with a plurality of aced studs, or severing said scored portlons and positively uniting the cut-outs 05 thus formed to the laminated board.

ositive contact pressure rolls for adhesively uniting the corrugated sheet to the laminated board, knockout means, comprising a cylinder, the surface of which is provided with a plurality of spaced studs, for severing said scored portions and positively uniting! the cut-outs thus formed to the laminated board, and means comprising a continuous chain of transversely extending bars insertable between the rigs of the corrugated sheet in consecutive order to prevent flattening of the corrugations.

7. A machine for manufacturing plaster board comprising in combination, corrugating rolls for forming alternate ribs and depressions in a continuously advancing sheet, scoring rolls for scoringsaid ribs at spaced intervals, pressure rolls for uniting a plurality of continuously advancing sheets to form a laminated board, a second set of pressure rolls for adhesively uniting the corrugated sheet to the laminated board, knockout means, comprising a cylinder, the surface of which is provided with a plurality of spaced studs, for severing said scored portions and positively uniting the cut-outs thus formed to the laminated board, means comprising a continuous chain of transversely extending bars insertable between the ribs of the corrugated sheet in consecu tive order to prevent flattening of the corrugations, and means for maintaining pressure on-the corrugated sheet and laminated board after being united to prevent them from separating.

8. A machine comprising in combination, a corrugating unit comprising a pan of co-acting cylinders, the surface of one of which, is provided with spaced longitudinal ribs, and the surface of the other of whlch is provided with a plurality 'of alternate spaced ribs and spaced beads, an endless chain comprising spaced transverse bars providedv with longitudinal grooves adapted to be insertable between the ribs of the first mentioned cylinder, said grooves and the beads of the second cylinder being in register, and means for passing the material to be corrugated continuously between the two cylinde I In testimony whereof I aflix my signature HARRY A. CUMFER.

Images