Shaping Fluent Material To Form Mold Patents (Class 164/15)
  • Patent number: 10347936
    Abstract: Set forth herein are garnet material compositions, e.g., lithium-stuffed garnets and lithium-stuffed garnets doped with alumina, which are suitable for use as electrolytes and catholytes in solid state battery applications. Set forth herein are lithium-stuffed garnet thin films having fine grains therein. Disclosed herein are novel and inventive methods of making and using lithium-stuffed garnets as catholytes, electrolytes and/or anolytes for all solid state lithium rechargeable batteries. Disclosed herein are novel electrochemical devices which incorporate these garnet catholytes, electrolytes and/or anolytes. Set forth herein are methods for preparing novel structures, including dense thin free standing membranes of an ionically conducting material for use as a catholyte, electrolyte, and, or, anolyte, in an electrochemical device, a battery component (positive or negative electrode materials), or a complete solid state electrochemical energy storage device.
    Type: Grant
    Filed: April 6, 2017
    Date of Patent: July 9, 2019
    Assignee: QuantumScape Corporation
    Inventors: Dong Hee Anna Choi, Niall Donnelly, Tim Holme, Will Hudson, Sriram Iyer, Oleh Karpenko, Mohit Singh, Adrian Winoto
  • Patent number: 10179362
    Abstract: A core for use in casting an internal cooling circuit within a gas turbine engine component, the core including a core body with an outer skin in which a core body additively manufacturing binder is locally eliminated. A method of manufacturing a core for casting a component, including casting a core body for at least partially forming an internal passage architecture of a component; and forming an outer skin on the core body in which a core body binder is locally eliminated.
    Type: Grant
    Filed: July 20, 2016
    Date of Patent: January 15, 2019
    Assignee: United Technologies Corporation
    Inventors: Thomas N Slavens, James T Auxier
  • Patent number: 9975175
    Abstract: A method of casting a truss structure having spaced face sheets connected by columnar structures, including forming a three-dimensional pattern (3D pattern) in the shape of the truss structure with the spaced face sheets and columnar structures, forming a mold core of the 3D pattern by surrounding the pattern with a liquid and letting the liquid harden about the 3D pattern, removing the 3D pattern from the mold core, filling the mold core with a liquid alloy to cast and directionally solidify the truss structure.
    Type: Grant
    Filed: October 11, 2013
    Date of Patent: May 22, 2018
    Assignee: General Electric Company
    Inventors: Douglas Gerard Konitzer, James Herbert Deines, Brian David Przeslawski, Xi Yang
  • Patent number: 9944015
    Abstract: A system of rapid prototyping, comprises a calculate controller, a stage, a deliver, a frame former, a filler and a forming machine. A board material was disposed on the stage by the deliver. The frame former heats up the board material to melt the board material and then forms at least a space on the board material. The filler fills a solidable liquid into the space. The deliver disposes another board material on the board material filled with solidable liquid and repeats the abovementioned steps until the plurality of spaces constitute the target article. And then the forming machine heats up the board materials to melt the board materials, meanwhile, the solidable liquid is solidified to form the target article. Wherein the calculate controller connects and operates the deliver, the frame former, the filler and the forming machine.
    Type: Grant
    Filed: December 19, 2014
    Date of Patent: April 17, 2018
    Assignees: Inventec Appliances (Pudding) Corporation, Inventec Appliances Corp., Inventec Applicances (Shaghai) Co. Ltd.
    Inventors: Li Yu, Shih-Kuang Tsai
  • Patent number: 9651055
    Abstract: A slurry pump impeller which includes a front shroud and a back shroud each having an inner main face with an outer peripheral edge and a central axis, a plurality of pumping vanes extending between the inner main faces of the shrouds, the pumping vanes being disposed in spaced apart relation. Each pumping vane includes a leading edge in the region of the central axis and a trailing edge in the region of the outer peripheral edges of the shrouds with a passageway between adjacent pumping vanes. Each passageway has associated therewith a discharge guide vane, each discharge guide vane being disposed within a respective passageway and located closer to one or the other of the pumping vanes and projecting from the inner main face of at least one of the or each shrouds.
    Type: Grant
    Filed: August 19, 2013
    Date of Patent: May 16, 2017
    Assignee: Weir Minerals Australia Ltd.
    Inventors: Kevin Edward Burgess, Wen-Jie Liu, Luis Moscoso Lavagna, Garry Bruce Glaves
  • Patent number: 9517504
    Abstract: A method for forming an article includes providing a mold and casting a metal material within the mold so that a part is produced which has a first portion having a first grain pattern and a second portion having a second grain pattern different from said first grain pattern.
    Type: Grant
    Filed: September 29, 2014
    Date of Patent: December 13, 2016
    Assignee: United Technologies Corporation
    Inventor: Mark White
  • Patent number: 9474327
    Abstract: A sole structure may include a protected region at least partially defined by side walls of one or more sole structure features. The sole structure may further include indicial features formed in the protected region. The indicial features may have shapes of information-conveying indicia. A sole structure master corresponding to the sole structure may have indicial elements corresponding to the indicial features in a master indicial region corresponding to the protected region. A mold corresponding to the sole structure may have indicial elements corresponding to the indicial features in a mold indicial region corresponding to the protected region. A sole structure master modeling a sole structure may have textures formed on one or more surfaces by a laser.
    Type: Grant
    Filed: August 19, 2013
    Date of Patent: October 25, 2016
    Assignee: NIKE, Inc.
    Inventors: Dennis D. Bunnell, Michael Hughes
  • Patent number: 9422941
    Abstract: An impeller (2) for a pump is designed as a casting and includes at least one blade (4). The impeller (2), when casting, is molded by way of at least two core parts (14, 16). Partition lines (26, 28) between the at least two core parts (14, 16) are distanced to an end-edge (10) of the at least one blade. The end-edge is at a front in a flow direction (S).
    Type: Grant
    Filed: December 21, 2011
    Date of Patent: August 23, 2016
    Assignee: Grundfos Management a/s
    Inventors: Jon Ricky Nielsen, Christian A. Jørgensen
  • Patent number: 9381570
    Abstract: A preform intended for the manufacture of a metal foam having a porosity of between 62% and 85%, the preform including a set of precursors in the form of balls formed of a mixture of 12% to 25% of organic binder, 72% to 87% of sodium chloride and 1 to 3% of kalinite. The precursors have a diameter of around 1 mm to 10 mm, and preferably 4 mm, the precursors being obtained by granulating the mixture using a fluidized bed process.
    Type: Grant
    Filed: December 28, 2011
    Date of Patent: July 5, 2016
    Assignee: FILTRAUTO
    Inventor: Frederic Poggi
  • Publication number: 20150122445
    Abstract: A tooling for fabricating a foundry core, for making a circuit for cooling a blade of a turbine engine, the tooling including: a mold for injecting a paste and including imprints for a first portion and for at least one other portion of the core; a mechanism bearing against and/or engaging end portions of at least one ceramic rod that interconnects the portions of the core and that passes through the imprint for the first portion of the core; and a support mechanism in the imprint for the first portion of the core to support a substantially middle portion of the or each rod.
    Type: Application
    Filed: May 7, 2013
    Publication date: May 7, 2015
    Applicant: SNECMA
    Inventors: Franck Edmond Maurice Truelle, Christian Bariaud, Philippe Bouthemy, Patrick Pourfilet, Jean-Louis Martial Verger, Alain Grandin, Daniel Quach
  • Publication number: 20150122446
    Abstract: An investment casting method for a cast ceramic core (110), including an airfoil portion (116) shaped to define an inner surface (56) of an airfoil (52) of a vane segment (50) and an integral shell portion (122) having a backside-shaping surface (120) shaped to define a backside surface (68) of a shroud (62) of the vane segment. The backside-shaping surface has a higher elevation (132) and a lower elevation (134). The higher elevation is set apart from a nearest point (138) on the airfoil portion by the lower elevation. The airfoil portion and the shell portion are cast as a monolithic body during a single casting pour.
    Type: Application
    Filed: November 7, 2013
    Publication date: May 7, 2015
    Inventors: Ching-Pang Lee, Gerald L. Hillier, Jae Y. Um, Gm Salam Azad
  • Publication number: 20150118057
    Abstract: A multi-wall gas turbine airfoil (192) and method of forming same using a casting core (150) having a monolithic body configured to define a pressure side wall (12), a suction side wall (14), and a third wall (16). The casting core is formed around a fugitive insert (96) during a single pour casting process.
    Type: Application
    Filed: October 31, 2013
    Publication date: April 30, 2015
    Inventors: Ching-Pang Lee, Gary B. Merrill
  • Publication number: 20150096713
    Abstract: A method of fabricating a die cast article is disclosed and includes forming an insert with an additive manufacturing process to define a cavity for generating desired part geometry. The insert is then mounted within a mold tool, material is injected into the cavity to fill the cavity and form a cast article.
    Type: Application
    Filed: September 30, 2014
    Publication date: April 9, 2015
    Inventor: John Joseph Marcin
  • Publication number: 20150083356
    Abstract: A method for producing a hollow metal part by casting, wherein a destructible core (20) is provided including a body (22) made of aggregate, and a shell (40) which surrounds the body and adheres thereto; the core (20) is positioned inside a mold (50); metal is melted and the liquid metal is injected, generally under pressure, into the mold (50), surrounding the core (20) embodying an interior space of the part; after solidification of the part, the body is disaggregated and it is removed through removal openings provided in the shell and the part; and said shell is destroyed and removed through removal openings provided in the part.
    Type: Application
    Filed: April 11, 2013
    Publication date: March 26, 2015
    Inventors: Yves Longa, Jean De Ruffray
  • Publication number: 20150075745
    Abstract: A casting mold (260) comprises a shell (262) extending from a lower end (264) to an upper end (266) and having: an interior space (280) for casting metal; and an opening (268) for receiving metal to be cast. A plurality of thermocouples (900) are vertically-spaced from each other on the shell.
    Type: Application
    Filed: September 16, 2014
    Publication date: March 19, 2015
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: John J. Marcin, JR., Steven J. Bullied, Dilip M. Shah, Alan D. Cetel, Emily K. Kreek
  • Publication number: 20150000855
    Abstract: A holder block system suitable for producing metal castings. The holder block system includes a holder block primary mold that has one or more cavities that accept a sub-mold that incorporates the features of the part to be cast, wherein the sub-mold can be produced utilizing 3-D printing. Methods of preparing holder block patterns and cast objects are with the holder block system disclosed.
    Type: Application
    Filed: June 25, 2014
    Publication date: January 1, 2015
    Inventor: David SCHWAM
  • Patent number: 8910700
    Abstract: A mold in which a fine uneven structure is formed on the surface by anodizing a surface of an aluminum base material having a purity of equal to or more than 99.5% by mass, wherein a 60-degree gloss of the surface on the side where a fine uneven structure is formed is equal to or more than 750%.
    Type: Grant
    Filed: April 22, 2011
    Date of Patent: December 16, 2014
    Assignee: Mitsubishi Rayon Co., Ltd.
    Inventors: Katsuhiro Kojima, Tadashi Nakamura
  • Publication number: 20140326425
    Abstract: A method for machining a molding core from an aggregate material block, comprising: positioning the aggregate material block on a rotative base member; and rotating the base member and simultaneously machining the aggregate material block into the molding core. There is also provided a method for forming a casting mold including a molding core and a foundry casting core comprising: a core body having at least one convex shaped core print. The method comprises: providing at least one molding element having a mold cavity with at least one core-print pocket defined in a top side of the molding element; forming the molding core having at least one convex shaped core print; and inserting the molding core in the mold cavity with the at least one convex shaped core print engaged in a respective one of the at least one core-print pocket.
    Type: Application
    Filed: July 17, 2014
    Publication date: November 6, 2014
    Inventors: Philippe Dubuc, Marc Savard
  • Publication number: 20140262107
    Abstract: A refractory mold is disclosed. The refractory mold includes a fugitive pattern assembly comprising a hollow sprue that comprises a sprue wall disposed about a longitudinal axis; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material; and a refractory mold formed on and having a mold cavity defined by an outer surface of the fugitive pattern assembly.
    Type: Application
    Filed: March 14, 2013
    Publication date: September 18, 2014
    Applicant: HITCHINER MANUFACTURING CO., INC.
    Inventors: Michael R. Hanrahan, Skip L. Patteuw
  • Publication number: 20140277382
    Abstract: A method for manufacturing a stent includes forming a stent blank from a first material, the stent blank comprising a plurality of struts and a plurality of crowns, each crown connecting at least two struts, and a plurality of slots in at least some of the plurality of struts and/or the plurality of crowns, depositing a second material over outer surfaces of the struts and the crowns and in the slots to encase the stent blank in the second material, creating at least one opening through the second material, and removing the first material to form a stent comprising the second material, the stent having a continuous lumen from one end of the stent to the other end of the stent, the continuous lumen being partitioned in portions corresponding to the locations of the slots in the stent blank. The lumen may then be filled with a therapeutic substance.
    Type: Application
    Filed: March 13, 2014
    Publication date: September 18, 2014
    Applicant: Medtronic Vascular, Inc.
    Inventors: Mark Dolan, Stuart Kari, Christopher W. Storment
  • Publication number: 20140251567
    Abstract: A method of manufacturing a golf club head can include: creating a mold of the golf club head; forming two or more portions of a model of the golf club head using the mold, each of the two or more portions of the model include a part of a body of the golf club head and at least one first alignment mechanism; assembling the model of the golf club head using the at least one first alignment mechanism of each of the two or more portions of the model to align the two or more portions of the model, the model comprises the body of the golf club head and a joined alignment mechanism, the joint alignment mechanism comprises the at least one first alignment mechanism of each of the two or more portions of the model; using the model of the golf club head to create a cast for the golf club head; removing the model of the golf club head from the cast; and using the cast of the golf club head to create the golf club head with the joined alignment mechanism; and removing the joined alignment mechanism from the golf club he
    Type: Application
    Filed: September 10, 2013
    Publication date: September 11, 2014
    Applicant: Karsten Manufacturing Corporation
    Inventors: Rick Solesbee, Rick MacMillan
  • Publication number: 20140190647
    Abstract: An investment casting method involves producing a casting shell by applying a hardenable refractory material to a sacrificial pattern. The casting shell having a plurality of phosphate bonds in the hardenable refractory material, which provide increased structural integrity during casting and improved frangibility during shell removal. The casting shell may also have a plurality of gaseous pockets suspended in the refractory material, which do not degrade the structural integrity during casting and provide improved frangibility during shell removal.
    Type: Application
    Filed: January 7, 2013
    Publication date: July 10, 2014
    Applicant: WiSys Technology Foundation, Inc.
    Inventors: Daniel Scott McGuire, Eric Ernst Hellstrom
  • Publication number: 20140190649
    Abstract: A method for protecting a turbomachine from corrosion may include creating a first sand mold in a drag of a casting flask, coupling a cope of the casting flask to the drag, removing the runner pin and the at least one riser pin from the cope to expose a runner and at least one riser, respectively, and pouring a molten first material in the runner to cast a first component of the turbomachine. The method may further include removing the first sand mold, creating a second sand mold utilizing the first component in the drag, coupling the cope to the drag, removing the runner pin and the at least one riser pin from the cope to expose a runner and at least one riser, respectively, and pouring a molten second material in the runner to cast a second component of the turbomachine integral with the first component.
    Type: Application
    Filed: December 9, 2013
    Publication date: July 10, 2014
    Inventor: Byron L. Mohr
  • Patent number: 8770259
    Abstract: An apparatus for cast-product production line includes a kneader for kneading casting sand for making mold; a mold maker for making a sand casting mold from the casting sand for making mold, the sand casting mold being provided with a molding cavity for forming a singular cast product or plural products; a molten-metal pourer for pouring molten metal into said molding cavity of the sand casting mold; and a mold disassembler for disassembling the sand casting mold having undergone molten-metal pouring. Upon disassembling the sand casting mold by the mold disassembler, the sand casting mold is disassembled in such a state that the cast product is supported by means of a cast-product supporter element.
    Type: Grant
    Filed: January 10, 2013
    Date of Patent: July 8, 2014
    Assignee: Aisin Takaoka Co., Ltd.
    Inventors: Hiroaki Kato, Shinichi Tyomatsuken
  • Patent number: 8770260
    Abstract: The process for investment casting of complex shapes has historically had 6 basic steps in it. Depending upon the path taken, these discrete steps have been reduced to either 5 steps, or to 2 steps, discarding the unwanted steps. Instead of having to generate the shape of each sacrificial pattern, the process generates either (A) a male tree containing a plurality of sacrificial patterns, already on their runners, onto which a mold shell can be formed, or, (B) a female shell, made of a refractory material, and forming internally the outside surfaces of the plurality of patterns and runners. This process removes both capital expenditure for tooling and process time by up to 90%. By removing several lengthy, time-dependant steps from the process the part cost and lead time are reduced.
    Type: Grant
    Filed: June 24, 2009
    Date of Patent: July 8, 2014
    Assignee: Borg Warner Inc.
    Inventor: Stephen I. Roby
  • Publication number: 20140178644
    Abstract: A structure and method for a post plate of a die set that can be used to emboss a plurality of contact pads of a flexible printed circuit during the formation of a printer printhead. In one embodiment, a plurality of post plate posts can be formed, where each post plate post has a flat upper surface, generally straight sides, and a sharp corner where the flat upper surface and the generally straight sides intersect. Each post can be polished using, for example, a pad and an abrasive polishing compound or an electrochemical polishing process, to round the sharp corners to form a post having a rounded contour. In another embodiment, a plurality of post plate posts each having a rounded contour can be formed using a molding process.
    Type: Application
    Filed: December 20, 2012
    Publication date: June 26, 2014
    Applicant: XEROX CORPORATION
    Inventors: Peter J. Nystrom, Bryan R. Dolan, Gary D. Redding
  • Publication number: 20140102656
    Abstract: A casting core assembly includes a metallic core and a ceramic core. A protuberant portion of a metallic core is received in a compartment of the ceramic core.
    Type: Application
    Filed: October 12, 2012
    Publication date: April 17, 2014
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Tracy A Propheter-Hinckley, Eric A Hansen
  • Patent number: 8689854
    Abstract: A method of fabricating a decomposition conduit with an in-line static mixer, the method including molding a decomposition conduit housing around a sand core by inserting molding material into a cavity between a decomposition conduit housing mold and the sand core, where the sand core includes a static mixer and, where the act of molding the decomposition conduit housing is operative to mount the static mixer to the molded decomposition conduit housing.
    Type: Grant
    Filed: February 22, 2011
    Date of Patent: April 8, 2014
    Assignee: Deere & Company
    Inventor: David S. Young
  • Publication number: 20140060767
    Abstract: The disclosure relates generally to mold compositions comprising calcium aluminate and calcium titanate. The disclosure also relates to methods of molding and the articles so molded using the mold compositions. More specifically, the disclosure relates to calcium aluminate/calcium titanate mold compositions and methods for casting titanium-containing articles, and the titanium-containing articles so molded.
    Type: Application
    Filed: August 29, 2012
    Publication date: March 6, 2014
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick BEWLAY, Joan MCKIEVER, Brian Michael ELLIS, Nicholas Vincent MCLASKY
  • Patent number: 8656981
    Abstract: A root portion 7a of a sipe blade 7 that protrudes from a surface 12a of a plaster casting mold 12 is coated with a coating layer 10 of an easily collapsible refractory material. A string-shaped exhaust hole forming member 11 of a casting refractory material is attached to the sipe blade 7 so as to be in contact with the coating layer 10. Molten metal M is poured onto the surface 12a of the plaster casting mold 12 in this state so as to cast a mold with the shape of the surface 12a transferred thereon and with the root portion 7a of the sipe blade 7 cast therein. The coating layer 10 is thereafter removed to form a slit around the root portion 7a of the sipe blade 7. The exhaust hole forming member 11 is also removed to form an exhaust hole communicating with the outside of the piece. Therefore, the slit and the exhaust hole communicate with each other. In this way, a mold provided with an exhaust mechanism can be simply produced.
    Type: Grant
    Filed: July 20, 2011
    Date of Patent: February 25, 2014
    Assignee: The Yokohama Rubber Co., Ltd.
    Inventor: Kenji Enokido
  • Patent number: 8657948
    Abstract: Methods of reducing the permeability of a subterranean formation to aqueous-based fluids using a water-soluble relative permeability modifier that comprises a hydrophobically modified polymer, wherein the hydrophobically modified polymer is a reaction product of: a hydrophilic polymer that comprises a polymer selected from the group consisting of a polyvinylamine, a poly(vinylamine/vinyl alcohol), and an alkyl acrylate polymer; and, a hydrophobic compound comprising at least one alkyl chain having a carbon chain length between about 4 and about 22 carbons. The water-soluble relative permeability modifier may be placed within a subterranean drilling operation such that the water-soluble relative permeability modifier attaches onto surfaces within the subterranean formation to effect permeability of aqueous fluids.
    Type: Grant
    Filed: August 26, 2011
    Date of Patent: February 25, 2014
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Charles Landis, Thomas Anderson, Eric Frantz, Don Dell, Matthew Hilfiger
  • Publication number: 20140023739
    Abstract: A vulcanizing mold manufacturing method, and a tire vulcanizing mold are disclosed. Tubular bodies each formed by oppositely arranging the inner peripheral surfaces of both end portions of a plate-shaped body are each arranged so that the gap between both opposite end portions thereof is narrowed and that the tips of both end portions come in contact with the surface of the plaster mold, by inserting and fitting both opposite end portions into a fitting portion of a plate-shaped metal fitting protruding from the surface of the plaster mold. Molten metal is poured over the surface of the plaster mold to embed the tubular body in a mold while exposing the tips of both opposite end portions at the tire molding surface of the mold. The metal fitting is removed from the mold, so that a mold having a small gap between both opposite end portions is manufactured.
    Type: Application
    Filed: April 10, 2012
    Publication date: January 23, 2014
    Applicant: THE YOKOHAMA RUBBER CO., LTD.
    Inventor: Noboru Takada
  • Publication number: 20140000831
    Abstract: A method for casting a diafram having inner and outer rings with preformed vanes circumferentially spaced therebetween is disclosed. A digital representation of a sand core is created. Based on this digital representation, a sand core is produced by bonding together successive layers of sand with droplets of a binder material using a binder printhead having nozzles for supplying jets of binder material droplets. A plurality of vanes is inserted into the cavities of the sand core. The sand core is then placed into a casting mold and filled with liquid metal. After the liquid metal has solidified and cooled, the sand core and any remaining sand is removed from the cast diafram.
    Type: Application
    Filed: August 13, 2012
    Publication date: January 2, 2014
    Applicant: ELLIOTT COMPANY
    Inventor: Michael Arthen Mindock, III
  • Publication number: 20130309098
    Abstract: A turbocompressor rotor for a turbocompressor for compressing process gas has a rotor body which makes contact with the process gas and which is produced entirely from a stainless steel material including 0.3 to 1.2% carbon and 12 to 19% chromium, wherein the steel material includes the alloy X39CrMo17-1.9. A process for producing such a turbocompressor rotor by casting includes manufacturing a casting model corresponding to the geometry of the rotor body by rapid technology and producing a casting mold using the casting model, or manufacturing a casting mold corresponding to the negative geometry of the rotor body by rapid technology, introducing the liquid steel material into the casting mold to form a cast workpiece as the rotor body, and finishing the turbocompressor rotor with the rotor body.
    Type: Application
    Filed: February 1, 2012
    Publication date: November 21, 2013
    Inventor: Ralf Bode
  • Publication number: 20130272857
    Abstract: A method produces a casting, in particular a housing of a turbocharger. Wherein at least one mold part for forming the casting has a respective parting plane which is arranged at a predetermined angle with respect to the longitudinal axis of the casting, and wherein at least one core element is provided.
    Type: Application
    Filed: September 27, 2011
    Publication date: October 17, 2013
    Applicant: CONTINENTAL AUTOMOTIVE GMBH
    Inventors: Ralf Böning, Stefan Krauss, Stefan Nowack, Friedheim Reitz, Burkhard Strieder
  • Patent number: 8555950
    Abstract: Heat flow and mechanical strength of an engine component are improved by an organic-like casting core. Hardened granules are formed of a core material having a three-dimensional solid shape. A secondary binder is applied to the hardened granules. A multiplicity of the granules are agglomerated in a master mold in a shape of a water jacket of the engine component, and the secondary binder is hardened to form an organic-like core having a continuous web structure. A plurality of other cores are formed in respective master molds to define respective surfaces of the engine component. The organic-like core is assembled with the other cores to form a casting mold. The engine component is cast by flowing molten metal into the casting mold, thereby forming a continuous parent metal bridging the water jacket having a predetermined porosity. The core material is removed from the engine component after casting.
    Type: Grant
    Filed: October 25, 2011
    Date of Patent: October 15, 2013
    Assignee: Ford Global Technologies, LLC
    Inventor: Charles Fabros
  • Publication number: 20130264022
    Abstract: The invention relates to a method for producing a cylinder (10, 110) for a two-stroke engine, comprising the following steps: producing a casting core (30, 130), wherein a central core slide (31, 131) for the cylinder chamber (11, 111) and at least one salt core (33, 133) for an overflow channel (18, 19; 118, 119) are produced and the at least one salt core (33, 133) is connected to the central core slide (31, 131), inserting the casting core (30, 130) into a casting mold, casting the cylinder (10, 110) in a die-casting process, removing the central core slide (31, 131) from the cylinder (10, 110), wherein the at least one salt core (33, 133) is separated from the central core slide (31, 131), and flushing the at least one salt core (33, 133) out of the cylinder (10, 110). The invention further relates to a casting core (30, 130) for such a method.
    Type: Application
    Filed: July 5, 2011
    Publication date: October 10, 2013
    Applicant: MAHLE INTERNATIONAL GMBH
    Inventors: Guenther Mayer, Juergen Schwarz, Torsten Eil
  • Publication number: 20130264021
    Abstract: A method for machining a sand molding element, comprising: inserting at least one hollow center body having an internal cavity in a predetermined position in a casting flask; filling the internal cavity of the hollow center body with unbonded sand; filling the casting flask with bonded sand to obtain a sand block; machining a mold cavity in the sand block; and emptying the internal cavity from the unbounded sand. There is also provided a method for machining a molding core from a sand block, comprising: providing a core base member having a concave upper surface; forming a sand block on the core base member with a lower surface of the sand block resting on the concave upper surface; and machining the molding core into the sand block, the molding core having a convex lower surface complementary to the concave upper surface of the core base member.
    Type: Application
    Filed: October 11, 2011
    Publication date: October 10, 2013
    Applicant: NOPATECH INC.
    Inventors: Philippe Dubuc, Marc Savard
  • Publication number: 20130220570
    Abstract: A method comprising the use of additive manufacturing techniques for creating molds and pattern parts for subsequent use in the casting of die components and die shoes for use in die stamping processes.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: Ford Motor Company
    Inventors: Harold P. Sears, James Todd Kloeb, Evangelos Liasi, Larry Edward Ellis, Ronald Hasenbusch, John Philips, Alan Lawrence Jacobson
  • Publication number: 20130220571
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.
    Type: Application
    Filed: March 13, 2013
    Publication date: August 29, 2013
    Applicant: Howment Corporation
    Inventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
  • Publication number: 20130200541
    Abstract: The invention relates to a stamper in which an oxide film having a fine concave-convex structure made up of a plurality of fine pores having an aspect ratio represented by [the depth of the fine pores/the average interval between the fine pores] of 1 to 4 is formed on the surface of an aluminum base material which is made of aluminum having a content of Ti of 150 ppm to 500 ppm, a content of B or C of 1 ppm to 50 ppm and a purity of 99.9% or more. According to the invention, it is possible to provide a low-cost stamper in which the emergence of a pattern derived from the traces of crystal grains on the surface of the oxide film is suppressed, an article having a favorable appearance, which is manufactured using the above stamper, and a method for manufacturing the above.
    Type: Application
    Filed: September 28, 2011
    Publication date: August 8, 2013
    Applicant: Mitsubishi Rayon Co., Ltd.
    Inventors: Hiroaki Kita, Kota Shirai, Katsuhiro Kojima
  • Publication number: 20130196014
    Abstract: A root portion 7a of a sipe blade 7 that protrudes from a surface 12a of a plaster casting mold 12 is coated with a coating layer 10 of an easily collapsible refractory material. A string-shaped exhaust hole forming member 11 of a casting refractory material is attached to the sipe blade 7 so as to be in contact with the coating layer 10. Molten metal M is poured onto the surface 12a of the plaster casting mold 12 in this state so as to cast a mold with the shape of the surface 12a transferred thereon and with the root portion 7a of the sipe blade 7 cast therein. The coating layer 10 is thereafter removed to form a slit around the root portion 7a of the sipe blade 7. The exhaust hole forming member 11 is also removed to form an exhaust hole communicating with the outside of the piece. Therefore, the slit and the exhaust hole communicate with each other. In this way, a mold provided with an exhaust mechanism can be simply produced.
    Type: Application
    Filed: July 20, 2011
    Publication date: August 1, 2013
    Inventor: Kenji Enokido
  • Publication number: 20130126118
    Abstract: An apparatus for cast-product production line includes a kneader for kneading casting sand for making mold; a mold maker for making a sand casting mold from the casting sand for making mold, the sand casting mold being provided with a molding cavity for forming a singular cast product or plural products; a molten-metal pourer for pouring molten metal into said molding cavity of the sand casting mold; and a mold disassembler for disassembling the sand casting mold having undergone molten-metal pouring. Upon disassembling the sand casting mold by the mold disassembler, the sand casting mold is disassembled in such a state that the cast product is supported by means of a cast-product supporter element.
    Type: Application
    Filed: January 10, 2013
    Publication date: May 23, 2013
    Inventors: Hiroaki KATO, Shinichi Tyomatsuken
  • Publication number: 20130098574
    Abstract: Heat flow and mechanical strength of an engine component are improved by an organic-like casting core. Hardened granules are formed of a core material having a three-dimensional solid shape. A secondary binder is applied to the hardened granules. A multiplicity of the granules are agglomerated in a master mold in a shape of a water jacket of the engine component, and the secondary binder is hardened to form an organic-like core having a continuous web structure. A plurality of other cores are formed in respective master molds to define respective surfaces of the engine component. The organic-like core is assembled with the other cores to form a casting mold. The engine component is cast by flowing molten metal into the casting mold, thereby forming a continuous parent metal bridging the water jacket having a predetermined porosity. The core material is removed from the engine component after casting.
    Type: Application
    Filed: October 25, 2011
    Publication date: April 25, 2013
    Applicant: FORD MOTOR COMPANY
    Inventor: Charles Fabros
  • Publication number: 20130081774
    Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.
    Type: Application
    Filed: September 19, 2012
    Publication date: April 4, 2013
    Inventors: Boyd Mueller, Darren Rogers, Timothy J. Molamphy
  • Publication number: 20130082021
    Abstract: A method for casting a thrower for a railcar coupler includes creating a mold box that is vertically parted in halves, each half defining a side of a thrower cavity and that includes at least a portion of a sprue at a location above the thrower cavity, the thrower cavity also being oriented vertically; pouring molten metal into the mold box through the sprue and into the thrower cavity while the mold is oriented vertically; and shaking out the mold box to release the thrower after the thrower has cooled. Creating the mold box may be executed through a cold shell process. The halves of the mold box may include reflective images of the sides of two thrower cavities and an ingate connected between the sprue and one of the two thrower cavities.
    Type: Application
    Filed: September 30, 2011
    Publication date: April 4, 2013
    Applicant: Bedloe Industries LLC
    Inventors: F. Andrew Nibouar, Jerry R. Smerecky, Kelly S. Day, Noland Brooks
  • Publication number: 20130042989
    Abstract: In order to produce molds or cores for foundry purposes from a mixture (M) of molding compound or sand and at least one binder, the mixture is mixed (M) by a mixing device (20) and is fed with the aid of a feeding system (30) to at least one sand storage unit (40) of a core or mold production device (50), wherein the mixture-free region (21) of the mixing device (20), at least at times, and/or the feeding system (30) located between the mixing device (20) and the core or mould production device (50), and/or the sand storage unit (40) downstream of the feeding system (30) and upstream of the core or mould production device (50), is moistened or kept moist by means of a liquid (71). The liquid (71) used for moistening is atomised by at least one ultrasonic atomiser (60) to form a suspended aerosol and is fed to the mixing device (20) and/or the feeding system (30) and/or the sand storage unit (40) via pipes (81, 82, 83).
    Type: Application
    Filed: April 8, 2011
    Publication date: February 21, 2013
    Applicant: LAEMPE & MOSSNER GMBH
    Inventors: Rudolf Wintgens, Martin Faller
  • Publication number: 20130025810
    Abstract: A rapid manufacturing method includes forming tooling in a rapid manufacturing process. The tooling is coated with a conductive material.
    Type: Application
    Filed: July 28, 2011
    Publication date: January 31, 2013
    Inventors: Lea Kennard Castle, John Joseph Marcin, Steven J. Bullied, Mario P. Bochiecchio, Kevin W. Chittenden, Carl R. Verner
  • Publication number: 20130000482
    Abstract: An aluminum-based diesel engine piston and a method of making the piston. The method involves casting the piston with complex geometries, including undercut or reentrant features. The casting uses an aggregate disposable mold that can be removed from the as-cast part. In one form, the complex geometry includes an undercut combustion bowl formed in the piston dome, while in another, it may include an internal cooling passage. The undercut bowl and internal passages may be produced using the aggregate disposable mold.
    Type: Application
    Filed: September 11, 2012
    Publication date: January 3, 2013
    Applicant: GM Global Technology Operations LLC
    Inventors: Joseph C. Kopchick, Mark A. Osborne, Richard D. Ricchi
  • Publication number: 20120292281
    Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.
    Type: Application
    Filed: May 20, 2011
    Publication date: November 22, 2012
    Inventors: F. Andrew Nibouar, Jerry R. Smerecky, Kelly Day, Vaughn Makary, Nick Salamasick