Patents by Inventor Carl R. Verner

Carl R. Verner has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 9878368
    Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.
    Type: Grant
    Filed: February 10, 2016
    Date of Patent: January 30, 2018
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Mario P. Bochiechio, John Joseph Marcin, Carl R. Verner, John F. Blondin, Mark F. Bartholomew, Raymond P. Ristau, Kevin W. Chittenden, Gary M. Tamiso, Robert C. Renaud, Dennis M. Kraemer, Robert E. LeBrun, Paul R. Zamjohn, Charles A. Roohr, Kerry Kozaczuk, Roy A. Garrison, Steven J. Bullied
  • Patent number: 9808862
    Abstract: A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.
    Type: Grant
    Filed: May 9, 2017
    Date of Patent: November 7, 2017
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Carl R. Verner, John Joseph Marcin
  • Publication number: 20170239717
    Abstract: A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.
    Type: Application
    Filed: May 9, 2017
    Publication date: August 24, 2017
    Inventors: Carl R. Verner, John Joseph Marcin
  • Publication number: 20170136532
    Abstract: A die casting plunger tip includes a hollow outer portion and a hollow inner portion. The outer portion has a first closed end. The inner portion has a second partially closed end. The inner portion is disposed within the outer portion and the second partially closed end is adjacent the first closed end of the outer portion in an axial direction. A plurality of connectors connects the outer portion and the inner portion. A plenum is formed between the outer portion and the inner portion.
    Type: Application
    Filed: November 23, 2015
    Publication date: May 18, 2017
    Inventors: Thomas N. Slavens, Carl R. Verner, Albert Rabinovich, Weiduo Yu, Awadh B. Pandey
  • Publication number: 20170081967
    Abstract: A casting mold assembly includes an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.
    Type: Application
    Filed: October 5, 2016
    Publication date: March 23, 2017
    Inventors: Steven J. Bullied, Carl R. Verner, Steven D. Porter, James B. Park
  • Patent number: 9486853
    Abstract: A casting mold assembly includes an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.
    Type: Grant
    Filed: September 14, 2012
    Date of Patent: November 8, 2016
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Carl R. Verner, Steven D. Porter, James B. Park
  • Publication number: 20160311016
    Abstract: A method of manufacturing includes providing a casting assembly, providing a material having solid, transition, and liquid phases, heating the material to form the liquid phase, supplying the material to the casting assembly, cooling the material, monitoring the solidification of the material from the liquid phase through the transition phase, and moving one of the casting mold or the reusable core in a first direction relative to the other when a substantial portion of the reusable core contacts the transition phase. The casting assembly comprises a casting mold and a reusable core inserted within the casting mold.
    Type: Application
    Filed: April 24, 2015
    Publication date: October 27, 2016
    Applicant: United Technologies Corporation
    Inventors: Dilip M. Shah, John Joseph Marcin, Steven J. Bullied, Carl R. Verner, Ryan C. Breneman
  • Publication number: 20160288201
    Abstract: A method casts a plurality of alloy parts in a mold (600; 700) having a plurality of part-forming cavities (601). The method comprises pouring a first alloy into the mold causing: the first alloy to branch into respective flows along respective first flowpaths (676, 684; 708) to the respective cavities; and a surface of the first alloy in the part-forming cavities to equilibrate. The method further comprises pouring a second alloy into the mold causing: the second alloy to branch into respective flows along respective second flowpaths (676, 680; 712) to the respective cavities.
    Type: Application
    Filed: November 7, 2014
    Publication date: October 6, 2016
    Applicant: United Technologies Corporation
    Inventors: Steven J. Bullied, John J. Marcin, JR., Emily K. Kreek, Carl R. Verner, Mario P. Bochiechio
  • Publication number: 20160158835
    Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.
    Type: Application
    Filed: February 10, 2016
    Publication date: June 9, 2016
    Inventors: Mario P. BOCHIECHIO, John Joseph MARCIN, Carl R. VERNER, John F. BLONDIN, Mark F. BARTHOLOMEW, Raymond P. RISTAU, Kevin W. CHITTENDEN, Gary M. TAMISO, Robert C. RENAUD, Dennis M. KRAEMER, Robert E. LeBRUN, Paul R. ZAMJOHN, Charles A. ROOHR, Kerry KOZACZUK, Roy A. GARRISON, Steven J. BULLIED
  • Patent number: 9289823
    Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.
    Type: Grant
    Filed: November 10, 2014
    Date of Patent: March 22, 2016
    Assignee: United Technologies Corporation
    Inventors: Mario P. Bochiechio, John Joseph Marcin, Carl R. Verner, John F. Blondin, Mark F. Bartholomew, Raymond P. Ristau, Kevin W. Chittenden, Gary M. Tamiso, Robert C. Renaud, Dennis M. Kraemer, Robert E. LeBrun, Paul R. Zamjohn, Charles A. Roohr, Kerry Kozaczuk, Roy A. Garrison, Steven J. Bullied
  • Publication number: 20160074933
    Abstract: A method of die casting a component with an integral sea according to an exemplary aspect of the present disclosure includes, among other things, defining a first portion of a die cavity of a die to include an open cell structure and defining a second portion of the die cavity without the open cell structure. The first portion is located within an opening formed in a first die element of the die and the second portion is located within a void formed in a second die element of the die. The method further includes injecting molten metal into the die cavity and solidifying the molten metal within the die cavity to form the component with the integral seal.
    Type: Application
    Filed: November 11, 2015
    Publication date: March 17, 2016
    Inventors: Steven J. Bullied, Carl R. Verner, Gaurav M. Patel
  • Publication number: 20160038999
    Abstract: A shot tube assembly for a die casting process includes a spiral passage for circulating a coolant about a cavity containing the molten metal material. The circulating coolant provides temperature control of the shot tube that improves the casting process and increases shot tube life.
    Type: Application
    Filed: March 11, 2014
    Publication date: February 11, 2016
    Inventors: Mario P. Bochiechio, Carl R. Verner, Mark F. Bartholomew, John F. Blondin, Yan Seng Loh, Yuan Kwang Lim
  • Publication number: 20160031006
    Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.
    Type: Application
    Filed: June 5, 2015
    Publication date: February 4, 2016
    Applicant: United Technologies Corporation
    Inventors: Dilip M. Shah, Paul D. Genereux, Alan D. Cetel, John J. Marcin, JR., Steven J. Bullied, Mario P. Bochiechio, Kevin W. Schlichting, Bradford A. Cowles, Carl R. Verner, David U. Furrer, Venkatarama K. Seetharaman
  • Publication number: 20160031004
    Abstract: A shot tube includes an inner bore for delivering molten material into a die-cast mold. The shot tube has an outer peripheral surface with at least one surface for receiving a locking member to lock the shot tube into an aperture in a fixed mold portion and an alignment structure for properly aligning the shot tube in the fixed mold portion. An opening receives molten material into the inner bore. A die-cast machine is also disclosed.
    Type: Application
    Filed: March 6, 2014
    Publication date: February 4, 2016
    Inventors: Mario P. Bochiechio, Yee Ling Kwan, Carl R. Verner
  • Publication number: 20160008867
    Abstract: A method comprises: providing a spiral metallic workpiece having a cast structure associated with such spiral; and at least partially flattening the workpiece.
    Type: Application
    Filed: June 24, 2015
    Publication date: January 14, 2016
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Dilip M. Shah, Alan D. Cetel, John J. Marcin, JR., Steven J. Bullied, Carl R. Verner
  • Publication number: 20150174653
    Abstract: A system and methods are provided for removing core elements of cast components. In one embodiment, a method includes controlling a first high temperature autoclave cycle for a cast component in a vessel with a first solution concentration to remove at least a first portion of core elements, wherein the first solution concentration, temperature and pressure in the vessel are controlled to expose one or more casting pins in the cast component. The method may also include controlling a second high temperature autoclave cycle for the cast component in the vessel with second solution concentration, wherein the second solution concentration, temperature and pressure in the vessel during the second high temperature autoclave cycle are controlled to loosen one or more of the casting pins from the cast component, and controlling one or more low temperature autoclave cycles to remove core and casting pins from the cast component.
    Type: Application
    Filed: December 16, 2014
    Publication date: June 25, 2015
    Applicant: United Technologies Corporation
    Inventors: Carl R. VERNER, John Joseph MARCIN
  • Publication number: 20150060002
    Abstract: A method of manufacturing a component in a die casting cell that includes a die casting system according to an exemplary aspect of the present disclosure includes, among other things, isolating a first chamber from a second chamber of the die casting system, melting a charge of material in the first chamber, sealing the second chamber relative to the first chamber, and simultaneously injecting the charge of material within the second chamber to cast the component and melting a second charge of material within the first chamber.
    Type: Application
    Filed: November 10, 2014
    Publication date: March 5, 2015
    Inventors: Mario P. BOCHIECHIO, John Joseph MARCIN, Carl R. VERNER, John F. BLONDIN, Mark F. BARTHOLOMEW, Raymond P. RISTAU, Kevin W. CHITTENDEN, Gary M. TAMISO, Robert C. RENAUD, Dennis M. KRAEMER, Robert E. LeBRUN, Paul R. ZAMJOHN, Charles A. ROOHR, Kerry KOZACZUK, Roy A. GARRISON, Steven J. BULLIED
  • Patent number: 8919422
    Abstract: A die casting system includes a die, a shot tube, a melting system and a vacuum system. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity and is operable to deliver a charge of material to the die cavity. The melting system is positioned adjacent to the die and includes an alloy loader, a melting unit and a crucible. The vacuum system defines a first chamber and a second chamber separated from the first chamber by an isolation valve. The melting system is disposed within the first chamber, and the die is disposed within the second chamber.
    Type: Grant
    Filed: February 18, 2011
    Date of Patent: December 30, 2014
    Assignee: United Technologies Corporation
    Inventors: Mario P. Bochiechio, John Joseph Marcin, Carl R. Verner, John F. Blondin, Mark F. Bartholomew, Raymond P. Ristau, Kevin W. Chittenden, Gary M. Tamiso, Robert C. Renaud, Dennis M. Kraemer, Robert E. LeBrun, Paul R. Zamjohn, Charles A. Roohr, Kerry Kozaczuk, Roy A. Garrison, Steven J. Bullied
  • Patent number: 8814557
    Abstract: An apparatus for casting material has a die for receiving a compressive force, the die having a shaped-opening for receiving a die insert. The die insert has an exterior shape that is adapted to cooperate with and be received in the opening such that compressive forces impinging upon the die are focused upon the die insert such that tensile forces within the die and impinging upon the die insert are minimized.
    Type: Grant
    Filed: March 24, 2010
    Date of Patent: August 26, 2014
    Assignee: United Technologies Corporation
    Inventors: Daniel A. Bales, Steven J. Bullied, Carl R. Verner
  • Patent number: 8784066
    Abstract: An example die casting system includes a die that defines a cavity having a first section and a second section. The first section is configured to receive a first portion of a component. The second section is configured to receive a molten material. The die holds the molten material as the molten material solidifies to form a second portion of the component.
    Type: Grant
    Filed: November 5, 2010
    Date of Patent: July 22, 2014
    Assignee: United Technologies Corporation
    Inventors: Mario P. Bochiechio, Steven J. Bulliad, Carl R. Verner