Extracting Pattern In Liquid State Patents (Class 164/35)
  • Patent number: 10265591
    Abstract: Embodiments of golf club weight attachment mechanisms are described herein. In some embodiments, a golf club head comprises a head body with an interior cavity, a shell portion, and a bracket with a weight member coupled to the bracket. In one embodiment, the bracket and the weight member can be configured to be fully contained within the interior cavity. Other examples and related methods are also described herein.
    Type: Grant
    Filed: January 4, 2018
    Date of Patent: April 23, 2019
    Assignee: Karsten Manufacturing Corporation
    Inventors: Eric J. Morales, Martin R. Jertson
  • Patent number: 10253782
    Abstract: The present invention provides a shaped component for a compressor wheel that can be used to manufacture a turbo compressor wheel which is excellent in terms of high-temperature strength, rigidity, and dynamic balance and, furthermore, has optimal performance suitable for diverse required characteristics in individual portions.
    Type: Grant
    Filed: December 10, 2014
    Date of Patent: April 9, 2019
    Assignee: SHOWA DENKO K.K.
    Inventor: Masahiro Sato
  • Patent number: 9566642
    Abstract: A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: February 14, 2017
    Assignee: General Electric Company
    Inventors: Ching-Pang Lee, Hsin-Pang Wang, Ram Kumar Upadhyay, Paul Richard Myers, Marc Thomas Edgar, Thomas Donald Martyn, Eric Alan Estill
  • Patent number: 9545545
    Abstract: A method for manufacturing a high-strength steel wooden golf head solves the difficulty in reducing the thickness of the striking faceplate of a conventional wooden golf head. The method includes placing a shell mold having a crucible portion and a cavity portion in communication with the crucible portion on a rotary table, placing a metal ingot in the crucible portion, followed by melting the metal ingot into molten metal in a vacuum environment, rotating the rotary table to cause molten metal to flow into the cavity portion under a centrifugal force, gradually slowing down the rotary table after the molten metal cools and solidifies, destroying the shell mold to obtain a casting including a cast product portion, and separating the cast product portion from the casting to obtain a casting product of the wooden golf head having a tensile strength of 240-350 ksi and a minimum thickness of 1.4-1.8 mm not including a groove depth of the striking faceplate.
    Type: Grant
    Filed: December 19, 2014
    Date of Patent: January 17, 2017
    Assignee: Fusheng Precision Co., Ltd.
    Inventor: Chien-Liang Li
  • Patent number: 9545661
    Abstract: A method includes placing a shell mold with a crucible portion and a casting portion in communication with the crucible portion on a rotary table, with the heterogeneous material including an embedded portion inlaying in the casting portion of the shell mold and a non-embedded portion locating in a cavity of the casting portion, placing a metal ingot into the crucible portion, followed by melting the metal ingot into molten metal in a vacuum environment, rotating the rotary table, causing the molten metal to flow into the cavity, destroying the shell mold after the molten metal solidifies to obtain a casting including a cast product portion separated from the casting to obtain a cast product of a golf club head, and removing the embedded portion of the heterogeneous material protruding from an outer periphery of the cast product of the golf club head.
    Type: Grant
    Filed: December 22, 2014
    Date of Patent: January 17, 2017
    Assignee: Fusheng Precision Co., Ltd.
    Inventor: Chien-Liang Li
  • Patent number: 9545546
    Abstract: A method for manufacturing a low-density steel wooden golf head solves the difficulty in reducing the thickness of a conventional wooden golf head. The method includes placing a shell mold having a crucible portion and a cavity portion in communication with the crucible portion on a rotary table, placing a metal ingot into the crucible portion, followed by melting the metal ingot in molten metal in a vacuum environment, rotating the rotary table to cause the molten metal to flow into the cavity portion under a centrifugal force, gradually slowing down the rotary table after the molten metal cools and solidifies, destroying the shell mold to obtain a casting including a cast product portion, and separating the cast product portion from the casting to obtain a casting product of a wooden golf head having a density of 6.5-7.6 g/cm3 and a minimum thickness of 0.4-0.6 mm.
    Type: Grant
    Filed: December 19, 2014
    Date of Patent: January 17, 2017
    Assignee: Fusheng Precision Co., Ltd.
    Inventor: Chien-Liang Li
  • Patent number: 9539638
    Abstract: A prefabricated sprue assembly provides attachment to independently-produced investment casting molds to substantially reduce the need for pattern material. Installable connections between the prefabricated sprue assembly and the investment mold allow substantial reduction of scrap loss caused by errors in production of individual investment molds by culling defective molds before installation to the sprue assembly.
    Type: Grant
    Filed: January 7, 2013
    Date of Patent: January 10, 2017
    Assignee: WISYS Technology Foundation, Inc.
    Inventors: Daniel Scott McGuire, Eric Ernst Hellstrom
  • Patent number: 9498819
    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: Grant
    Filed: March 14, 2013
    Date of Patent: November 22, 2016
    Assignee: Hitchiner Manufacturing Co., Inc.
    Inventors: Michael R. Hanrahan, Skip L. Patteuw
  • Patent number: 9492970
    Abstract: The invention relates to a method for manufacturing the impeller of a centrifugal, that is, a radial compressor or radial blower, said impeller being mounted directly on the shaft of an electric motor. An essential feature of the invention is that the composite material impeller is made using an RTM process, wherein the RTM mold has a core and accurately trimmed fabrics placed therein in such a manner that the fabric layers, or preforms, are pulled onto the core thus achieving a maximally optimized use of materials in the structure.
    Type: Grant
    Filed: February 25, 2010
    Date of Patent: November 15, 2016
    Assignee: RUNTECH SYSTEMS OY
    Inventor: Juha Karvinen
  • Patent number: 9200518
    Abstract: A turbocharger including a turbine wheel having a hub-to-tip ratio of no more than 60% and blades with a high turning angle and a curved leading edge, a turbine housing forming an inwardly spiraling primary-scroll passageway that significantly converges to produce highly accelerated airflow into the turbine at high circumferential angles, and a two-sided parallel compressor. The compressor and turbine each produce substantially no axial force, allowing the use of minimal axial thrust bearings.
    Type: Grant
    Filed: October 24, 2013
    Date of Patent: December 1, 2015
    Assignee: Honeywell International Inc.
    Inventor: Vaclav Kares
  • Patent number: 9169342
    Abstract: There is provided an imprint material forming a film having high abrasion resistance even after a pattern has been transferred thereto, specifically an imprint material forming a film having a small number of pieces of scratch when the film after a pattern has been transferred thereto is subjected to a steel wool abrasion test. An imprint material comprising: a component (A): a compound having at least one ethylene oxide unit and having at least one polymerizable group; a component (B): a polycaprolactone-modified urethane compound having a C13-25 long chain alkyl group and at least one polymerizable group; and a component (C): a photopolymerization initiator.
    Type: Grant
    Filed: January 18, 2012
    Date of Patent: October 27, 2015
    Assignee: NISSAN CHEMICAL INDUSTRIES, LTD.
    Inventors: Junpei Kobayashi, Keisuke Shuto, Taku Kato, Masayoshi Suzuki
  • Publication number: 20150090419
    Abstract: A method for manufacturing a high-strength blade-type golf iron head with a thin blade includes placing a shell mold onto a rotary table. At least one metal ingot is placed into a crucible portion of the shell mold and is heated to melt in a vacuum environment. The rotary table rotates to cause the molten metal to flow into a cavity portion of the shell mold. The rotating shaft is slowly stopped, and the shell mold is removed after pouring. The shell mold is destroyed after the molten metal cools and solidifies, obtaining a casting. A cast product portion is separated from the casting to obtain at least one blade-type golf iron head having the blade with a minimum thickness of 3.5-5.0 mm. The weight of the blade-type golf iron head is reduced by 0.9-2.5%, and the center of gravity of the blade-type golf iron head is lowered by 0.2-0.75 mm.
    Type: Application
    Filed: August 6, 2014
    Publication date: April 2, 2015
    Inventor: Chien-Liang Li
  • Publication number: 20150090418
    Abstract: A method for manufacturing a high-strength golf iron head with a thin striking faceplate includes placing a shell mold onto a rotary table. At least one metal ingot is placed into a crucible portion of the shell mold and melts in a vacuum environment. The rotary table rotates to cause the molten metal to flow into a cavity portion of the shell mold. The rotating shaft is slowly stopped, and the shell mold is removed after pouring. The shell mold is destroyed after the molten metal cools and solidifies, obtaining a casting. A cast product portion is separated from the casting to obtain at least one golf iron head subsequently treated with heat treatment to provide a striking faceplate of the golf iron head with a tensile strength of 280-340 ksi, an elongation of 4%-20%, and a minimum thickness of 1.4-1.8 mm excluding a groove depth of the striking faceplate.
    Type: Application
    Filed: August 6, 2014
    Publication date: April 2, 2015
    Inventor: Chien-Liang Li
  • Publication number: 20150078958
    Abstract: The disclosure relates generally to core compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to core compositions and methods for casting hollow titanium-containing articles, and the hollow titanium-containing articles so molded.
    Type: Application
    Filed: September 18, 2013
    Publication date: March 19, 2015
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Bernard Patrick BEWLAY, Joan MCKIEVER, Brian Michael ELLIS, Nicholas Vincent MCLASKY
  • Publication number: 20140311697
    Abstract: Integral liquid-coolant passageways in an x-ray tube. In one example embodiment, an x-ray tube includes a can at least partially defining an evacuated enclosure, a cathode at least partially positioned within the evacuated enclosure, and an anode at least partially positioned within the evacuated enclosure. The can has first integral liquid-coolant passageways formed therein. The can is configured to have a liquid coolant circulated through the first integral liquid-coolant passageways to thereby cool the can without the can being submersed in a liquid coolant.
    Type: Application
    Filed: March 17, 2014
    Publication date: October 23, 2014
    Applicant: VARIAN MEDICAL SYSTEMS, INC.
    Inventors: Travis Lee Astle, David Craig Smith, Lawrence Wheatley Bawden, Jeffrey Steven Wassom
  • 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: 20140133967
    Abstract: An intermediate case (IMC) for use in a compressor section of a gas turbine engine includes a bleed duct and an IMC centerbody. The bleed duct is formed via sand casting. The IMC centerbody is formed via investment casting and is fixedly attached to the bleed duct.
    Type: Application
    Filed: November 12, 2012
    Publication date: May 15, 2014
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Brian Desfosses, Willoughby Marshall Quin
  • Publication number: 20140060115
    Abstract: A method for digital manufacturing of a jewelry item includes printing a three-dimensional wax model on a substrate and printing a three-dimensional sprue, the sprue being adapted to support the wax model. A fixture for handling wax models includes a platform, a plurality of holders, a plurality of standoffs, and a tie. A method of manufacturing a jewelry item, comprises forming a first wax model for a portion of a jewelry item, forming a second wax model for a portion of a jewelry item using a rapid prototyping process, and performing one or more lost wax processes with the first and second portion to create the jewelry item.
    Type: Application
    Filed: August 29, 2013
    Publication date: March 6, 2014
    Applicant: Jostens, Inc.
    Inventors: Tim Saarela, Kevin Abernathy, Richard Wells, Lev Neyman, Jon Joriman
  • Publication number: 20130330201
    Abstract: A casting method for obtaining a part that includes a tapering portion, and also a turbine engine blade obtained by casting and including a tapering trailing edge. According to the invention, the method comprises the following steps: providing an insert element having a tapering portion; making a shell around the insert element; and casting a molten material into said shell including the insert element.
    Type: Application
    Filed: June 10, 2013
    Publication date: December 12, 2013
    Inventors: Sebastien DIGARD BROU DE CUISSART, Josserand Bassery, Stephanie Deflandre
  • Patent number: 8453709
    Abstract: A method of providing a positive three-dimensional image of a textured object on metal jewelry, plates, or tags, etc. The textured object may be a finger, fingertip, or any object with a three-dimensional texture. A negative-impression mold is formed in a thermoplastic material, and a positive-impression model then obtained from the negative-impression mold. The positive-impression model is used in the lost-wax process to obtain a piece of metal jewelry having the positive, three-dimensional image of the textured object. The jewelry may be a ring, a pendant, a bracelet, etc., made of gold, silver, platinum, or other metal.
    Type: Grant
    Filed: August 13, 2011
    Date of Patent: June 4, 2013
    Inventor: Brent Williams
  • Publication number: 20130108459
    Abstract: The disclosure relates generally to mold compositions and methods of molding and the articles so molded. More specifically, the disclosure relates to mold compositions and methods for casting titanium-containing articles, and the titanium-containing articles so molded.
    Type: Application
    Filed: October 28, 2011
    Publication date: May 2, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventor: Bernard Patrick BEWLAY
  • Patent number: 8336606
    Abstract: A method involves forming a core assembly. The forming includes deforming a wire, the deforming including increasing a transverse linear dimension along at least one portion of the wire. The wire is assembled to a ceramic core.
    Type: Grant
    Filed: September 1, 2011
    Date of Patent: December 25, 2012
    Assignee: United Technologies Corporation
    Inventor: Justin D. Piggush
  • Patent number: 8251123
    Abstract: A casting core assembly includes a metallic core and a ceramic core. The process for forming the casting core assembly includes inserting a ceramic plug of a metallic core and ceramic plug core subassembly into a compartment of the ceramic core. The ceramic plug is secured to the ceramic core.
    Type: Grant
    Filed: December 30, 2010
    Date of Patent: August 28, 2012
    Assignee: United Technologies Corporation
    Inventors: John R. Farris, Tracy A. Propheter-Hinckley, Douglas C. Jenne, Matthew S. Gleiner, Peter H. Thomas
  • Patent number: 8240355
    Abstract: A method of forming a cast component includes at least partially surrounding an investment mold in a heat-insulating packing material, feeding a molten alloy into the investment mold to provide a filled investment mold, and agitating the filled investment mold while solidifying the molten alloy.
    Type: Grant
    Filed: January 29, 2010
    Date of Patent: August 14, 2012
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, John Joseph Marcin, John F. Blondin, Mark F. Bartholomew
  • Patent number: 8235092
    Abstract: An insulated investment casting shell mold is made by first mixing at least one refractory material with a slurry vehicle forming a prime coat slurry, and optionally mixing at least one refractory material with a slurry vehicle forming a backup slurry. The prime slurry is coated onto a fugitive pattern and optionally dried and/or stuccoed wherein the stucco has at least one refractory material. Optionally, at least one coat of the backup slurry is applied to the prime coated fugitive pattern and optionally dried and/or stuccoed after each coat of the backup slurry. The backup and stucco may be applied a plurality of times to obtain a desired shell wall thickness. An insulating slurry is formed by introducing gas into a slurry vehicle having at least one refractory material and containing a stabilizer and a foaming agent wherein gaseous bubbles become entrained therein forming an insulating slurry having closed porosity therein.
    Type: Grant
    Filed: June 14, 2010
    Date of Patent: August 7, 2012
    Assignee: Minop Co.
    Inventor: David H Scott
  • Patent number: 8225841
    Abstract: A sprue for use in investment casting may comprise a pin and a shell enclosing a part of the pin. A method for creating a sprue may comprise partially enclosing a pin in a shell.
    Type: Grant
    Filed: January 3, 2011
    Date of Patent: July 24, 2012
    Assignee: James Avery Craftsman, Inc.
    Inventor: Bill Davidson
  • Patent number: 8171978
    Abstract: The pattern has a pattern material and a casting core combination. The pattern material has an airfoil. The casting core combination is at least partially embedded in the pattern material. The casting core combination comprises a metallic casting core and at least one additional casting core. The metallic casting core has opposite first and second faces. The metallic core and at least one additional casting core extend spanwise into the airfoil of the pattern material. In at least a portion of the pattern material outside the airfoil of the pattern material, the metallic casting core is bent transverse to the spanwise direction so as to at least partially surround an adjacent portion of the at least one additional casting core.
    Type: Grant
    Filed: November 21, 2008
    Date of Patent: May 8, 2012
    Assignee: United Technologies Corporation
    Inventors: Tracy A. Propheter-Hinckley, Justin D. Piggush, Yongxiang D. Xue, Amarnath Ramlogan, Anthony P. Cherolis, Matthew A. Devore, Eric P. Letizia
  • Patent number: 8122583
    Abstract: Removing of a casting core from a metal casting leaves at least one opening in a surface of the metal. The opening is filled with a sacrificial material. The metal and sacrificial material are machined at the opening. After the machining, a remainder of the sacrificial material is removed.
    Type: Grant
    Filed: June 5, 2007
    Date of Patent: February 28, 2012
    Assignee: United Technologies Corporation
    Inventors: Blake J. Luczak, Glenn A. Cotnoir, James T. Beals, Thomas M. Morin, Joseph J. Parkos, Jr.
  • Patent number: 8096343
    Abstract: In precision casting of metallic components with very thin passage ducts, in particular turbine blades, by the lost-wax process, the ceramic core pins provided for forming the passage ducts are covered and stabilized via a low-melting reinforcing coat prior to injection of the wax material required for forming the wax pattern for the production of the ceramic casting mold, with the low-melting reinforcing coat being melted out together with the wax material after the casting mold has been formed on. The ceramic core pins are therefore not damaged during the production of the wax pattern, enabling very thin passage ducts to be formed in the precision casting process.
    Type: Grant
    Filed: March 7, 2008
    Date of Patent: January 17, 2012
    Assignee: Rolls-Royce Deutschland Ltd & Co KG
    Inventor: Richard Whitton
  • Patent number: 8091608
    Abstract: A method of forming a hollow sand core involves placing a preform into a cavity defined in a mold, where the preform has a predetermined configuration. A granular material is then introduced into the mold cavity and around the preform. The introduced granular material is established around the preform to form the hollow sand core. The preform is deformed in a manner sufficient to enable removal of the preform from inside the hollow sand core, and then is removed from the sand core. The removal of the preform exposes a hollow portion of the sand core.
    Type: Grant
    Filed: May 15, 2009
    Date of Patent: January 10, 2012
    Assignee: GM Global Technology Operations LLC
    Inventors: Michael J. Walker, Thomas C. Pederson
  • Patent number: 8082972
    Abstract: A process for creating a lost wax tree, including the steps of assembling a wax tree having a wax pattern and a wax runner, using automated equipment to flex either the wax tree or the wax pattern to bring disconnected sections into proximity, heating at least one of the disconnected sections, contacting the disconnected sections and then moving the sections slightly away from one another. A process for casting a part including the steps of creating a lost wax tree and where the wax tree is later covered with a mold material and the wax tree is removed to create a mold, the mold is then used to cast a part similar to the wax pattern. A lost wax tree having a wax tree with a wax pattern and a wax runner, automated equipment for flexing, a heating element, and automated equipment for manipulating disconnected sections.
    Type: Grant
    Filed: October 5, 2010
    Date of Patent: December 27, 2011
    Assignee: MPI Incorporated
    Inventor: Bruce Phipps
  • Patent number: 8083511
    Abstract: System and methods involving pattern molds are provided. In this regard, a representative system includes a mold assembly unit having a movable fixture holder operative to engage a portion of a pattern mold and position the pattern mold for assembly.
    Type: Grant
    Filed: December 5, 2007
    Date of Patent: December 27, 2011
    Assignee: United Technologies Corp.
    Inventors: Timothy P. Hasselberg, Carl R. Verner, Steven J. Bullied, Mark F. Bartholomew
  • Patent number: 8025094
    Abstract: Method for producing a mold for use in casting reactive metals comprising preparing a slurry of a yttria-based refractory composition and a binder, and using said slurry as a mold facecoat by applying said slurry onto a surface of a mold pattern, wherein said yttria-based refractory composition is obtainable by (a) mixing particles of a yttria-based ceramic material and a fluorine containing dopant, and (b) heating the resulting mixture to effect fluorine-doping of said yttria-based ceramic material.
    Type: Grant
    Filed: May 15, 2008
    Date of Patent: September 27, 2011
    Assignee: Treibacher Industrie AG
    Inventors: Peter Janz, Sigrun Tauber
  • Patent number: 8020606
    Abstract: A method of making a wax mold for a golf club head includes the steps of: a) positioning a male die in a cavity of a female die; b) injecting and filling dissolvable wax into a gap between an outer surface of the male die and an inner surface of the female die; c) cooling and solidifying the dissolvable wax in the gap to obtain a wax shell; d) removing the wax shell from the male die and the female die, the wax shell being provided with a hole extending through inner and outer surfaces of the wax shell; and e) inserting a wax plug into the hole to form the wax mold.
    Type: Grant
    Filed: September 15, 2008
    Date of Patent: September 20, 2011
    Assignee: O-TA Precision Industry Co. Ltd.
    Inventors: Hsiao-Wen Chao, Lung-Sheng Sun, Yung-Yueh Liu
  • Patent number: 8006744
    Abstract: A system and method of drying casting molds for forming metal parts is provided. In one embodiment, the method includes providing a casting mold comprised of a meltable pattern coated with a ceramic slurry containing a liquid solvent and a binder, placing the casting mold in a chamber, encapsulating the casting mold in a desiccant material, sealing the chamber sufficient to pull a vacuum in the chamber, and applying a variable vacuum to the chamber to dry the mold. In one embodiment, the vacuum is controlled and gradually increased over time from atmospheric pressure to a predetermined maximum vacuum pressure. The vacuum is preferably applied at a rate such that the meltable pattern has a temperature that does not decrease more than about 5 degrees F. from atmospheric pressure to maximum vacuum pressure in one embodiment. In another embodiment, the retained moisture level of the desiccant may be controlled to minimize temperature swings of the meltable pattern during the vacuum application.
    Type: Grant
    Filed: September 11, 2008
    Date of Patent: August 30, 2011
    Assignee: Sturm, Ruger & Company, Inc.
    Inventor: Mark Oles
  • Patent number: 7967055
    Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.
    Type: Grant
    Filed: October 4, 2007
    Date of Patent: June 28, 2011
    Assignee: United Technologies Corporation
    Inventors: Joseph J. Parkos, Jr., Gary M. Lomasney, Joshua E. Persky
  • Patent number: 7946334
    Abstract: A sprue former of the type used to produce a casting mold includes a generally hollow body or a body having hollow sections. The body includes an inlet forming member and at least one first interface member. The inlet forming member is configured to provide an inlet cavity in the casting mold to enable casting material to enter the casting mold. The first interface members are configured to couple to casting patterns. The casting patterns represent items to be cast. The body can also includes a reservoir forming member and at least one connecting member coupling the reservoir forming member to the inlet forming member.
    Type: Grant
    Filed: November 7, 2007
    Date of Patent: May 24, 2011
    Assignee: Geodigm Corporation
    Inventors: Michael Craig Marshall, Kerry Glewwe
  • Patent number: 7942189
    Abstract: The present invention is a novel sprue rod assembly for lost wax investment casting and its method of use. The sprue rod is reusable because it is made of material with a high melting point, such as metal, instead of wax. The sprue rod assembly also comprises a weight pull system, which causes the sprue rod to fall out of the investment mold when it is heated prior to dewaxing or early during dewaxing. The reusable sprue rod assembly reduces wasted wax, increases the efficiency of dewaxing and decreases flaws from the expansion of trapped wax during dewaxing. In addition, the sprue rods can be stacked to create the desired length.
    Type: Grant
    Filed: April 16, 2008
    Date of Patent: May 17, 2011
    Inventors: Mashallah Quraishi, Khalid Mansoor
  • Patent number: 7913743
    Abstract: A method of forming a pattern includes providing an actual core having dimensions which are different from dimensions of an ideal core. A best fit spatial relationship of the actual core to a spatial envelope for an ideal core is determined. Locating surfaces in a die are moved to positions, at least some of which are offset from ideal core locating positions, in which the actual core is positioned in a best fit spatial relationship with the spatial envelope for the ideal core. A plurality of motors may be utilized to move the core locating surfaces to desired locating positions. The actual core is positioned in engagement with the core locating surfaces and a flow of wax is conducted into the die. If desired, a best fit spatial relationship of the actual core to a die cavity may be determined, rather than a best fit with an ideal core.
    Type: Grant
    Filed: June 12, 2008
    Date of Patent: March 29, 2011
    Assignee: PCC Airfoils, Inc.
    Inventor: Joseph Bedzyk
  • Patent number: 7900685
    Abstract: In an investment casting procedure using microwave energy as the heat source virgin wax models are attached to a spree of wax-type pattern material incorporating a susceptor, the spree having a pour cup also of a wax-type pattern material, the pour cup material having a higher percentage of the susceptor than the material of the spree. In use the pour cup will melt first and the spree second, unblocking the path of the virgin wax so that its expansion will not crack ceramic with which it has been coated.
    Type: Grant
    Filed: May 6, 2005
    Date of Patent: March 8, 2011
    Assignee: Process Technology (Europe) Limited
    Inventor: Anthony Wilfred Bolton
  • Patent number: 7866371
    Abstract: A method of forming a gating fixture for a lost wax casting process includes determining an optimal orientation of a gate in relation to a part, and forming a fixture that can repeatably be used to consistently locate the gate relative to the part. In one example, stereolithography is used to form the fixture.
    Type: Grant
    Filed: September 12, 2007
    Date of Patent: January 11, 2011
    Assignee: United Technologies Corporation
    Inventors: Timothy P. Hasselberg, Lea D. Kennard, Carl R. Verner, Steven J. Bullied, Mark F. Bartholomew
  • Patent number: 7753104
    Abstract: A method involves forming a core assembly. The forming includes molding a first ceramic core over a first refractory metal core to form a core subassembly. The subassembly is assembled to a second ceramic core.
    Type: Grant
    Filed: October 18, 2006
    Date of Patent: July 13, 2010
    Assignee: United Technologies Corporation
    Inventors: Blake J. Luczak, Eric A. Hudson, James T. Beals, Eric L. Couch
  • Patent number: 7735542
    Abstract: Dental appliances including multiple components and a system and method for constructing the same are disclosed herein. The dental components are designed to fit together to form the dental appliance. The components of the dental appliance are electronically modeled, printed, and pressed sequentially, separately, or as a unitary piece. Forming the dental appliance from multiple components enables each component of the dental appliance to be formed from a different material, each material having different features associated with it. In various embodiments, different materials have different colors, textures, opacities, and transformation factors associated with them. Furthermore, each component can be formed from multiple components. In some other embodiments, a support structure is designed and constructed in order to minimize deformation of a dental component during fabrication of the component.
    Type: Grant
    Filed: December 18, 2007
    Date of Patent: June 15, 2010
    Assignee: GeoDigm Corporation
    Inventors: Michael Craig Marshall, James Todd Ledin
  • Patent number: 7686068
    Abstract: A blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a proximal end joining the first end portion; a main body portion; and a free distal portion. Second legs each have: a proximal end joining the second end portion; a main body portion; and a free distal portion.
    Type: Grant
    Filed: August 10, 2006
    Date of Patent: March 30, 2010
    Assignee: United Technologies Corporation
    Inventors: Susan M. Tholen, Paul M. Lutjen, Richard H. Page, Richard W. Hoff, Roger J. Gates, Michael F. Blair
  • Patent number: 7686065
    Abstract: In a method for manufacturing a combination investment casting core, a plurality of cores are each formed by cutting a metallic sheet to define a first portion and a number of separate second portions linked by the first portion. The second portions are bent out of local alignment with the first portion. The first portions of the cores are assembled and secured to each other.
    Type: Grant
    Filed: May 15, 2006
    Date of Patent: March 30, 2010
    Assignee: United Technologies Corporation
    Inventor: Blake J. Luczak
  • Patent number: 7681627
    Abstract: A method is disclosed for molding a component with at least one microstructured functional element, which is configured intentionally with a defined structure, in relief, at a defined point on the surface of the component in order to specifically fulfill a function. The element has a characteristic dimension in the micrometer range in at least one spatial direction. The component is shaped from a substantially metallic material using a mould. At least one functional element is formed in a negative impression that is configured on the surface of the mould.
    Type: Grant
    Filed: September 28, 2005
    Date of Patent: March 23, 2010
    Assignee: GROHNO-Guss GmbH
    Inventors: Georg Schmitz, Manfred Grohn, J├╝rgen Nominikat
  • Patent number: 7669637
    Abstract: A lost-wax cast impeller for a supercharger having no parting line on a hub surface and a blade surface in each space demarcated by pairs of long blades adjacent to each other and having excellent aerodynamic performance. A method of manufacturing the impeller involves forming a lost form pattern in substantially the same shape as the impeller, forming a mold by eliminating the lost form pattern after the lost form pattern is coated with a refractory, and pouring a molten metal in the mold for casting. In the molding step, lost material is injection-molded in a space demarcated by radially arranging, toward a center shaft, a plurality of slide molds having short blade-shaped bottomed groove parts and space shapes between the pairs of long blades adjacent to each other, and the slide molds are released by moving in the radial direction of the center shaft while rotating.
    Type: Grant
    Filed: March 30, 2005
    Date of Patent: March 2, 2010
    Assignees: Hitachi Metals Ltd., Hitachi Metals Precision, Ltd.
    Inventors: Yasuhiro Kubota, Hirokazu Itoh
  • Patent number: 7650926
    Abstract: A blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a first end joining the first end portion; a main body portion; and a second end. Second legs each have: a second end joining the second end portion; a main body portion; and a first portion. At least one of the second legs may have its first end joining the core first end portion and a plurality of apertures in the main body portion. Alternatively, at least one of the first legs may have its second end joining the core second end portion and a plurality of apertures in its main body portion.
    Type: Grant
    Filed: September 28, 2006
    Date of Patent: January 26, 2010
    Assignee: United Technologies Corporation
    Inventor: Susan M. Tholen
  • Publication number: 20090254193
    Abstract: A method of casting a hollow hip prosthesis head comprises forming a wax pattern of a femoral head including two cores. The first is a central socket-forming core and the second a ceramic hollow-forming core. The wax pattern is coated with a ceramic slurry to form a shell in which core extensions are captivated. The wax is melted and evacuated and the shell is fired to form a mould. Metal is cast and, when cool, the shell and cores are removed and each aperture formed in the head by the hollow-forming core is sealed.
    Type: Application
    Filed: October 27, 2006
    Publication date: October 8, 2009
    Applicant: DONCASTERS MEDICAL TECHNOLOGIES LIMITED
    Inventor: Guillaume Kerboul
  • Patent number: 7594529
    Abstract: A method for the production of a shell mould. The method comprises the sequential steps of: (i) dipping a preformed expendable pattern into a slurry of refractory particles and colloidal liquid binder whereby to form a coating layer on said pattern, (ii) depositing particles of refractory material onto said coating, and (iii) drying, steps (i) to (iii) being repeated as often as required to produce a shell mould having a primary coating layer and at least one secondary coating layer, characterised in that during at least one performance of step (ii) a gel-forming material is also deposited onto the coating layer formed in step (i).
    Type: Grant
    Filed: August 8, 2003
    Date of Patent: September 29, 2009
    Assignee: University of the Birmingham
    Inventor: Samantha Jones