MOLD TOP INSULATING ASSEMBLY AND METHOD OF USE

Abstract

An ingot mold top comprising a base having a pair of side walls, each side wall having a first end and a second end, each of the first ends terminating in an angled portion and the second ends connected by a first end wall, a wedge having an end wall and a pair of side walls, the pair of side walls extending generally perpendicularly away from the end wall, and wherein the wedge pair of side walls each terminate in an angled portion and the base and wedge completely encompass an interior periphery of a mold.

Description

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates generally to mold top insulating assemblies and exothermic assemblies. More particularly, the invention relates to a safer and easily installed mold top. Specifically, the invention relates to a multiple piece mold top assembly which can be safely installed with an alignment device and provide an increased usable ingot yield.

2. Background Information

The use of a mold top in casting metal has been common place for numerous years. Traditionally, a mold top is used to insulate the molten metal and maintain a more constant temperature during the solidification process. The constant temperature provides a more consistent material with fewer contaminants.

Mold tops, or “hot tops”, have varying heights and dimensions. Initially, the mold top is sized and shaped to fit the mold and extends from the top of the mold only the distance necessary to provide consistent cooling for the molten metal. Originally, mold tops were a two-piece assembly with the base installed first and the top located on the base after the molten was poured.

FIGS. 1 and 2 illustrate a pair of three and four piece, respectively, mold tops with wedging side walls. The prior art mold top in FIG. 1 uses a pair of angled side walls to ensure that the mold top base is securely held in place and located at the extreme interior periphery of the mold. The FIG. 1 mold top suffers from numerous shortcomings, including the fact that two side walls must be installed. Since the two side walls will each move the mold top in opposing directions, the side walls must be installed simultaneously, requiring two people working together, or the installer must fight to install the second side wall as the first attempts to move out of place. Yet another shortcoming of the FIG. 1 mold top is that it requires the operator to stand over the mold in order to install both side walls. Although one side wall may be located close to the working edge of the ledge, the second end will be on the opposite side. Thus, the installer is required to stand over the mold which is very dangerous and not practical.

The mold top of FIG. 2 is used for installation of round molds. Although the round mold has advantages over the two-piece base of FIG. 1, the round mold top still suffers from shortcomings. In particular, the round mold top is difficult to place perfectly centered along the extreme interior periphery. While having only one angled side wall prevents the installer from having to step over the mold, it is much more difficult for the installer to provide a force tangential to the mold top so that the side wall opposite the angled side wall is located proximate the interior periphery.

Thus there is a long-felt need in the art for a mold top which can easily and safely be installed in a mold by a single installer and provides a higher usable yield of material.

SUMMARY OF THE INVENTION

The present invention broadly comprises an ingot mold top comprising a base having a pair of side walls, each side wall having a first end and a second end, each of the first ends terminating in an angled portion and the second ends connected by a first end wall, a wedge having an end wall and a pair of side walls, the pair of side walls extending generally perpendicularly away from the end wall, and wherein the wedge pair of side walls each terminate in an angled portion and the base and wedge completely encompass an interior periphery of a mold.

The present invention further broadly comprises a method of installing an ingot mold top comprising the steps of inserting a mold top base having a pair of side walls with angled terminating portions within a mold, locating a mold top wedge at least partially between the base and the mold, and forcing the wedge downwards to provide axial movement in a direction along the angled terminating portions.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiment of the invention, illustrative of the best modes in which Applicant has contemplated applying the principles of the invention, are set forth in the following description and are shown in the drawings.

FIG. 1 is a perspective view of a prior art mold top with two opposing angled side walls;

FIG. 2 is a perspective view of a prior art mold top for a round mold with a single angled side wall;

FIG. 3 is a perspective view of three molds and a preferred embodiment mold top;

FIG. 4 is an exploded perspective view of a preferred embodiment mold top of the present invention;

FIG. 5 is a top plan view of a preferred embodiment mold top wedge of the present invention;

FIG. 6 is a top plan view of a preferred embodiment mold top base of the present invention;

FIG. 7 is a right plan view of a preferred embodiment mold top lid of the present invention;

FIG. 8 is a right plan view of a preferred embodiment mold top wedge of the present invention;

FIG. 9 is a right plan view of a preferred embodiment mold top base of the present invention;

FIG. 10 is a perspective view of a preferred embodiment alignment device of the present invention;

FIG. 11 is a perspective view of a person installing a preferred embodiment mold top base within the mold;

FIG. 12 is a perspective view of a preferred embodiment mold top base located within the mold;

FIG. 13 is a perspective view of a person installing a preferred embodiment mold top wedge;

FIG. 14 is a cross-sectional view of a preferred embodiment mold top wedge being installed;

FIG. 15 is a perspective view of a person installing a preferred embodiment mold top wedge with a preferred embodiment alignment device;

FIG. 16 is a cross-sectional view of a preferred embodiment mold wedge being installed with a preferred embodiment alignment device;

FIG. 17 is a front plan view of a preferred embodiment mold top wedge being installed with a preferred embodiment alignment device;

FIG. 18 is a perspective view of a person installing a preferred embodiment mold top wedge with a preferred embodiment alignment device by providing a downward force on the alignment device;

FIG. 19 is a cross-sectional view of a preferred embodiment mold top installed within the mold;

FIG. 20 is a perspective view of a person removing a preferred embodiment alignment device after installing a preferred embodiment mold top wedge;

FIG. 21 is a perspective view of molten metal being poured into a mold with a preferred embodiment mold top installed.

FIG. 22 is a cross-sectional view of molten metal in a mold with a preferred embodiment mold top installed;

FIG. 23 is perspective view of a person installing a preferred embodiment mold top lid;

FIG. 24 is a perspective view of a preferred embodiment mold top lid partially installed;

FIG. 25 is cross-sectional view of a preferred embodiment mold top lid partially installed;

FIG. 26 is a perspective view of a person pushing a preferred embodiment mold top lid towards the far end of the mold top;

FIG. 27 is a perspective view of a preferred embodiment mold top with the lid completely installed; and,

FIG. 28 is a cross-sectional view of a preferred embodiment mold top with the lid completely installed.

DESCRIPTION OF THE PREFERRED EMBODIMENT

At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred embodiment, it is to be understood that the invention as claimed is not limited to the disclosed aspects.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described.

The mold top assembly of the present invention is indicated generally at 30, as is particularly shown in FIGS. 1 through 28 sitting on a platform 32, shown with the components separated.

As seen in FIG. 3, mold top assembly 30 generally includes a base 34, a wedge 36, and a lid 38. Platform 32 is preferably located close to molds 40 so that the operator can easily locate the mold top assembly within the mold. Each mold preferably has a distal end 41 and a proximate end 43. In particular, mold top assembly 30 is placed on sidewalls 42 and within an opening 44 formed by the sidewalls. Thus, the mold top assembly is shaped complimentary to the opening of the molds, which is generally rectangular in a preferred embodiment.

FIGS. 4 through 9 illustrate various views of mold top assembly 30. Base 34 includes a first side wall 46, a second side wall 48, and a first end wall 50. First side wall 46 and second side wall 48 are preferably parallel to each other and spaced apart by first end wall 50. An end 52 of first side wall 46 opposite first end wall 50 terminates in an angled portion, while an end 54 of second side wall 48 opposite first end wall 50 terminates in an angled portion. The angled portions extend along the end parallel to first end wall 50 and the distance from the first end wall to the ends (52 and 54) increases from top to bottom, or in other words, the end walls are angled. Although the ends may have any suitable angle, a preferred embodiment angle is in the range of approximately 5 to 45 degrees.

Base 34 also includes a shoulder 56 attached to the exterior periphery, which may be formed integral to the base in a preferred embodiment. Shoulder 56 forms the top surface of the base, as well as extends outward of the first side wall, the second side wall, and the first end wall. Since the shoulder extends outwards of the remainder of the base, the bottom side of shoulder 56 rests on the top of mold sidewall 42.

Further, base 34 includes a ledge 58 attached to the interior periphery, which may be formed integral to the base in a preferred embodiment. Ledge 58 extends outward from the upper portion of the first side wall, the second side wall, and the first end wall. Ledge 58 may be formed by locating shoulder 56 partially outward of the side walls and end wall of base 34. Advantageously, ledge 58 provides a locating and holding area for lid 38, as will be described in greater detail below.

As seen in FIGS. 4 and 5, wedge 36 includes an end wall 60, a first side wall 62, and a second side wall 64. First side wall 62 and second side wall 64 are preferably arranged generally parallel to one another and separated by end wall 60. Further, first side wall 62 terminates in an angled portion 66, while second side wall 64 terminates in an angled portion 68.

In accordance with one of the main features of the present invention, first side wall 62 and second side wall 64 extend away from end wall 60 a sufficient distance to allow an angled portion that is complimentary to ends 52 and 54 respectively. In particular, the angled portions of first side wall 62 and second side wall 64 are preferably in the same range as ends 52 and 54, namely 5 to 45 degrees. However, it should be immediately apparent to one of ordinary skill in that art that almost any angle would be sufficient.

FIG. 8 illustrates a side profile view of a preferred embodiment of wedge 36, while FIG. 9 illustrates a side profile view of a preferred embodiment of base 34. As can be seen, wedge 36 is preferably the same height as base 34. In addition, base ends (52 and 54) and angled portions (66 and 68) are complimentary shaped to each other to provide a vertical sliding engagement that yields a horizontal movement in base 34.

FIGS. 4 and 7 illustrate lid 38, which is sized and shaped to fit within the assembled combination of base 34 and wedge 36. Specifically, lid 38 preferably has a thickness T approximately equal to the distance between ledge 58 and the top of shoulder 56. Advantageously, this allows the lid to fit securely along ledge 58 without the possibility of lid 38 easily failing off. Further, when wedge 36 is fully seated, a top side 70 of the wedge is located on approximately the same plane as shoulder 56 and lid 38 fits between base 34 and wedge 36.

Base 34, wedge 36, and lid 38 are all preferably composed of a heat resilient material such as a ceramic composite or ceramic fiber, however any suitable material which can reduce impurities in the ingot head and still be located within the mold opening as detailed below may be used and is within the spirit and scope of the invention as claimed.

Having described the structure of a preferred embodiment of the mold top assembly, a preferred mold top installation device 72 will now be described in detail and should be viewed in light of FIG. 10. FIGS. 15 through 20 illustrate an installation process with the device and will be described with the full installation procedure of the mold top assembly.

Installation device 72 includes tube 74 with an inner rod 76 movable axially within tube 74. Tube 74 terminates in first end 78 and inner rod 76 terminates in second end 80. A guide 82 is attached at each end (78 and 80), each guide includes a central member 84 arranged generally perpendicular to tube 74 and generally parallel to side walls 46 and 48 of base 34 during operation. Further, an angled member 86 extends from both the top and bottom of central member 84. Each angled member is preferably directed back towards tube 74. Advantageously, the angled members help to locate and center the installation device, as well as spread base 34 apart in order to facilitate installation of wedge 36. In particular, the gradual increase in distance between the angled members allows the installation device to more easily slide between side walls 46 and 48 of base 34 since there is less contact at the guides.

The installation device also includes an arm 88 and a driving bar 90. The driving bar is spaced apart from tube 74 by the generally L-shaped arm 88 in a preferred embodiment. In particular, the driving bar remains parallel to tube 74, but the driving bar is offset from tube 74 both vertically and horizontally. Driving bar 90 is preferably rectangular in shape, with the widest end directed upwards so that the installer can strike the face to urge the installation device and wedge 36 downwards.

Having described the structure of the a preferred embodiment of the mold top assembly and installation device, a preferred method of installing a mold top assembly will now be described in detail and should be viewed in light of FIGS. 11 through 28.

FIGS. 11 and 12 illustrate an installer locating base 34 within mold opening 44. The installer preferably picks up and handles base 34 by the open end and leads with first end wall 50. Base 34 is then inserted within opening 44 such that end wall 50 is adjacent distal end 41 of the mold and first wall end 52 and second wall end 54 are located near proximate end 43 of the mold. As described above, shoulder 56 rests on side walls 42 of the mold.

As seen in FIGS. 13 and 14, the installer then locates wedge 36 within a gap 92 formed by proximate end 43 of the mold and base 34. A lower end of wedge 36 is inserted within gap 92 first in order to properly align angled portions 66 and 68 of wedge 36 with ends 52 and 54 of base 34. As particularly seen in FIG. 14, after partially installing wedge 36, the installer pushes on top side 70 in the direction associated with arrow 94 until the wedge is at least partially installed within the mold.

FIGS. 15, 16, and 17 illustrate the use of installation device 72 to seat wedge 36 within the mold. Next, the installer locates top side 70 of wedge 36 proximate the bottom side of driving bar 90. Since wedge 36 is partially located within gap 92, guides 82 are arranged proximate the interior periphery of base first side wall 46 and base second side wall 48.

FIG. 17 is an endwise view of the installation device being used to locate wedge 36 and illustrates how guides 82 and specifically central members 84 maintain the distance between the first and second side walls of base 34. Further, it should be noted that angled members 86 also operate to ensure proper alignment of the installation device, as the angled members tend to urge the guides into alignment with one another due to the consistent angled wall at each guide.

Averting to FIGS. 18 and 19, the installer then uses a mallet or other solid object to provide a force in the direction associated with arrow 96 on driving bar 90 until the wedge is fully seated between base 34 and proximate end 43 of mold 40. The force in the direction associated with arrow 96 directs wedge 36 downwards and the interaction between wedge 36 and base 34 at angled portions 66 and 68 translates a portion of the force into an axial force in the direction associated with arrow 98. In particular, the complimentary shaped angled ends of base 34 and wedge 36 moves base 34 in the direction associated with arrow 98 and forces first end wall 50 to a position adjacent distal end 41.

The next step is seen in FIG. 20, where the installer removes the installation device by pulling upwards in the direction associated with arrow 100. Advantageously, angled members 86 help to ease removal of the installation device from the mold top assembly in the same manner as angled members 86 assisted in the installation.

Next, as seen in FIGS. 21 and 22, molten metal 102 is poured into the mold until the top of the molten metal is still below shoulder 56. In a preferred embodiment, top pouring is utilized, however it should be immediately apparent to one of ordinary skill in the art that bottom pouring may be incorporated without departing from the spirit and scope of the present invention as claimed.

Averting to FIGS. 23-28, the final step is installing lid 38. The installer locates one end of lid 38 on ledge 58, as seen in FIGS. 24 and 25. Next, lid 38 is moved in the direction associated with arrow 104 and the end of lid 38 slides along ledge 58 until the end is located proximate distal end 41. Further, the installer may use a pushing rod 106 or other similarly situated tool to help move the lid into place. Rod 106 is helpful due to the gap between mold 40 and platform 32. As specifically seen in FIGS. 27 and 28, in the full installed position, lid 38 rests on ledge 58 and abuts wedge 36. Further, the combination of base 34, wedge 36, and lid 38 provide a sealed mold top assembly that can easily and efficiently be installed within a mold by a single person while minimizing potential danger.

Accordingly, the mold top assembly is an effective, safe, inexpensive, and efficient device that achieves all the enumerated objectives of the invention, provides for eliminating difficulties encountered with prior art devices, systems, and methods, and solves problems and obtains new results in the art.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.

Having now described the features, discoveries, and principles of the invention, the manner in which the mold top assembly is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangement, parts, combinations, and methods are set forth in the appended claims.

Claims

1. An ingot mold top comprising:

a base having a pair of side walls, each side wall having a first end and a second end, each of the first ends terminating in an angled portion and the second ends connected by a first end wall;

a wedge having an end wall and a pair of side walls, the pair of side walls extending generally perpendicularly away from the end wall; and,

wherein the wedge pair of side walls each terminate in an angled portion and the base and wedge completely encompass an interior periphery of a mold.

2. The ingot mold top of claim 1 wherein the base side walls and first end wall are a single component and the wedge pair of side walls and end wall are a single component.

3. The ingot mold top of claim 1 wherein the base angled portions are complimentary shaped to the wedge side walls angled portions.

4. The ingot mold top of claim 1 wherein the base angled portions and the wedge angled portions each have an angle in a range between 5 degrees and 45 degrees.

5. The ingot mold top of claim 1 wherein the wedge end wall locates the base within the mold.

6. The ingot mold top of claim 1 wherein the base side walls and first end wall define a ledge integral to the interior periphery.

7. The ingot mold top of claim 1 wherein the base side walls and first end wall define a shoulder integral to the exterior periphery.

8. The ingot mold top of claim 1 wherein the base is taller than the wedge.

9. The ingot mold top of claim 1 further comprising a lid complimentary shaped with the base.

10. The ingot mold top of claim 6 wherein a lid slides along the ledge during installation.

11. The ingot mold top of claim 1 wherein the first end wall opposes the wedge end wall.

12. A method of installing an ingot mold top comprising the steps of:

inserting a mold top base having a pair of side walls with angled terminating portions within a mold;

locating a mold top wedge at least partially between the base and the mold; and,

forcing the wedge downwards to provide axial movement in a direction along the angled terminating portions.

13. The method of claim 12 further comprising the step of aligning the base angled terminating portions with the wedge.

14. The method of claim 12 further comprising the step of locating an installation device proximate the wedge before the step of forcing the wedge downwards to provide axial movement in a direction along the angled termination portions.

15. The method of claim 12 further comprising the step of forcing the base axially in a direction opposite the wedge by providing the downward force on the wedge.

16. The method of claim 12 further comprising the step of positioning a lid at least partially on a shoulder of the mold top base.

17. The method of claim 16 further comprising the step of sliding the lid along the shoulder to completely cover the molten material.

18. The method of claim 12 further comprising the step of positioning the base along substantially three walls of an interior periphery of the mold before the step of locating a mold top end wall at least partially between the base and the mold.

19. The method of claim 12 further comprising the step of locating the mold top wedge without standing over the mold.

20. The method of claim 12 further comprising the step of forcing the mold top wedge downwards to provide axial movement in a direction along the angled terminating portions without standing over the mold.