Shaping Plural Separable Mold Parts Patents (Class 164/27)
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Patent number: 10421119Abstract: A method of forming a component including coupling an array of receptacles to a mold core. Each receptacle in the array contains an amount of uncured mold material. The method further includes forming a layer of fugitive material on the mold core such that the array of receptacles is encapsulated within the layer of fugitive material. The method also includes forming a layer of uncured mold material on the layer of fugitive material, thereby forming an uncured mold assembly. The uncured mold assembly is heated to a temperature that solidifies the uncured mold material within each receptacle and of the layer, thereby forming an array of pins and a layer of solidified mold material. The uncured mold assembly is also heated to the temperature that removes the layer of fugitive material from between the mold core and the layer of solidified mold material such that a mold cavity, including the array of pins, is defined therebetween.Type: GrantFiled: January 3, 2017Date of Patent: September 24, 2019Assignee: General Electric CompanyInventor: James Albert Tallman
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Patent number: 8813819Abstract: Provided are a die change apparatus for use in a flaskless molding machine capable of mounting dies for producing a casting mold on die bases even when the dies have a great thickness, and a die carrying-in device used therein. The die carrying-in device comprises a first movable plate provided so as to be slidable along a die carrying-in direction toward a first die base, and a second movable plate placed so as to face the first movable plate in a standby position. A die drive source causes dies which have been positioned in a height direction to be detached from the movable plates, move toward the die bases, and be supported by clamping elements. An intersection drive source causes at least one of the first movable plate and the second movable plate to move in a direction to intersect the die carrying-in direction independently of the other.Type: GrantFiled: March 25, 2011Date of Patent: August 26, 2014Inventors: Keisuke Yabuhana, Syuichi Furukawa, Syozaburo Tsuzuki, Eiji Ito
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Patent number: 8074701Abstract: A method for producing a pattern for the precision-cast representation of a component having a cavity is provided. In the method wherein the component is a turbine component having a cavity, the finished pattern comprises a core and an outer contour pattern, the outer contour pattern at least partially surrounds the core and at least partially defines the outer contour of the turbine component. The core is produced from a curable core material, which cures during the course of the method, and the outer contour pattern is produced from a material which can be burned or melted out. In this case, first the outer contour pattern is produced with a cavity corresponding to the cavity of the turbine component and subsequently the curable core material is filled into the cavity and cured to produce the core.Type: GrantFiled: September 21, 2007Date of Patent: December 13, 2011Assignee: Siemens AktiengesellschaftInventor: Uwe Paul
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Patent number: 7806161Abstract: Disclosed is a sand casting molding machine for double indexing molds in a mold string. The machine can include a shot chamber having sand, a swingable squeeze head, a lateral squeeze head, a core setter, a mold hold down, a mold retention device and a mold string conveyor.Type: GrantFiled: December 10, 2007Date of Patent: October 5, 2010Assignee: Thyssenkrupp Waupaca Inc.Inventor: Robert Jezwinski
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Patent number: 7137433Abstract: A lightweight part and process and device of making the same, the lightweight part including an inner core including a metal foam. A dense core surface layer is metallically joined to the inner core. An outer wall includes an essentially pore-free cast metal layer that is at least one of positively engaged with the dense core surface layer and surrounding the inner core, and metallically joined to the dense core surface layer and surrounding the inner core. The process includes creating a core part by forming the dense core surface layer, forming the inner core of a metal foam, and metallically joining together the inner core and the dense core surface layer. The process further includes creating a finished part by positioning the core part in a casting mold, feeding a melt material into the casting mold, and allowing the melt material to solidify so as to form the outer wall.Type: GrantFiled: April 16, 2003Date of Patent: November 21, 2006Assignee: Huette Klein-Reichenbach Gesellschaft m.b.H.Inventors: Franz Dobesberger, Herbert Flankl, Dietmar Leitlmeier, Alois Birgmann
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Patent number: 7114546Abstract: A tire mold according to the invention includes a plurality of tread sectors for forming a tread portion of a tire and two shell inserts for molding the sidewalls of a tire wherein the tread sectors and the shell inserts are castings formed from the same model. A method for manufacturing a mold in accordance with the invention includes the steps of providing a casting model having the tread and sidewall features of a tire, the casting model having parting zones between the tread and sidewall, casting an element from the model, the cast element accordingly having parting zones between the tread and sidewall portions, and separating the cast element into a plurality of tread sectors and opposing sidewall shells.Type: GrantFiled: May 4, 2005Date of Patent: October 3, 2006Assignee: Michelin Recherche et Technique S.A.Inventor: Keith Ward
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Publication number: 20020185243Abstract: An impregnated fired porous alumina-based ceramic core for use in an investment shell mold in the casting of molten metals and alloys wherein the core is impregnated with yttria to improve core creep resistance at elevated casting temperatures and times.Type: ApplicationFiled: August 8, 2001Publication date: December 12, 2002Inventors: Gregory R. Frank, Ronald J. Keller, Rodney S. Haaland, Charles F. Caccavale, Alfred P. Kaulius
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Patent number: 6270710Abstract: A process for manufacturing hollow synthetic resin bodies or objects in which cores are produced in casting molds, then placed into molds of injection molding machines, and subsequently enveloped with injected synthetic resin material (35) which then solidifies. The molds are then heated up to a temperature at which the cores melt and at which the molten cores can be removed from the molds. The cores are made of shell halves (32, 33) which are assembled before the synthetic resin material (35) is injection molded around them.Type: GrantFiled: November 19, 1999Date of Patent: August 7, 2001Assignee: Filterwerk Mann & Hummel GmbHInventors: Walther Bartel, Wolfgang Cedzich, Robert Vaculik, Richard Veigel
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Patent number: 5778965Abstract: The sand-metal ratio of a mold used for casting a crank shaft or cam shaft having discrete shapes is reduced to make the mold more compact. Basic discrete cavities (15) including cavities (6) corresponding to one half of shaft portions and cavities (7) corresponding to one half of cam portions are staggered by axially offsetting them in horizontal and/or vertical direction.Type: GrantFiled: November 13, 1996Date of Patent: July 14, 1998Assignees: Kabushiki Kaisha Riken, Riken Castec CorporationInventor: Sumitoshi Mai
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Patent number: 5662155Abstract: A pouring basin (1) or funnel made of a mold material, such as sand is molded, and then positioned on a sand casting mold (2). In order to increase the usable casting time in the casting of a workpiece in the casting mold and at the same time avoid any increase in station time, the apparatus includes a mechanism designed to mold and consolidate the pouring basin (1) and then to place the consolidated pouring basin (1) directly on the casting mold (2) in alignment with the pouring hole thereof.Type: GrantFiled: May 21, 1996Date of Patent: September 2, 1997Assignee: Adolf Hottinger Maschinenbau GmbHInventor: Werner Landua
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Patent number: 5291936Abstract: The apparatus includes a mold unit for at least two mold parts, with in each case at least two separate shooting heads and sand magazines with separate shooting hood shoot-out areas and in which the shooting heads are subject to the action of individual shooting air sources. In the method a unit with mold cavities for at least two mold parts to be interconnected is moved under a shooting station, which is provided with at least two shooting heads and sand magazines with separate shooting hood shoot-out areas and from the magazines sand is shot into the mold unit cavities for the different mold parts with different pressures and different sand compositions.Type: GrantFiled: October 25, 1991Date of Patent: March 8, 1994Assignee: Adolf Hottinger Maschinenbau GmbHInventors: Reiner Rommel, Werner Landua
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Patent number: 5067548Abstract: Individual mold sections are injection molded from a slurry of ceramic particles and a binder. Each of the green individual mold sections is low temperature fired to remove therefrom a major portion of the binder while leaving therein a minor portion of the binder sufficient to afford structural strength thereto, and the individual mold sections are assembled together to form a mold. Finally the mold is high temperature fired to complete removal of the binder.Type: GrantFiled: March 19, 1991Date of Patent: November 26, 1991Assignee: Certech IncorporatedInventor: Stuart Z. Uram
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Patent number: 4733712Abstract: A plurality of identical green sand molds are sequentially formed by horizontal compaction on automatic mold making machinery. Each mold has a front and back vertical face with a recess formed in the front face and a plurality of down runners formed in the back face. A mold piece insert is formed of a mixture of green sand and a chemical bonding agent, preferably a resin binder and cold set in a pattern box to form the cavities for the cast articles. The mold piece insert is received flush in the mold front face recess with the cavities opening to the front face. A plurality of molds, with inserts, are adjoined in front-to-back relationship with the down runners overlapping the cavities for feeding the molten pour thereto.Type: GrantFiled: July 25, 1986Date of Patent: March 29, 1988Assignee: Eaton CorporationInventor: Roger L. Koppenhofer
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Patent number: 4499939Abstract: Process for obtaining, by pig iron casting, machine elements provided with protection cages suitable to preserve delicate portions of machine elements from breaking and deforming during the production phase. The process consists in applying raised impressions of the cages on a pattern for green casting which impression corresponds to a print of a hardened shell reproducing the outer portions of the machine elements.Type: GrantFiled: December 7, 1983Date of Patent: February 19, 1985Assignee: Necchi, Societa per AzioniInventor: Giulio Marton
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Patent number: 4367782Abstract: An improved method is utilized to make an improved mold for forming a plurality of small objects, such as piston rings. The mold is made by stacking a plurality of mold sections formed of gas permeable material, such as CO.sub.2 sand, resin bonded sand or green sand. The stacked mold sections are then clamped together to hold them against movement relative to each other. A wet coating of liquid ceramic material is then applied over the stack of mold sections. This liquid ceramic mold material is dried to form a rigid gas permeable ceramic casing which encloses the stack of mold sections. The rigid casing of ceramic material holds the mold sections against movement relative to each other to prevent break-out of metal from between the mold sections when a flow of molten metal is directed into the mold cavities. Due to the gas permeable construction of both the rigid ceramic casing and the mold sections, gas can readily escape from the mold as the molten metal enters the mold cavities.Type: GrantFiled: June 1, 1976Date of Patent: January 11, 1983Assignee: TRW Inc.Inventor: Gustav E. Schrader
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Patent number: 4315537Abstract: An improved method is utilized to make a mold for a cast product having a plurality of spaced apart surfaces. Although the method could be used for forming molds for different products, the method is advantageously used to form a mold for a cast product having a plurality of airfoils disposed in a circular array. To form the mold, a plurality of airfoil pattern segments are placed in a circular array with surfaces of the segments abutting at joints which are free of material interconnecting the segments. A coating of liquid ceramic mold material is applied over the airfoil pattern segments. Since the joints between the airfoil pattern segments are free of interconnecting material, the liquid ceramic mold material can flow into the joints. After the ceramic mold material has been dried and the airfoil pattern segments disposed of, the ceramic mold material which entered the joints between the airfoil pattern segments forms a plurality of relatively thin projections from the main wall of the mold.Type: GrantFiled: May 21, 1976Date of Patent: February 16, 1982Assignee: TRW Inc.Inventor: William S. Blazek
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Patent number: 4276922Abstract: A method of forming a mold for use in casting is disclosed. The method includes as a first step forming a positive pattern having a surface the shape of a part to be cast. Next a negative partial pattern is formed having a casting surface complimentary to a selected portion of the surface of the positive pattern and also having a reference surface in a fixed spatial relationship with the casting surface. The casting surface of the negative partial pattern is placed in complimentary engagement with the selected portion of the surface of the positive pattern to form a pattern assembly. A first mold section having a surface complimentary to the reference surface and to the surface of the part is formed by dipping the assembly formed in the preceding step in a ceramic material.Type: GrantFiled: May 24, 1978Date of Patent: July 7, 1981Assignee: TRW Inc.Inventor: Ronald R. Brookes
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Patent number: 3939900Abstract: A process and apparatus for producing continuous length shaped metal filaments by casting a stream of molten metal within a groove formed in the inner periphery of a cylindrical chill roll. The groove is flanked by a tapered opening of a material which has low thermal conductivity and which is not wetted when contacted by the molten metal. This novel technique increases the tolerance of the position in which the molten stream may be introduced into the groove while ensuring the production of an approximately rounded cross section by preventing the molten stream from spreading out of the groove.Type: GrantFiled: January 27, 1975Date of Patent: February 24, 1976Assignee: Allied Chemical CorporationInventors: Donald E. Polk, John R. Bedell