Means Applying Vacuum Or Suction Directly To Molten Casting Material Patents (Class 164/254)
  • Patent number: 9802349
    Abstract: A method includes placing a package structure into a mold chase, with top surfaces of device dies in the package structure contacting a release film in the mold chase. A molding compound is injected into an inner space of the mold chase through an injection port, with the injection port on a side of the mold chase. During the injection of the molding compound, a venting step is performed through a first venting port and a second venting port of the mold chase. The first venting port has a first flow rate, and the second port has a second flow rate different from the first flow rate.
    Type: Grant
    Filed: June 12, 2014
    Date of Patent: October 31, 2017
    Assignee: Taiwan Semiconductor Manufacturing Company, Ltd.
    Inventors: Bor-Ping Jang, Yeong-Jyh Lin, Chien Ling Hwang, Chung-Shi Liu, Meng-Tse Chen, Ming-Da Cheng, Chen-Hua Yu
  • Publication number: 20150144292
    Abstract: Disclosed is an apparatus comprising at least one gate and a vessel, the gate being configured to move between a first position to restrict entry into an ejection path of the vessel and contain a material in a meltable form within the vessel during melting of the material, and a second position to allow movement of the material in a molten form through the ejection path. The gate can move linearly or rotate between its first and second positions, for example. The apparatus is configured to melt the material and the at least one gate is configured to allow the apparatus to be maintained under vacuum during the melting of the material. Melting can be performed using an induction source. The apparatus may also include a mold configured to receive molten material and for molding a molded part, such as a bulk amorphous alloy part.
    Type: Application
    Filed: October 14, 2011
    Publication date: May 28, 2015
    Applicant: Crucible Intellectual Property, LLC
    Inventors: Quoc Tran Pham, Michael Deming, Theodore A. Waniuk, Sean O'Keeffe
  • Publication number: 20150107796
    Abstract: A wear ring for a piston of a die-casting apparatus comprises an annular body having a gap extending therethrough. The gap is configured to define at least two circumferentially offset pairs of circumferentially spaced apart facing surfaces. The facing surfaces of each pair are angled and configured to contact each other in a flush manner when the wear ring is circumferentially compressed.
    Type: Application
    Filed: October 17, 2014
    Publication date: April 23, 2015
    Inventor: Paul Henry Robbins
  • Publication number: 20150013931
    Abstract: A molding device for vacuum casting a metal ingot is provided. The mold includes a mold cavity defined by an ingot mold, a core and a bottom. The mold is arranged inside a vacuum-cast enclosure and includes a source of introducing molten metal at the upper portion thereof. A distribution device for receiving and distributing molten metal, which is suitable for receiving the molten steel introduced into the vacuum-cast enclosure and for redistributing the molten metal in the mold cavity, is arranged at the upper portion of the mold cavity. The molten metal is introduced into the enclosure so as to form a first jet of molten steel under a vacuum, in order to pour the molten metal over the distribution device and to form at least one second jet of molten steel under a vacuum, which originates with the distribution device and terminates in the mold cavity so as to fill the mold cavity with molten metal.
    Type: Application
    Filed: September 29, 2014
    Publication date: January 15, 2015
    Inventors: Thierry FAUDAN, Jean-Luc DABIN, Gilbert LACAGNE, Maxime LEROY, Bruno SAVALLI, Franck BRACONNIER
  • 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: 8875776
    Abstract: A method for producing a metal ingot using a mold which includes a mold cavity defined by an ingot mold, a core and a bottom arranged inside a vacuum-cast enclosure including a portion for introducing molten metal at the upper portion thereof. A portion for receiving and distributing molten metal, which is suitable for receiving the molten steel introduced into the vacuum-cast enclosure and for redistributing the molten metal in the mold cavity, is arranged at the upper portion of the mold cavity. The molten metal is introduced into the enclosure to form a first jet of molten steel under a vacuum, to pour the molten metal over the portion and to form at least one second jet of molten steel under a vacuum, which originates with the portion and terminates in the mold cavity to fill the mold cavity with molten metal.
    Type: Grant
    Filed: October 21, 2009
    Date of Patent: November 4, 2014
    Assignee: Arcelormittal Investigación Y Desarrollo, S.L.
    Inventors: Thierry Faudan, Jean-Luc Dabin, Gilbert Lacagne, Maxime Leroy, Bruno Savalli, Franck Braconnier
  • Publication number: 20140284019
    Abstract: Disclosed is an injection molding system including a plunger rod and a melt zone that are provided in-line and on a horizontal axis. The plunger rod is moved in a horizontal direction through the melt zone to move molten material into a mold. The melt zone can have a vessel that is configured to receive the plunger therethrough. A transfer sleeve provided between the vessel and the mold and/or an inlet into a mold can also be horizontally in line with the plunger. The injection molding system can perform the melting and molding processes under a vacuum.
    Type: Application
    Filed: September 30, 2011
    Publication date: September 25, 2014
    Inventors: John Kang, Sean Timothy O'Keeffe, Tran Quoc Pham, Michael Blaine Deming, Theodore Andrew Waniuk
  • Publication number: 20140158317
    Abstract: Metal alloy injection molding techniques are described. In one or more implementations, these techniques may also include adjustment of injection pressure, configuration of runners, and/or use of vacuum pressure, and so on to encourage flow of the metal alloy through a mold. Techniques are also described that utilize protrusions to counteract thermal expansion and subsequent contraction of the metal alloy upon cooling. Further, techniques are described in which a radius of edges of a feature is configured to encourage flow and reduce voids. A variety of other techniques are also described herein.
    Type: Application
    Filed: December 11, 2012
    Publication date: June 12, 2014
    Applicant: MICROSOFT CORPORATION
    Inventors: Paul C. Bornemann, Raj N. Master, Michael Joseph Lane, Seah Sun Too
  • Patent number: 8286690
    Abstract: A casting method and apparatus are provided capable of producing high-quality castings having extremely few defects attributable to entrainment of gas, oxide film and the like both economically and while conserving energy. The invention relates to a high-vacuum-suction casting apparatus for producing cast products by raising up molten metal and introducing the molten metal into a die above, having a holding furnace for retaining the molten metal, a die arranged above the holding furnace, a feeding tube for supplying the molten metal from the holding furnace to the die cavity, and a movable sealing member capable of opening and closing a space between the gate provided in a bottom of the die and the outlet of the feeding tube.
    Type: Grant
    Filed: August 31, 2009
    Date of Patent: October 16, 2012
    Assignee: IE Solution Corporation
    Inventor: Itsuo Ohnaka
  • Publication number: 20120211193
    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: Application
    Filed: February 18, 2011
    Publication date: August 23, 2012
    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: 20120048498
    Abstract: A reduced size vacuum die-casting machine wherein an amount of powder release agent which is fed to a mold cavity each time is stable and loss of velocity of the air flow for sucking out the powder release agent is difficult, the apparatus provided with a powder control valve which has a powder release agent passage through which a powder release agent passes and which moves back and forth inside of a sleeve to switch between a state communicating a discharge hole with a molten metal holding chamber and a state communicating a discharge hole with a powder release agent passage, the powder release agent passage of the powder control valve formed inside of the powder control valve, the inlet and outlet of the powder release agent passage being formed at the outer surface of the powder control valve.
    Type: Application
    Filed: July 6, 2011
    Publication date: March 1, 2012
    Applicant: DENSO CORPORATION
    Inventors: Kyohei INABA, Kenji YAMAZAKI, Minoru YAMAMOTO, Akihito MIZUNO
  • Patent number: 8104528
    Abstract: A vacuum die casting method according to the present invention solves the problems relating to seal performance, differential pressure, and the stability of the degree of vacuum. The method carries out the casting with a casting cavity evacuated. In the method, a molten metal is poured from a molten metal inlet of a plunger sleeve, followed by forming a vacuum chamber surrounding the inlet and an open end of the plunger sleeve located on the opposite side of the die, and an evacuation of the vacuum chamber and the cavity starts before starting an operation of a plunger tip. When the evacuation starts, the plunger tip is positioned between the open end of the plunger sleeve and the inlet so that the vacuum chamber is communicated to the inside of the plunger sleeve through the inlet.
    Type: Grant
    Filed: October 11, 2007
    Date of Patent: January 31, 2012
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Shoichi Tsuchiya, Norihiro Amano
  • Publication number: 20110094700
    Abstract: A method and system of forming a micro-wire including heating metal feedstock to a liquid state within a glass tube, wherein the metal feedstock includes an iron based glass forming alloy comprising one or more of nickel and cobalt present in the range of 7 atomic percent to 50 atomic percent and one or more of boron, carbon, silicon, phosphorous and nitrogen present in the range of 1 to 35 atomic percent. Negative pressure may be provided to the interior the glass tube and the glass tube containing the metal feedstock may be drawn down. The metal feedstock in the glass tube may be cooled at a rate sufficient to form a wire exhibiting crystalline microstructures present in the range of 2 to 90 percent by volume in a glass matrix.
    Type: Application
    Filed: October 22, 2010
    Publication date: April 28, 2011
    Applicant: THE NANOSTEEL COMPANY, INC.
    Inventors: Daniel James BRANAGAN, Alla V. SERGUEEVA, Jikou ZHOU, James N. MILLOWAY
  • Publication number: 20090321036
    Abstract: A casting method and apparatus are provided capable of producing high-quality castings having extremely few defects attributable to entrainment of gas, oxide film and the like both economically and while conserving energy. Namely, a sealing plate having a seal, an opening and a pressure reduction vent is arranged between a gate of a die cavity and a feeding tube, and the die cavity is depressurized by sealing the gate. Next, the inside of the feeding tube is depressurized through the pressure reduction vent provided in the lower surface of the sealing plate to suck a molten metal, the opening of the sealing plate is moved to between the gate and the feeding tube when the molten metal has entered the pressure reduction vent, and the molten metal is filled into the die cavity due to the pressure difference between the die cavity and the molten metal in the feeding tube. A consumable seal made of a material similar to the molten metal can also be used for the gate seal.
    Type: Application
    Filed: August 31, 2009
    Publication date: December 31, 2009
    Inventor: Itsuo Ohnaka
  • Publication number: 20090194246
    Abstract: A vacuum die casting method according to the present invention solves the problems relating to seal performance, differential pressure, and the stability of the degree of vacuum. The method carries out the casting with a casting cavity evacuated. In the method, a molten metal is poured from a molten metal inlet of a plunger sleeve, followed by forming a vacuum chamber surrounding the inlet and an open end of the plunger sleeve located on the opposite side of the die, and an evacuation of the vacuum chamber and the cavity starts before starting an operation of a plunger tip. When the evacuation starts, the plunger tip is positioned between the open end of the plunger sleeve and the inlet so that the vacuum chamber is communicated to the inside of the plunger sleeve through the inlet.
    Type: Application
    Filed: October 11, 2007
    Publication date: August 6, 2009
    Inventors: Shoichi Tsuchiya, Norihiro Amano
  • Patent number: 7275583
    Abstract: An apparatus for processing molten material into a desired shape comprises a die or mold forming a cavity to receive molten material and to allow its solidification within the cavity. A source of vacuum is connectable to the cavity for sucking air out. A hollow after-pressure cylinder is in communication with the cavity so as to receive a portion of the material. The after-pressure cylinder has a first end for connection to the cavity, and a second, opposite end. In the region of the second end is a connection opening for connecting the vacuum source. An after-pressure piston is moveable in the after-pressure cylinder to press its portion of material into the cavity to compensate for any shrinkage of the material in the cavity. There is a drive for moving the after-pressure piston in its after-pressure cylinder into three different positions, i.e.
    Type: Grant
    Filed: September 1, 2004
    Date of Patent: October 2, 2007
    Assignee: Fondarex SA
    Inventor: Peter Eisen
  • Patent number: 7011137
    Abstract: The molding device comprises a lower mold unit and an upper mold unit. When the upper mold unit approaches the lower mold unit, a molding cavity is defined between the lower and upper mold units. The lower mold unit has a storing chamber that is communicated with the molding cavity. The lower mold unit comprises a pressure-decreasing mechanism and a pushing mechanism. A molten material is stored in the storing chamber. When the molding cavity is formed between the lower mold unit and the upper mold unit, the pressure-decreasing mechanism decreases pressure in the molding cavity. Afterwards, in sync with the operation that the upper mold unit pushing down a lower mold-holding member of the lower mold unit, an injection rod of the pushing mechanism pushes out the molten material in the storing chamber to the molding cavity. As a result, the efficiency of the molding operation is improved.
    Type: Grant
    Filed: April 14, 2003
    Date of Patent: March 14, 2006
    Assignee: Toshihara Kanagata Kogyo Co., LTD
    Inventor: Akira Itoh
  • Patent number: 6910520
    Abstract: There is disclosed a mold (1) for casting including: a lower mold (6) having four gates (5) (at least one gate); an upper mold (7) being matched with the lower mold (6) to form a cavity; and side molds (2a), (2b) being matched with the lower mold (6) and upper mold (7) to form the cavity and being split (into at least two). In the mold (1) for casting is constituted an upper surface of a weir (4) of a flat portion of side molds (2a), (2b), and other surfaces of the weir (4) is constituted of a concave portion of the lower molds (6), and the weir (4) is disposed so as to keep a parting line (3) between the side molds (2a), (2b) away. The mold (1) for casting can easily be demolded, and the desired number of gate systems can be formed in desired positions.
    Type: Grant
    Filed: July 25, 2003
    Date of Patent: June 28, 2005
    Assignee: Asahi Tec Corporation
    Inventor: Tatsuya Aoki
  • Patent number: 6752197
    Abstract: An injector particularly for a vacuum die-casting apparatus, comprising an injector body provided with at least one first opening for injecting/aspirating a protective gas and at least one second opening for loading molten material, which are arranged in order of operation. The injector body is further provided with a chamber for containing material and for the sliding of a piston for pushing the material into a die. The injector also comprises elements for cleaning and lubricating the external surface of the piston which are arranged in order of operation on a corresponding supporting element which is separate from the injector body.
    Type: Grant
    Filed: June 12, 2001
    Date of Patent: June 22, 2004
    Assignee: Idra Presse S.p.A.
    Inventor: Graziano Mortari
  • Patent number: 6523598
    Abstract: The vacuum induction melting system is designed to be operated in a continuous or semi-continuous manner for extended periods of time for increased efficiency, and makes it possible to easily and quickly remove the induction furnace from the melt chamber when it becomes necessary to replace and rebuild the furnace. The melting system includes a melt chamber which forms an airtight enclosure, with an induction furnace located within the melt chamber. A charging chamber is communicatively connected to the melt chamber adjacent its upper end. The charging chamber includes a door providing access to the interior of the charging chamber so that a charge of raw materials can be placed therein. An isolation valve is located between the melt chamber and the charging chamber and is movable between open and closed positions.
    Type: Grant
    Filed: January 9, 2002
    Date of Patent: February 25, 2003
    Assignee: ATI Properties, Inc.
    Inventor: Sterry A. Shaffer
  • Patent number: 6360810
    Abstract: A vacuum induction melting system includes a melt chamber which forms an airtight enclosure, with an induction furnace located within the melt chamber. A mold tunnel is connected to the melt chamber adjacent its lower end, with the mold tunnel including a pour opening which communicates with the melt chamber and through which molten metal poured from the furnace can enter the mold tunnel. A mold carriage is positioned within the mold tunnel for receiving and carrying one or more molds adapted for receiving molten metal. An isolation valve is located between the melt chamber and the mold tunnel for isolating the mold tunnel from the melt chamber to allow for removing the mold carriage from the mold tunnel for loading or unloading of molds thereon. A mold transport assembly is provided for moving the mold carriage from a pouring position within the mold tunnel to a loading position located outside of the mold tunnel.
    Type: Grant
    Filed: February 23, 1999
    Date of Patent: March 26, 2002
    Assignee: ATI Properties, Inc.
    Inventor: Sterry A. Shaffer
  • Patent number: 6202733
    Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.
    Type: Grant
    Filed: December 10, 1998
    Date of Patent: March 20, 2001
    Inventor: Robert W. Ratte
  • Patent number: 6148902
    Abstract: A vacuum die casting system has three die casting machines connected to a single vacuum system, all of which is controlled by a programmable logic controller. The controller allows any two of the machines to be operatively connected to the vacuum system so that the casting operation of those two machines are performed under vacuum. The controller comprises six address relays, a sixteen channel input card, a processor, a sixteen channel output card, an interface and two high speed counter cards. The result is an efficient, reliable, and economical vacuum die casting system.
    Type: Grant
    Filed: October 8, 1997
    Date of Patent: November 21, 2000
    Assignee: Outboard Marine Corporation
    Inventors: Michael D. Zielinski, Edward M. Nelson, Walter H. Yelczyn, David M. Regenauer
  • Patent number: 6035922
    Abstract: To provide an apparatus for manufacturing a casting, in which sealing can be formed between joint surfaces of a mold without using any packing material. An apparatus for manufacturing a casting comprising a mold split into at least two mold parts designed so as to define a cavity, an introduction port provided at one end of the mold for introducing molten metal into the cavity, and an exhaust port provided at the other end of the mold for exhausting air in the cavity; characterized by further comprising a groove which is provided around a portion defining the cavity in at least one of joint surfaces of the at least two mold parts so as to connect the introduction port to the exhaust port.
    Type: Grant
    Filed: November 10, 1998
    Date of Patent: March 14, 2000
    Assignees: Sugitani Kinzoku Kogyo Kabushiki Kaisha, Toyo Aluminium Kabushiki Kaisha
    Inventors: Nobuhiro Sugitani, Shoichi Makimoto
  • Patent number: 5908065
    Abstract: Squeeze casting of high integrity, near net shape castings is performed in a mould cavity defined by cooperating die parts which are movable with respect to each other and have a separation distance which is selected to define a predetermined cavity volume for the cast article. A conduit has a first end connected to an entrance in the lower die part of the mould cavity and a second end connected to a receptacle which contains molten metal. Molten metal is transferred upwardly from the receptacle through the conduit to fill or substantially fill the mould cavity. The entrance to the mould cavity is sealed, and pressure is applied on the die parts to further reduce the cavity volume during solidification of the metal in the mould cavity.
    Type: Grant
    Filed: September 26, 1997
    Date of Patent: June 1, 1999
    Assignee: Papervision Limited
    Inventor: Geoffrey Allan Chadwick
  • Patent number: 5842509
    Abstract: An application method of a powder mold lubricant for a vacuum die-casting mold can effectively apply the powder mold lubricant onto a mold surface of the mold cavity with supplying the powder mold lubricant in small amount, can avoid liquefying of the power mold lubricant to degrade quality of a product, and can avoid loss in cycle time in a vacuum die-casting operation.
    Type: Grant
    Filed: April 11, 1997
    Date of Patent: December 1, 1998
    Assignee: Keihin Corporation
    Inventors: Katsuo Nagashima, Shinichi Oomachi, Fumihiro Sakuma
  • Patent number: 5540271
    Abstract: The apparatus comprises a vessel having an interior. A mold is disposed within the interior of the vessel. A casting material is contained in the interior of the vessel. The apparatus also comprises a mechanism for providing the casting material to the mold in a manner such that vapors of the casting material are prevented from communicating with the interior of the vessel. The providing mechanism is in communication with the vessel. The providing mechanism comprises an inner chamber within which the mold and casting material are contained in. The providing mechanism further comprises a mechanism for heating the inner chamber, such as heating coils. The heating mechanism is disposed within the interior of the vessel adjacent to the inner chamber. Preferably, the inner chamber has a tube extending therefrom having a filter element, disposed therein for catching vapors of the casting material.
    Type: Grant
    Filed: August 30, 1993
    Date of Patent: July 30, 1996
    Assignee: PCC Composites, Inc.
    Inventor: Arnold J. Cook
  • Patent number: 5454416
    Abstract: A vacuum casting apparatus in which a molding cavity is reduced in pressure substantially to a vacuum, and upon opening a gate, a molten metal which has been raised to a molten metal retaining dome is charged into the molding cavity via a runner at a high speed. The runner has a first portion making a pool of molten metal, a second portion connecting the molten metal retaining dome to the first portion, and a third portion connecting the first portion to the molding cavity. A pin is slidably provided in the first portion of the runner. An opening of the second portion of the runner to the first portion is located nearer to the pin than an opening of the third portion of the runner to the first portion. When the pin is moved into the first portion of the runner, the pin first closes the opening of the second portion and then begins to apply pressure the molten metal in the molding cavity.
    Type: Grant
    Filed: June 29, 1994
    Date of Patent: October 3, 1995
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Atushi Ota, Yasuyuki Arakawa, Tamotsu Hasegawa
  • Patent number: 5443111
    Abstract: For a steel mold, one or more titanium melt inlet-forming members are provided for cooperating with the steel mold members to form an melt ingate that communicates to the mold cavity for supplying the melt thereto in a manner to avoid harmful iron contamination of the melt during casting. The mold body-to-mold cavity volume ratio is controlled between 10:1 to 0.5:1 to minimize casting surface defects and mold wear/damage.
    Type: Grant
    Filed: November 5, 1993
    Date of Patent: August 22, 1995
    Assignee: Howmet Corporation
    Inventors: Gregory N. Colvin, Leonard L. Ervin, Robert F. Johnson
  • Patent number: 5431212
    Abstract: In a method of vacuum casting wherein when the molten metal previously introduced into a molten metal reservoir is fed into a cavity, the lowest head of the molten metal in the molten metal reservoir is held to be higher than the level of a sprue, so that the cycle time of casting may be shortened and the quality of cast products may be improved. To this end, the interior of the molten metal reservoir is held gas tight while the sprue is opened by a gate member of straight tubular shape.
    Type: Grant
    Filed: July 6, 1994
    Date of Patent: July 11, 1995
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Yasuyuki Arakawa, Tamotsu Hasegawa, Atushi Ota, Minoru Uozumi
  • Patent number: 5427170
    Abstract: A vacuum casting apparatus includes a plurality of pressure pins arranged in a molding cavity, and at least one pressure pin is located in a portion of the molding cavity farthest from a gate. The pressure pins are operated to pressurize the molding cavity in an order from the pressure pin located farthest from the gate to a pressure pin located nearest to the gate. A cross-sectional area reduced portion can also be formed in a portion of a runner connecting the molding cavity and the molten metal retaining dome. A molten metal in the molding cavity is thereby suppressed from flowing backward into the molten metal retaining dome when being pressurized by the pressure pins, so that the quality of the cast products is improved.
    Type: Grant
    Filed: July 8, 1994
    Date of Patent: June 27, 1995
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Yasuyuki Arakawa, Tamotsu Hasegawa, Atushi Ota, Minoru Uozumi
  • Patent number: 5423369
    Abstract: In a method of vacuum casting molten metal sucked from a molten metal reservoir into a cavity held under a reduced pressure by opening a gate having been blocking the communication between the molten metal reservoir and the cavity, the trapping of gas and foreign matter in the cavity is effectively prevented. To this end, an accommodation space for accommodating gas and foreign matter is provided in the molten metal reservoir. The accommodation space is provided at a position from which the accommodated matter is not sucked into the cavity.
    Type: Grant
    Filed: June 24, 1993
    Date of Patent: June 13, 1995
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Atsushi Ota, Minoru Uozumi, Shigeki Tamura, Hirokazu Onishi, Yasuyuki Arakawa
  • Patent number: 5385198
    Abstract: A vacuum casting apparatus of the type wherein a gate mechanism (12 and 10) is closed to form a seal. The interior of a cavity (6) is evacuated by a vacuum pump. The side of the gate mechanism (12 and 10) opposite to the cavity is filled with molten metal. The gate mechanism includes a ring-shaped groove (10e) having a V-shaped cross section positioned on the side opposite to the cavity which extends towards the sealing portion of the gate mechanism (12 and 10). With this arrangement, the molten metal in passage (8) fills the ring-shaped groove (10e) and enters the small clearance which exists in the sealing portion of the gate mechanism. The molten metal solidifies both within the ring-shaped groove (10) and this small clearance formed in the sealing portion. The resulting solidified metal piece has generally a ring shape that can be readily peeled off from the gate mechanism (12 and 10) following die release.
    Type: Grant
    Filed: August 18, 1993
    Date of Patent: January 31, 1995
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Atsushi Ota, Minoru Uozumi, Hirokazu Onishi
  • Patent number: 5383514
    Abstract: A vacuum casting apparatus includes a molten metal passage for delivering molten metal into a sprue of a casting die encapsulated in a enclosure, a cylindrical stoke for communicating the molten metal passage with a reservoir tank, a stoke connecting member for biasing the stoke to a member on which the molten metal passage is formed, an auxiliary flange positioned around the stoke connecting member and contacting a surface of said enclosure, and a flexible plate member for air tightly closing a space between the stoke connecting member and the auxiliary flange.
    Type: Grant
    Filed: June 7, 1993
    Date of Patent: January 24, 1995
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Masahiro Taguchi, Yoshiro Hayashi, Ryuichi Masuda, Yoshio Ekino
  • Patent number: 5358027
    Abstract: A vacuum-assisted gravity pour casting apparatus (10) has a vacuum housing (12) with a fixed top portion (14) and a moveable bottom portion (16). A lower portion (80) of a filling vessel (62) extends through an opening (30) in the top portion (14) and seals the opening (30) against leakage. The bottom housing portion (16) is supported on a scissors-lift mechanism (48) which lowers and raises the bottom portion (16) to open and close the chamber (20) for cycling molds into and out of the chamber (20). A stopper rod (86) controls the flow of molten metal (M) through a bottom nozzle (70) and into the mold.
    Type: Grant
    Filed: March 5, 1993
    Date of Patent: October 25, 1994
    Assignee: CMI International
    Inventors: Douglas R. Callihan, Mark A. Cassel, Charles H. Kinloch, Jesse M. Raver
  • Patent number: 5317591
    Abstract: In a direct-current arc furnace having a bottom contact (3) which has a large area, electromagnetically produced bath agitations are influenced by an electromagnet (9) disposed underneath the vessel bottom (4) such that the natural flow in the melt bath, caused by the current flow in the melt, is reversed in direction. In this way the stability of the bottom electrode (3) is substantially increased. The electromagnet (9) is preferably integrated into the electric supply system of the furnace and serves as a smoothing choke.
    Type: Grant
    Filed: June 19, 1992
    Date of Patent: May 31, 1994
    Assignee: Asea Brown Boveri Ltd.
    Inventor: Sven-Einar Stenkvist
  • Patent number: 5275226
    Abstract: A porous preform is placed in a nonporous mold chamber of a pressure vessel. A material is placed in a crucible of the pressure vessel. The pressure vessel is evacuated through a snorkel fluidically connected to the mold chamber and extending therefrom out of the pressure vessel. The material in the crucible is melted. The crucible is placed in fluidic communication with the mold chamber such that the melted material fluidically seals the inside of the mold chamber and the snorkel from the interior of the pressure vessel to fluidically isolate the mold chamber from the interior of the pressure vessel so that a pressure differential exists therebetween.
    Type: Grant
    Filed: April 21, 1992
    Date of Patent: January 4, 1994
    Assignee: Arnold J. Cook
    Inventor: Arnold J. Cook
  • Patent number: 5257658
    Abstract: An inexpensive vacuum casting chamber is provided to considerable increase casting production in vacuum assist casting machines. This vacuum casting chamber will increase casting production in vacuum assist casting machines by allowing perforated flask to be casted in said machines.
    Type: Grant
    Filed: September 21, 1992
    Date of Patent: November 2, 1993
    Inventor: Enrique E. Perera
  • Patent number: 5246055
    Abstract: A vacuum die-casting machine has a bellows forming a sealed enclosure between the rear of the fill chamber and the piston rod. A vacuum is applied to the enclosure during evacuation of the die cavity and charging of the fill chamber with molten metal. As the piston moves forward, an inert gas at about atmospheric pressure is introduced into the enclosure and extends into the feed tube.
    Type: Grant
    Filed: September 6, 1991
    Date of Patent: September 21, 1993
    Assignee: Aluminum Company of America
    Inventors: James R. Fields, Lawrence W. Cisko, Robert C. Wallace
  • Patent number: 5111871
    Abstract: A porous preform is placed within a permanent, nonporous, thin walled mold chamber. The mold chamber is disposed within a pressure vessel. A material is placed in a crucible of the pressure vessel. The pressure vessel is evacuated through a snorkel fluidically connected to the mold chamber. There is means for cooling the snorkel in thermal communication with the snorkel. The material is melted within the crucible. The crucible is placed in fluidic communication with the mold chamber such that the melted material seals the inside of the mold chamber from the pressure vessel to isolate a vacuum within the mold chamber.
    Type: Grant
    Filed: November 1, 1990
    Date of Patent: May 12, 1992
    Assignee: PCast Equipment Corporation
    Inventor: Arnold J. Cook
  • Patent number: 5101882
    Abstract: A die casting vacuum valve has a cover die block and ejector die block. A cushion member is positioned in the cover die block and a reciprocating member is positioned in the ejector die block such that upon reciprocation of the reciprocating member, it contacts the cushion member and cover die block to seal the reciprocating member with the cover die block and the surrounding surface. A controller mechanism controls the reciprocation of the reciprocating member such that the reciprocating member contacts the cushion when the molten material enters the mold cavity and slot to prevent further flow of the molten material in the slot past the reciprocating member.
    Type: Grant
    Filed: March 14, 1990
    Date of Patent: April 7, 1992
    Assignee: Chrysler Corporation
    Inventor: Lewis G. Freeman
  • Patent number: 5092390
    Abstract: Molten metal is cast in a cavity formed within a permanent, metal mold. The major portion of the cavity is lined with a sand liner whose thickness is reversely correlated to the thickness of the integral sections of a varying thickness cast metal article. However, portions of the metal cavity are bare and such portions form a part of the interior casting surface defined by the sand liner. Thus, the cast metal contacting the bare metal portions of the mold uniformly and rapidly chills to produce harder surface areas on the finished cast article, while the remaining portions of the cast article tend to cool at a generally equalized cooling rate corresponding reversely to the thickness of the sand liner. A vacuum is applied to the casting cavity during filling with molten metal for rapidly filling the sand lined cavity and insuring complete contact between the molten metal and the bare metal portions of the casting cavity.
    Type: Grant
    Filed: August 31, 1990
    Date of Patent: March 3, 1992
    Assignee: CMI International, Inc.
    Inventor: Raymond H. Witt
  • Patent number: 5044911
    Abstract: Molds for making metallic nuclear fuel rods are provided which present reduced risks to the environment by reducing radioactive waste. In one embodiment, the mold is consumable with the fuel rod, and in another embodiment, part of the mold can be re-used. Several molds can be arranged together in a cascaded manner, if desired, or several long cavities can be integrated in a monolithic multiple cavity re-usable mold.
    Type: Grant
    Filed: April 6, 1989
    Date of Patent: September 3, 1991
    Assignee: United States Department of Energy
    Inventors: Bobby R. Seidel, Donald B. Tracy, Vernon Griffiths
  • Patent number: 4649984
    Abstract: An apparatus for casting metal strip includes a nozzle having an orifice for depositing a stream of molten metal onto a casting region of a moving chill surface. A conditioning shoe is located generally upstream from the nozzle in a direction opposite to the direction of chill surface movement to delimit a conditioning chamber. The conditioning chamber communicates directly with the nozzle orifice and borders at least three sidelines of the chill surface casting portion. A shield for minimizing an intrusion of ambient atmosphere into the conditioning chamber and for deflecting an entrained gas boundary layer carried along by the chill surface is cooperatively connected to the conditioning shoe. Gas control provides a selected, low density atmosphere, such as a partial vacuum, within the conditioning chamber.
    Type: Grant
    Filed: June 17, 1986
    Date of Patent: March 17, 1987
    Assignee: Allied Corporation
    Inventors: John R. Bedell, Naim S. Hemmat, Paul Jeges
  • Patent number: 4628987
    Abstract: In the continuous ascending vertical casting of an iron tube T without the use of a core to form the hollow tube interior, the molten iron is contained in a crucible made up of a cooled tubular die 6, 7 and the base 1 of a syphon unit. The crucible comprises a coaxial central form 5 at least as high as the die, which creates with the latter an annular space for molten iron F. Such arrangement reduces the volume of molten iron in the crucible and thus results in considerable energy savings.
    Type: Grant
    Filed: December 28, 1984
    Date of Patent: December 16, 1986
    Assignee: Pont-a-Mousson S.A.
    Inventors: Yves Gourmel, Michel Pierrel
  • Patent number: 4524817
    Abstract: The present invention relates to a centrifugal casting unit, in which a casting mold has a central distributing pan into which melts, produced inductively, are introduced. The casting unit includes workpiece-molds for precision castings, arranged on the periphery of the distributing pan. The casting unit rotates on a rotating plate in a vessel which can be evacuated. The operations which are required for a working cycle, i.e., the opening and closing of the evacuable vessel, the control of the melting and casting operations etc., are accomplished mechanically, hydraulically, and under electrical control in a fully automatic manner.
    Type: Grant
    Filed: July 6, 1982
    Date of Patent: June 25, 1985
    Assignee: BBC Brown, Boveri & Company, Limited
    Inventors: Manfred Brugger, Peter Janczer, Hans Peter
  • Patent number: 4508157
    Abstract: A method of casting metal in a gas permeable shell mold in which a vacuum is applied to an external upper mold surface by engaging the mold in the downwardly facing opening of a generally cylindrical vacuum chamber, defined by a chamber wall with a threaded region sized and shaped to snuggly engage a side mold surface. Engagement is effected by forcing the mold into the chamber opening while causing relative rotation of the mold and chamber.
    Type: Grant
    Filed: April 15, 1983
    Date of Patent: April 2, 1985
    Assignee: Hitchiner Manufacturing Co., Inc.
    Inventors: Dennis A. Belliveau, Eugene W. Thomas
  • Patent number: 4478270
    Abstract: Apparatus for casting of low-density metals, such as magnesium alloys, into an air-permeable mold includes a housing forming a substantially airtight chamber in which is disposed a mold assembly including a mold secured between top and bottom plates by encircling bands or straps. A bottom-discharge reservoir vessel for molten metal is disposed above the mold, the vessel outlet communicating with the mold inlet through a coupling against which the mold assembly is resiliently urged by bias springs to insure an airtight coupling. A valve is selectively operable for opening and closing the vessel outlet and closure apparatus cooperates with the vessel for providing a substantially airtight closure thereof. A pressure control system is coupled to the vessel and the chamber for establishing a pressure differential therebetween which cooperates with gravity to urge the molten metal from the vessel into the mold when the valve is open.
    Type: Grant
    Filed: April 1, 1981
    Date of Patent: October 23, 1984
    Assignee: Interlake, Inc.
    Inventors: Hyman Rosenthal, Harry W. Hammond
  • Patent number: 4467857
    Abstract: A casting apparatus wherein a weighted lever operated plunger has its operational rate regulated by a friction brake. A movable weight on the lever provides a selection of amplified operating force on the plunger. The lever is coupled with the piston of a vacuum pump having a valve to regulate the rate of application of vacuum to the molding flask. Safety linkages coupled to the lever prevent non-scheduled operation of the casting apparatus.
    Type: Grant
    Filed: September 30, 1982
    Date of Patent: August 28, 1984
    Inventor: Lewis E. Massie
  • Patent number: 4425932
    Abstract: A device for transfer of critical liquids, such as molten metals, has a body member including a short leg inlet liquid conveying passage submergeable in a large storage vessel containing the critical liquid. An intermediate high level liquid conveying passage is disposed over the vessel and connected in fluid transferring relationship to the inlet portion at one end, and at its other end to a long down leg passage which is connected to a smaller liquid storing chamber positioned substantially lower than the liquid level in the storage vessel. A pouring outlet is connected to the lower chamber to conduct liquid out of the lower chamber. The flow of metal is controlled by a vacuum source selectively connectable to the high level passage which causes a siphon action through the device. The lower chamber is adapted in cooperation with its storage vessel, to maintain a vacuum in the system during start up and the transfer of liquid from the storage vessel to the outlet.
    Type: Grant
    Filed: June 8, 1981
    Date of Patent: January 17, 1984
    Inventor: Trent S. Herman