Patents Examined by Kevin P. Kerns
  • Patent number: 11364539
    Abstract: A counter-gravity casting method and apparatus in which the mold is held stationary and the crucible is moved generally laterally from a melt chamber to a fill chamber positioned below the mold with respect to gravity. A casting chamber is located generally above the fill chamber with respect to gravity. The method and apparatus utilize separate chambers for melting and casting in which the pressure in each chamber can be varied relative to each other in order to introduce molten metal into the mold.
    Type: Grant
    Filed: January 3, 2020
    Date of Patent: June 21, 2022
    Assignee: Metal Casting Technology, Inc.
    Inventors: Sanjay B. Shendye, Joseph C. Michalik, Jr.
  • Patent number: 11364537
    Abstract: Providing a method for reducing occurrences of a mold shift of a cope and a drag that have been molded by a flaskless molding machine and have been assembled by estimating a cause of a mold shift based on measurements and by taking appropriate measures, and a flaskless molding line that uses the method. The method for reducing occurrences of a mold shift of a cope and a drag (1, 2) that have been molded by a flaskless molding machine (200) and have been assembled comprises a step of measuring specific data at positions where a mold shift may occur during a process for manufacturing or taking out the cope and the drag, and a step of determining if the obtained specific data are within an allowable range.
    Type: Grant
    Filed: July 12, 2018
    Date of Patent: June 21, 2022
    Assignee: SINTOKOGIO, LTD.
    Inventors: Takashi Hanai, Takehiro Sugino
  • Patent number: 11364536
    Abstract: A manufacturing method uses layered slabs to create a final pattern for a mold or for creating the mold itself. The method includes: preparing a desired number of slabs including a first slab and a second slab; machining the first slab; machining the second slab; and after the second slab is coupled to the first slab, repeating the machining step for each additional slab included in the desired number of slabs to form the final pattern or mold.
    Type: Grant
    Filed: May 18, 2021
    Date of Patent: June 21, 2022
    Assignee: DEERE & COMPANY
    Inventors: Eric M. Johnson, Matthew Frank, Hema V. Guthy, Kalathur Pattabiraman, Ali Tayh, Darren J. Hellman, Michael C. Paisley
  • Patent number: 11358213
    Abstract: The device for controlling a flow in a mold in thin-slab casting of steel has a thickness on the short side of the meniscus portion of 150 mm or less and a casting width of 2 m or less and includes a DC magnetic field generation unit and an immersion nozzle having a slit formed at the bottom so that the slit leads to the bottom of the discharge hole and opens outside, the discharge hole and the slit are present in the DC magnetic field zone, and the magnetic flux density B (T) in the DC magnetic field zone and the distance L (m) from the lower end of the immersion nozzle to the lower end of the core satisfy Formulae (1) and (2) described below: 0.35T?B?1.0T??Formula (1) L?0.
    Type: Grant
    Filed: June 7, 2019
    Date of Patent: June 14, 2022
    Assignee: NIPPON STEEL CORPORATION
    Inventors: Hiroshi Harada, Keita Ikeda, Masashi Sakamoto, Yui Ito, Takuya Takayama
  • Patent number: 11358212
    Abstract: A riser sleeve (1) for using when pouring metals into a casting mould includes a riser body (2). The riser body (2) includes a riser cavity (3) for holding liquid metal and a riser opening (4) for joining the riser cavity (3) to a mould cavity of the casting mould during the casting process. The riser cavity (3) has a greater diameter than the diameter of the riser opening (4) in at least one portion, the riser body (2) is made of an insulating and/or exothermic riser material. The riser body (2) is formed as a single piece, the riser opening (4) defines an axis (5), and the riser cavity (3) is asymmetric to the axis (5).
    Type: Grant
    Filed: February 12, 2020
    Date of Patent: June 14, 2022
    Assignee: GTP Schäfer Gießtechnische Produkte GmbH
    Inventors: Olof Hilger, Jörg Schäfer, Thomas Schäfer
  • Patent number: 11358214
    Abstract: By setting an electric resistance of a trough to a value larger than an electric resistance of a molten metal stored in a storage space, in a non-driving state, a current is caused to flow along a first current path from one side wall of the pair of side walls to another side wall through the bottom wall, and in a driving state, a current is caused to flow through a second current path from the one side wall through a middle part of the first current path and bypass to the molten metal, and return to the first current path, and in the driving state, in the molten metal, causing the magnetic force lines running vertically and the current running horizontally to cross each other to generate a Lorentz force, and by the Lorentz force, driving and carrying the molten metal in the trough.
    Type: Grant
    Filed: October 29, 2020
    Date of Patent: June 14, 2022
    Inventor: Kenzo Takahashi
  • Patent number: 11351600
    Abstract: A nozzle put into a molten metal in vertical upwards continuous casting for casting a cast product by pulling up the molten metal, the nozzle includes a nozzle body having an intake hole through which the molten metal is taken in and which is formed in a lateral surface of the nozzle body and a flange portion formed on lower side of the intake hole and projecting beyond the nozzle body.
    Type: Grant
    Filed: September 19, 2019
    Date of Patent: June 7, 2022
    Assignee: NGK Insulators, Ltd.
    Inventors: Ken Suzuki, Naokuni Muramatsu
  • Patent number: 11351599
    Abstract: Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.
    Type: Grant
    Filed: March 23, 2020
    Date of Patent: June 7, 2022
    Assignee: General Electric Company
    Inventors: James Herbert Deines, Michael John McCarren, Brian Patrick Peterson, Brian David Przeslawski, Xi Yang, Douglas Gerard Konitzer, Mark Willard Marusko, Gregory Terrence Garay
  • Patent number: 11344947
    Abstract: A method for forming a battery bracket by semi-solid die casting, where the battery bracket is prepared by semi-solid die casting. The method includes: preparing an aluminum alloy raw material into liquid aluminum alloy, and incubating the liquid aluminum alloy at a first preset temperature; delivering the liquid aluminum alloy to a slurry machine for stirring to obtain a semi-solid slurry; pouring the semi-solid slurry into a die-casting machine for die-casting forming to obtain a prototype of the battery bracket; and subjecting the formed prototype of the battery bracket to solution treatment at a second preset temperature and then to aging treatment at a third preset temperature to obtain the battery bracket; where, the battery bracket mold structurally matches the battery bracket, and gates are disposed at positions in the battery bracket mold corresponding to threaded connections of a first boss and a second boss of the battery bracket, respectively.
    Type: Grant
    Filed: November 2, 2020
    Date of Patent: May 31, 2022
    Assignee: Qingdao Yuyuan New Material Co., Ltd.
    Inventor: Xuelei Song
  • Patent number: 11344946
    Abstract: A control device for continuous casting continuously producing a slab by injecting a molten metal from a nozzle to a mold and extracting the molten metal while solidifying the molten metal, includes a molten metal level meter measuring a molten metal level in the mold, a main control unit obtaining an operation amount of a flow rate adjusting mechanism that adjusts a flow rate of a molten metal injected to the mold from the nozzle such that a molten metal level measured by the molten metal level meter follows a molten metal level target value, a flowmeter measuring the flow rate of the molten metal injected to the mold from the nozzle, an input disturbance correction unit obtaining a first correction amount for the operation amount of the flow rate adjusting mechanism obtained by the main control unit.
    Type: Grant
    Filed: September 17, 2019
    Date of Patent: May 31, 2022
    Assignee: NIPPON STEEL CORPORATION
    Inventor: Hiroki Yamamoto
  • Patent number: 11338358
    Abstract: A diecasting tool system has a machine-related base plate, at least one set of contour-imparting mould components which in an assembled position on the base plate form a casting contour for an associated cast part to be cast, and a plurality of not contour-imparting tool receptacle module components. The base plate, the tool receptacle module components and the contour-imparting mould components are configured for releasably assembling the associated set of contour-imparting mould components and an assigned set of the tool receptacle module components on a fastening side of the base plate for casting the respective cast part. The base plate on the fastening side has a fastening grid of a plurality of fastening points which are disposed so as to be distributed in a regular or irregular pattern across a fastening region.
    Type: Grant
    Filed: May 4, 2021
    Date of Patent: May 24, 2022
    Assignee: Oskar Frech GmbH + Co. KG
    Inventors: Ronny Aspacher, Marco Beier, Nikolai Clauss
  • Patent number: 11338359
    Abstract: Composite parts (100) and methods of making the same are disclosed. A composite part may include an internal insert component (124) made of a first material. The internal insert component may be provided with surface features such as mechanical surface features or material surface features, on at least a portion of its surface. The composite part may further include an external part component (136) that is cast around at least a portion of the internal insert component, and is made of a second material different from the first material. The surface features of the internal insert component may help establish a bond within the composite part between the internal insert component and the external part component.
    Type: Grant
    Filed: February 9, 2018
    Date of Patent: May 24, 2022
    Assignee: Aludyne North America LLC
    Inventors: Alexandre Reikher, Sam A. Kassoumeh
  • Patent number: 11338361
    Abstract: The present disclosure discloses a shell mold chamber, a foundry furnace and a method for casting single crystal, fine crystal and non-crystal, which employ the technique of asynchronous-curving supercooling, and belongs to the technical field of precise casting apparatuses.
    Type: Grant
    Filed: April 8, 2020
    Date of Patent: May 24, 2022
    Inventor: Jingchen Zhao
  • Patent number: 11331715
    Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.
    Type: Grant
    Filed: June 11, 2018
    Date of Patent: May 17, 2022
    Assignee: WAGSTAFF, INC.
    Inventors: Craig Richard Cordill, Craig Lee Shaber, Michael Kim Anderson
  • Patent number: 11331717
    Abstract: A method of manufacturing semi-solidified molten metal includes a step of keeping discharging inert gas from a probe in a continuous manner, and inserting the probe into molten metal held at a temperature that is higher than a temperature of the probe and that is equal to or higher than a liquidus-line temperature, a step of extracting the inserted probe from the molten metal such that at least part of a region of a surface of the inserted probe that is in contact with the molten metal is exposed from the molten metal, and a step of inserting the extracted probe again into the molten metal.
    Type: Grant
    Filed: October 16, 2020
    Date of Patent: May 17, 2022
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Shuji Sotozaki
  • Patent number: 11331716
    Abstract: Continuous casting mold is provided having a mold copper plate having plural separate portions filled with foreign metal formed by filling concave grooves formed on the inner wall surface of the mold copper plate and having a diameter of 2 mm to 20 mm in the inner wall surface at least in the region from a meniscus to a position located 20 mm or more lower than the meniscus with the foreign metal whose thermal conductivity is 80% or less or 125% or more of the mold copper plate, the ratio of the Vickers hardness HVc of the mold copper plate to the Vickers hardness HVm of the filling metal satisfies expression (1), and the ratio of the thermal expansion coefficient ?c of the mold copper plate and the thermal expansion coefficient ?m of the filling metal satisfies expression (2). 0.3?HVc/HVm?2.3??(1), 0.7??c/?m?3.
    Type: Grant
    Filed: October 23, 2015
    Date of Patent: May 17, 2022
    Assignee: JFE STEEL CORPORATION
    Inventors: Kohei Furumai, Naomichi Iwata, Norichika Aramaki, Yuji Miki
  • Patent number: 11318528
    Abstract: Method and installation for making sand cores. The method includes a generating step which is implemented in a first station of the installation, in which the cores are generated with the desired shape in an inner space demarcated by a job box by means of 3D manufacturing, in which layers of a granular material and of an additive that solidifies the granular material are applied in an alternating manner on a platform of the job box. The method also includes a subsequent hardening step which is implemented in a second station of the installation, in which the cores generated in the generating step are hardened. In the hardening step, in order to harden the previously generated cores microwaves and a drying stream are applied in the inner space of the job box.
    Type: Grant
    Filed: November 20, 2020
    Date of Patent: May 3, 2022
    Assignee: LORAMENDI, S. COOP.
    Inventor: Luis Alfonso Fernandez Orive
  • Patent number: 11318529
    Abstract: A casting device includes a mold provided with an insert die, a molten metal supply device for supplying molten metal into the mold, and a gas supply mechanism for supplying a gas, which is used for forced cooling, to the insert die. The insert die is made of tungsten having a thermal conductivity significantly higher than that of die steel. The insert die has a spiral or meandering gas passage therein. The spiral or meandering gas passage has a passage length much longer than a straight passage.
    Type: Grant
    Filed: March 25, 2019
    Date of Patent: May 3, 2022
    Assignee: Honda Foundry Co., Ltd.
    Inventors: Shintaro Araki, Makoto Sawai, Keisuke Ishii
  • Patent number: 11318530
    Abstract: A slide for the high pressure die casting of at least one closed deck engine block having at least one cylinder is disclosed. The slide includes a tool steel portion with reliefs for forming a water jacket surrounding each cylinder. At least one expendable core is located in each relief, the expendable core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the expendable core is coextensive with an inner surface and outer surface of the tool steel portion. A method for high pressure die casting a closed deck engine block using the disclosed slide and expendable cores is also disclosed. The expendable cores are separable from the reliefs in the slide, and form bridges or supports across a water jacket to add stiffness and rigidity to the cast engine cylinders.
    Type: Grant
    Filed: February 12, 2020
    Date of Patent: May 3, 2022
    Assignee: Brunswick Corporation
    Inventors: Terrance M. Cleary, Kevin R. Anderson, Raymond J. Donahue, Alexander K. Monroe, Clayton T. Rasmussen
  • Patent number: 11305339
    Abstract: A roll line unit for a continuous casting apparatus includes a roll mantle having two ends and a non-rotatable shaft including a coolant line. The roll mantle is rotatably mounted on the non-rotatable shaft by means of a first bearing located in a first end region of the roll mantle and a second bearing located in a second end region of the roll mantle. The roll mantle includes at least one coolant channel having at least one fluid inlet that is arranged to be in fluid communication with the coolant line. The roll line unit includes two outer seals located on an axially outward side of each of the first and second bearings, whereby the outer seals and the first and second bearings are located axially inwards of the ends of the roll mantle.
    Type: Grant
    Filed: October 28, 2020
    Date of Patent: April 19, 2022
    Inventors: Mats Johansson, Erik Mitchell