Extracting Pattern In Liquid State Patents (Class 164/35)
  • Patent number: 7563397
    Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a shell or die used in the manufacture of a dental restoration. Three-dimensional printing includes ink-jet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound shell can be deposited concurrently slice after slice and sintered/cured simultaneously.
    Type: Grant
    Filed: June 18, 2004
    Date of Patent: July 21, 2009
    Assignee: Pentron Laboratory Technologies, LLC
    Inventors: Martin L. Schulman, Carlino Panzera
  • Patent number: 7513296
    Abstract: Investment-casting shells are disclosed that have at least one cluster of individual club-head casting molds for casting thin-walled, titanium alloy club-heads at high process yield and low material usage. The shells have respective combinations of cluster configuration and number, gating, and runners, as determined systematically. Some shell configurations include a cluster of at least ten casting molds for respective club-heads each (a) having a head-volume greater than 400 cm3, (b) defining at least one club-head wall having a thickness of less than 0.8 mm, and (c) defining at least one respective gate. The cluster is configured to produce a cast-ptoduct yield of greater than 80% at a material usage of less than 600 g, including process losses, per cast club-head. Also, at least one runner connects the gates together.
    Type: Grant
    Filed: December 28, 2006
    Date of Patent: April 7, 2009
    Assignee: Taylor Made Golf Company, Inc.
    Inventors: Joseph Yu, Bing-Ling Chao
  • Patent number: 7448433
    Abstract: Methods for rapid prototype casting metal components, wherein the metal components are cast in a secondary ceramic mold, the secondary ceramic mold is cast in a primary mold, and the primary mold is formed by rapid prototyping or rapid manufacturing. The secondary ceramic mold may comprise a one-piece integral shell and core(s), and the metal components may have at least one hollow portion or void therein, such as a hollow airfoil for a gas turbine engine.
    Type: Grant
    Filed: September 24, 2004
    Date of Patent: November 11, 2008
    Assignee: Honeywell International Inc.
    Inventors: Milton Ortiz, Malak F. Malak, Steve H. Halfmann
  • Publication number: 20080216983
    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 stabilised 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: Application
    Filed: March 7, 2008
    Publication date: September 11, 2008
    Inventor: Richard Whitton
  • Patent number: 7370688
    Abstract: A method of manufacture of a multilayer ceramic shell mould whereof at least one contact layer out of a wax master pattern or a part to be manufactured, or other similar material, includes a step of preparing a first slip containing ceramic particles and a binder; a step of dipping the master pattern in a first slip; a step of forming the contact layer, and a step of depositing sand particles particles onto the layer and drying the contact layer. The ceramic particles of the slip are mullite particles and the slip includes a texturing agent.
    Type: Grant
    Filed: May 10, 2005
    Date of Patent: May 13, 2008
    Assignee: Snecma
    Inventors: Arnaud Biramben, Christian Marty, Patrice Ragot, Jean-Christophe Husson, Franck Truelle, Patrick Chevalier, Serge Fargeas
  • Publication number: 20080093043
    Abstract: A process and casting media composition for casting three-dimensional parts and sacrificial models from a class of foaming casting compounds, and creating the foaming casting compounds by combining a radiation activated catalyst that causes a phase change from liquid to solid in the material and a foaming agent. In an alternate embodiment the combination is of a cold foaming casting compound and a compound which contains a radiation activated catalyst that causes a phase change from liquid to solid in the material. A further embodiment combines a hot melt casting compound with a compound which contains a radiation activated catalyst that causes a phase change from liquid to solid in the material and a foaming or blowing agent.
    Type: Application
    Filed: October 20, 2006
    Publication date: April 24, 2008
    Inventor: Victor F. Joyner
  • Patent number: 7360578
    Abstract: In one aspect, the present invention relates to a method of joining wax patterns for fabricating a golf club head. In one embodiment, the method has the step of providing a prefabricated first wax pattern and a prefabricated second wax pattern, embedding a joining portion of the second wax pattern into a recess portion of the first wax pattern, heating a flange formed on the recess portion to make the flange soften, and using a flattening tool to fold the flange over and into a chambered receiving portion on the second wax pattern such that the first wax pattern and second wax pattern are melted into a whole, joined surfaces of the first wax pattern and the second wax pattern are joined tightly with no gaps, and a single wax pattern if formed.
    Type: Grant
    Filed: August 15, 2006
    Date of Patent: April 22, 2008
    Assignee: Advanced International Multitech Co., Ltd.
    Inventor: Chieh-Fu Tseng
  • Patent number: 7318466
    Abstract: A method of manufacture of a multilayer ceramic shell mould out of a master pattern includes the steps of dipping the master pattern in a first slip containing ceramic particles and a binder, depositing sand particles to form a contact layer, dipping the master pattern in a second slip containing ceramic particles and a binder, depositing sand particles to form an intermediate layer, dipping the master pattern in at least a third slip containing ceramic particles to form a reinforcing layer. The ceramic particles of the slips includes mullite, alumina, or a mixture of the two, whereas no layer contains any zircon.
    Type: Grant
    Filed: May 12, 2005
    Date of Patent: January 15, 2008
    Assignee: SNECMA Moteurs
    Inventors: Arnaud Biramben, Patrick Calero, Patrick Chevalier, Jean-Christophe Husson, Christian Marty, Patrice Ragot, Jean-Pierre Richard, Franck Truelle, Isabelle Valente
  • Publication number: 20080000605
    Abstract: A combing method of wax patterns for fabricating a golf club head is provided in the present invention. Firstly, a golf club head is disassembled to two or more elements in advance, which are respectively formed into wax patterns. Next, a flange capable of being deformed upon being pressed under an appropriate temperature and a corresponding rabbet structure are predisposed on the two wax patterns, then, the temperature of the flange is raised to make it soften, and then, it is pressed into the rabbet by a flattening tool. By utilizing the softening characteristic of the wax upon being heated, the joint surfaces of the two wax patterns are melted into a single wax pattern. By the method, the two wax patterns are combined together without adding a medium there-between, and thereby forming a joint surface with no gaps.
    Type: Application
    Filed: August 15, 2006
    Publication date: January 3, 2008
    Inventor: Chieh-Fu Tseng
  • Patent number: 7290584
    Abstract: A wax pattern welding system and method for producing a pool of molten wax on an area of a surface of a wax component is provided. The wax pattern welding system includes a bar of heat conducting material and a heating element. The bar has a raised heating surface, which has a recessed area for retaining molten wax when the raised heating surface contacts the wax component, and a vent structure. The vent structure facilitates confining the pool of molten wax on an area of a surface of the wax component. In another embodiment, the pattern welding system includes an attachable plate of heat conducting material, which has a raised heating surface with a recessed area, and a vent structure. The attachable plate is configured to be fastened to the bar of heat conducting material.
    Type: Grant
    Filed: November 17, 2005
    Date of Patent: November 6, 2007
    Assignee: MPI Incorporated
    Inventors: Keith F. Hedrick, Keith B. Gardener
  • Patent number: 7287571
    Abstract: Pattern for the lost foam casting process including a pouring-basin-forming portion, a sprue-forming portion, a runner-forming portion, a gate-forming portion, and an inline-riser-forming portion. The runners formed by the pattern each have an inline riser through which melt flows between an inlet to and outlet from the riser during pouring, and in which melt is stored to feed the casting with melt during cooling/shrinkage of the casting. A sand dam surrounds the mouth of each gate and traps particulates from a liquid styrene layer that precedes the melt front in the riser.
    Type: Grant
    Filed: September 14, 2005
    Date of Patent: October 30, 2007
    Assignee: General Motors Corporation
    Inventor: Neil R. Cossey
  • Patent number: 7281566
    Abstract: A method for manufacturing a mold (70), which comprises a step of forming a layer (31) of combustible powdery particles (32) around a wax mold (21), which is a lost pattern, a step of forming a film (51) of a ceramic precursor slurry (52) around the wax mold (21) having powdery particles (32) formed thereon, a step of subjecting the resultant product to a heat treatment, to thereby dewax the wax mold (21), and a step of firing the slurry film (51), to thereby burn and vanish the powdery particles (32) in the slurry film (51) and form a shell (71). The mold (70) has the shell (71) and a porous layer (74) formed on the surface (76) of the cavity of the shell. The mold can be suitably used for manufacturing a porous body (90) having a porous layer (94) on the surface thereof.
    Type: Grant
    Filed: March 4, 2004
    Date of Patent: October 16, 2007
    Assignee: Ishikawajima-Harima Heavey Industries Co., Ltd.
    Inventors: Kazuyoshi Chikugo, Hidemi Ukai, Koichi Murakami, Koshichi Ogawa
  • Patent number: 7278465
    Abstract: An investment casting method involves producing a casting shell by applying a hardenable moist mixture to a sacrificial pattern. To hasten the hardening of the moist mixture to create the shell, a stucco coat is subsequently applied to the mixture. In some cases, the stucco coat comprises a drier mixture of the elements used in the moist mixture. The drier mixture preferably includes a material that alters the alkalinity of the underlying moist mixture. In some cases, the stucco coat also includes an amorphous mineral silicate. Once the shell is created, a molten metal is introduced into the shell to replace the sacrificial pattern, thereby producing a metal cast item.
    Type: Grant
    Filed: April 1, 2006
    Date of Patent: October 9, 2007
    Inventors: Daniel S. McGuire, Eric E. Hellstrom
  • Patent number: 7278461
    Abstract: The present invention provides a manufacturing method of high precision titanium compressor wheel in which by removing pads attached on an entire surface entirely as a machining allowance in manufacturing process, dimensional accuracy at the time of manufacturing is intensified, and correction work of dynamic balance (rotation balance) is simplified or omitted so as to improve yield of products and suppress boosting of manufacturing cost. The outer peripheral face of a front cast boss portion of a cast titanium product is fixed with a chuck of lathe. A plurality of receiving plates projecting from the lathe are positioned between respective cast blades and front ends thereof are pressed against a disc-like large-diameter front end face formed on a rear half portion of a cast core portion. With a large-diameter front end face of the cast core portion and the outer peripheral face of the front cast boss portion as reference plane, the cast titanium product is held by the chuck and receiving plates and rotated.
    Type: Grant
    Filed: September 28, 2005
    Date of Patent: October 9, 2007
    Assignee: Aikoku Alpha Corporation
    Inventors: Susumu Endo, Masaru Ogawa, Mitsuru Miyao
  • Patent number: 7270166
    Abstract: A fugitive pattern assembly is made by preforming one or more fugitive patterns of an article to be cast, placing the preformed patterns in an injection die, and injecting fluid gating material into the die to form gating connected to the patterns. The fugitive patterns are disposed in end-to-end and/or side-by-side relation and are interconnected by the gating.
    Type: Grant
    Filed: June 28, 2004
    Date of Patent: September 18, 2007
    Assignee: Howmet Corporation
    Inventors: Richard S. Jakus, Kurt R. Swartz
  • Patent number: 7246652
    Abstract: A method to recover wax from wax patterns used in investment casting using a lost wax technique without damaging incorporated ceramic cores is disclosed that includes subjecting the wax pattern to specific conditions. These conditions include chilling a casting tool including the wax pattern and ceramic cores such that a brittle transition temperature for the wax material is approached. Once chilled the wax pattern is subjected to brittle fracture release of the wax from the underlying ceramic cores without damage to those cores.
    Type: Grant
    Filed: May 11, 2005
    Date of Patent: July 24, 2007
    Assignee: Rolls-Royce PLC
    Inventor: Jeffery A. Fowler
  • Patent number: 7246653
    Abstract: A process for manufacturing a blade of a turbomachine using the lost-wax moulding technique, where the blade includes a first central longitudinal cavity and at least one second longitudinal cavity together forming a cooling circuit and communicating with each other at one longitudinal end via a transverse channel. The process includes manufacturing first and second cores corresponding to the cavities, where the two cores each have an end portion, by which they are connected together by an assembly of the mortise and tenon type. The assembly of the two cores is then positioned in a shell mould and the metal poured into the mould.
    Type: Grant
    Filed: September 20, 2005
    Date of Patent: July 24, 2007
    Assignee: SNECMA
    Inventor: Maurice Guy Judet
  • Patent number: 7231955
    Abstract: A method for investment casting includes the steps of positioning a base plate relative to a die; molding a first material between the die and at least a first surface portion of the base plate; securing one or more patterns to the base plate, the one or more patterns comprising a second material; applying one or more coating layers over at least portions of the one or more patterns and at least a portion of the first material; substantially removing the first material through an interior receptacle of a manifold body and the second material through an exterior receptacle of the manifold body to leave one or more shells formed by the coating layers; removing said base plate; introducing molten metal to the one or more shells through the interior receptacle of the manifold body; permitting the molten metal to solidify; and destructively removing one or more investment casting molds.
    Type: Grant
    Filed: January 30, 2006
    Date of Patent: June 19, 2007
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, P. Brennan Reilly
  • Patent number: 7216691
    Abstract: A process for the casting of metals includes the steps of providing a mold, delivering a molten metal into the mold, solidifying the molten metal, and removing at least a portion of the mold. The step of removing at least a portion of the mold begins before the step of solidifying the molten metal has been finished. An apparatus to deliver a solvent to a mold is also provided.
    Type: Grant
    Filed: July 7, 2003
    Date of Patent: May 15, 2007
    Assignee: Alotech Ltd. LLC
    Inventors: John R. Grassi, John Campbell, George W. Kuhlman
  • Patent number: 7204296
    Abstract: A method is provided for removing a fugitive pattern, such as wax or other meltable pattern material, residing inside of a refractory mold by discharging condensable vapor such as steam inside the mold to contact and melt the pattern while an exterior of the mold is subjected to a non-condensing gas atmosphere such as air outside of the mold wherein the condensable vapor inside the mold and the atmosphere outside of the mold are at substantially the same pressure. Condensable vapor is condensed inside the mold where the vapor has contacted the pattern while the exterior of the mold remains free of condenate. The condensed vapor and melted pattern material are drained out of the mold. The condensed vapor can be discharged initially inside a hollow sprue of a fugitive pattern assembly to melt the sprue and then inside the mold to melt the patterns of the pattern assembly.
    Type: Grant
    Filed: July 26, 2004
    Date of Patent: April 17, 2007
    Assignee: Metal Casting Technology, Incorporated
    Inventors: John A. Redemske, Richard Ullrich
  • Patent number: 7198091
    Abstract: The invention relates to a method for producing an effectively invisible gemstone setting by casting a wax model of the setting and inserting a flange or post between the stones and into the floor of the setting, or into a depression or aperture on the floor of the setting, in order to secure the stones placed in the wax model of the setting. The flange is shaped so that the majority of its body is hidden beneath the gemstones and so that a narrowed portion of the flange engages the sides or girdles of the gemstones. The upper portion of the flange has sloped sides and may reflect light to and from the crown of the gemstones mounted in the setting.
    Type: Grant
    Filed: March 29, 2004
    Date of Patent: April 3, 2007
    Assignee: MJJ Brilliant, Inc.
    Inventor: Nicolay Yakubovich
  • Patent number: 7173079
    Abstract: The casting-mold material designed to manufacture casting molds used in casting high melting-point substances. The casting mold formed from a powder component containing magnesium oxide and aluminum oxide and a liquid component. The powder component additionally contains a calcium aluminate and an alkali fluoride or an earth alkali fluoride and the liquid component contains a polyelectrolyte and a basic component, the latter determining the liquid component pH value between 10 and 14. A fluid slip is prepared by mixing the powder and liquid components and is dried, hardened and sintered to produce a hollow mold.
    Type: Grant
    Filed: December 7, 2001
    Date of Patent: February 6, 2007
    Assignees: Schutz-Dental GmbH, Fraunhofer-Gesellschaft zur Forderung der Angewandten Forschung E.V.
    Inventors: Susanne Rabe, Wolfgang Eiselt, Reinhard Lenk, Hans-J├╝rgen Richter
  • Patent number: 7152656
    Abstract: A manufacturing method for a hybrid one-piece design of a wax pattern of a golf club head includes the steps of: prefabricating a first wax pattern in a first molding assembly, the first wax pattern having a connecting portion; inserting the first wax pattern into a first mold cavity of a second molding assembly which has a configuration substantially corresponding to that of a first component of the golf club head; filling liquid wax into a second mold cavity of the second molding assembly which has a configuration substantially corresponding to that of a second component of the golf club head; and cooling the liquid wax in the second mold cavity to form a second wax pattern joined to the connecting portion of the first wax pattern.
    Type: Grant
    Filed: September 28, 2005
    Date of Patent: December 26, 2006
    Assignee: Fu-Sheng Industrial Co., Ltd.
    Inventors: Chun-Yung Huang, Chun-Yu Chen
  • Patent number: 7150307
    Abstract: A method and apparatus is disclosed for forming a metal casting sprue for a lost foam casting process, the sprue formed in sand for receiving molten metal and directing the molten metal to a foam pattern in a mold cavity, wherein the sprue formation is facilitated by an insert having a plurality of apertures formed therein, the apertures facilitating an application of a coating to sand surrounding the insert prior to removal of the insert from the sand, and wherein the sprue facilitates a minimization of production costs and an optimization of material properties of the resultant casting.
    Type: Grant
    Filed: August 3, 2005
    Date of Patent: December 19, 2006
    Assignee: GM Global Technology Operations, Inc.
    Inventor: David D. Goettsch
  • Patent number: 7147032
    Abstract: In a process for the assembly of wax trees, a wax runner is placed in a flat position, and a wax pattern is located adjacent to the wax runner. Both the wax pattern and the wax runner are heated and then placed in contact with one another where heated. Then the wax pattern and the wax runner are separated slightly to form a fillet weld between the wax pattern and the wax runner. An apparatus is also provided which, by robotics, brings a multiplicity of wax patterns to a wax runner and which automatically heats both the wax patterns and the wax runner before simultaneously pressing both the wax patterns and the wax runner together. Once a wax tree assembly is completed, a new wax runner replaces the wax runner that has been formed into a wax tree, and additional wax patterns are affixed in the same manner.
    Type: Grant
    Filed: June 14, 2005
    Date of Patent: December 12, 2006
    Assignee: MPI Incorporated
    Inventors: Richard Ludwig, Stephen Derby, Raymond H. Puffer, Jr., Bruce S. Phipps
  • Patent number: 7147031
    Abstract: A method and apparatus for the lost pattern casting of metals employs an erodable mold including a particulate material and a binder. An erodable backing or coating may be used to support the erodable mold. After a molten metal casting is poured in the mold, the erodable backing and the mold are contacted with a solvent. This cools the molten metal so that it at least partially solidifies to form a casting. At least a part of the mold is removed. Also, the coating or backing may be removed.
    Type: Grant
    Filed: September 19, 2003
    Date of Patent: December 12, 2006
    Assignee: Alotech Ltd. LLC
    Inventors: John R. Grassi, John Campbell, George W. Kuhlman
  • Patent number: 7134475
    Abstract: An investment casting pattern is formed by forming a metallic first core element including at least one recess. The first core element is engaged to at least a mating one of an element of the die and a second core element. The recess serves to retain the first core element relative to the mating one. The die is assembled and a sacrificial material is introduced to the die to at least partially embed the first core element. The recess may be pre-formed prior to cutting the first core element from a larger sheet of material.
    Type: Grant
    Filed: October 29, 2004
    Date of Patent: November 14, 2006
    Assignee: United Technologies Corporation
    Inventors: Jacob A. Snyder, James T. Beals
  • Patent number: 7121318
    Abstract: A method and apparatus for the lost pattern casting of metals is disclosed. In the method, a pattern is formed from a material and a mold is formed around at least a portion of the pattern. The mold includes a particulate material and a binder. The pattern is removed from the mold and molten metal is delivered into the mold. The mold is contacted with the solvent and the molten metal is cooled such that it at least partially solidifies to form a casting. The step of cooling includes contacting a shell of solidifying metal around the molten metal with the solvent. An apparatus is also disclosed.
    Type: Grant
    Filed: March 29, 2005
    Date of Patent: October 17, 2006
    Assignee: Alotech Ltd. LLC
    Inventors: John R. Grassi, John Campbell, George W. Kuhlman
  • Patent number: 7082984
    Abstract: The present invention is a method for casting a part having a complex shape or having a complex shape thereon. The method includes providing a pattern and securing at least one core to the pattern. A conformable material is located about the pattern and the core to create a complementary shape to the pattern and core in the conformable material. The pattern is removed and the core is left behind in the conformable material. The core leaves space, or an empty form, for a negative draw that cannot be formed in known casting methods. A mold is located adjacent the shaped, conformable material. A hardenable material is located between the mold and the shaped, conformable material and into the core. The hardenable material is allowed to harden and then it is removed. A cast part having a complex shape, or having a complex shape integrally formed with the part, results.
    Type: Grant
    Filed: July 30, 2004
    Date of Patent: August 1, 2006
    Assignee: Dana Corporation
    Inventor: Norberto Rizzo
  • Patent number: 7080678
    Abstract: There is provided a method or process for fabricating a hollow jewelry article which is hollowed or bored out. In accordance with this process, a metal ring model is prepared comprising a solid shank and a metal plate supported along the internal perimeter of the shank by means of a series of spokes extending from the shank. A first metal mold is produced from the metal ring model having the external shape of the jewelry article to be manufactured. From this mold, a wax model of the jewelry article is produced which is first filed down and then cast in order to form a metal model of a core insert; the core insert, like the ring model, has a plate disposed along the perimeter of the shank. This core insert is used to produce a second metal mold. This second mold may then be used repeatedly in order to form a soluble wax core insert model which is then inserted into the cavity of the first mold in order to define the hollow region of the article.
    Type: Grant
    Filed: November 4, 2004
    Date of Patent: July 25, 2006
    Assignee: Unimold Cast Ltd.
    Inventors: Ervant Hashiman, Garabed Ayvazian
  • Patent number: 7048030
    Abstract: A method of making an investment or lost foam casting assembly of a first part movable with respect to a second part includes making first and second separate wax or foam patterns of portions of the first part. Then, a third wax or foam pattern of the second part is made. Next, ceramic core pieces are made. At least one of the core pieces is mounted on the first pattern to form a subassembly. The subassembly is combined with the third pattern so that the core pieces maintain a separation between the third pattern and the first pattern. The first and second patterns are bonded together to trap the subassembly and to form a complete casting assembly.
    Type: Grant
    Filed: November 19, 2004
    Date of Patent: May 23, 2006
    Assignee: Deere & Company
    Inventors: Casee Michele Eisele, Michael Dean Kollath, Robert Lee Wood, Jr., Edwin Roy Kreis, Michael Carl Harting
  • Patent number: 7025110
    Abstract: A piece of jewelry such a pendant is first cast in wax to provide a wax replica thereof. A gemstone is heated above the melting temperature of the wax replica and is pressed therein. Alternatively, the gemstone is positioned on the surface of the wax replica and pressure is applied to the gemstone to partially embed the gemstone in the wax replica surface at room temperature. The wax replica is then used to from the plaster of Paris mold wherein liquid metal is then poured within the plaster of Paris mold to replace the plaster to form the finished product.
    Type: Grant
    Filed: June 12, 2003
    Date of Patent: April 11, 2006
    Inventor: Arthur Suozzi
  • Patent number: 6971436
    Abstract: A connecting method for the wax patterns of the golf club head includes the steps of: prefabricating a first wax pattern and a second wax pattern, the first wax pattern providing with an engaging portion for engaging with the second wax pattern; employing a temperature difference to generate a manufacturing volume tolerance between the first wax pattern and the second wax pattern; combining the engaging portion of the first wax pattern with the second wax pattern; and cooling the first wax pattern to shrink the engaging portion so as to fittingly combine the first wax pattern with the second wax pattern.
    Type: Grant
    Filed: April 8, 2004
    Date of Patent: December 6, 2005
    Assignee: Nelson Precision Casting Co., Ltd.
    Inventor: Chun-Yung Huang
  • Patent number: 6966354
    Abstract: An apparatus for shelling an investment casting pattern has a tank containing a coating material. There are means for holding the pattern immersed in the coating material. There may be means for vibrating the pattern during immersion of the pattern and a vacuum source coupled to the tank to withdraw air from at least one headspace of the tank.
    Type: Grant
    Filed: December 5, 2003
    Date of Patent: November 22, 2005
    Assignee: United Technologies Corporation
    Inventors: John J. Marcin, Jr., Stephen D. Murray, Carl R. Verner, Maria A. Herring, Lea D. Kennard, Donald D. Schofield, Richard L. Ritchie, Reade R. Clemens, Michael K. Turkington, Delwyn E. Norton
  • Patent number: 6957686
    Abstract: A knife for heating the wax on the surface of a wax runner. The knife as a surface which is recessed in the center of the surface to permit melted wax to flow up into the recessed area and not flow away from the knife. Alternately, conformal heating surface which melts only that portion of the wax runner to which the pattern gate is affixed. Additionally an electrical circuit is provided which includes a heater and a temperature controller to limit the temperature at which wax is melted.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: October 25, 2005
    Assignee: MPI Incorporated
    Inventors: Raymond H. Puffer, Jr., Bruce S. Phipps, Daniel Walczyk, Rory Mackean, Jason Chalfant, Keith F. Hendrck
  • Patent number: 6951239
    Abstract: An at least two step heating process is used to strengthen the shell of an investment casting mold including a refractory metal core. The first stage may occur under otherwise oxidizing conditions at a low enough temperature to avoid substantial core oxidation. The second stage may occur under essentially non-oxidizing conditions at a higher temperature.
    Type: Grant
    Filed: April 15, 2004
    Date of Patent: October 4, 2005
    Assignee: United Technologies Corporation
    Inventors: Jacob A. Snyder, James T. Beals, Joshua E. Persky, Carl R. Verner, Lea D. Kennard, Dawn D. Mandich, Stephen D. Murray
  • Patent number: 6929050
    Abstract: A wax runner is provided having risers along the edge of the surface which is melted to attach the wax gates of wax patterns to the wax runner. The risers prevent the flow of molten wax over the edge of the wax runner. In addition to the risers or separately, at least one locator extends from both ends of the wax runners, the locators are aligned with one another and assure a constant distance between the ends of the wax runner and the wax pattern being affixed to it. The locators further provide a fixed reference point.
    Type: Grant
    Filed: June 20, 2003
    Date of Patent: August 16, 2005
    Assignee: MPI Incorporated
    Inventors: Raymond H. Puffer, Jr., Bruce S. Phipps, Daniel Walczyk, Rory MacKean, Jason Chalfant
  • Patent number: 6910519
    Abstract: A process for the assembly of wax trees in which a wax runner is placed in a flat position and a wax pattern is located adjacent the wax runner. Both the wax runner pattern and the wax runner are heated and then are placed in contact with one another where heated. Then the wax pattern and the wax runner are separated slightly to form a fillet weld between the wax pattern and the wax runner. An apparatus is also provided which, by robotics, brings a multiplicity of wax patterns to a wax runner and which automatically heats both the wax patterns and the wax runner before simultaneously pressing both the wax pattern and the wax runner together. Once a wax tree assembly is completed a new wax runner replaces the wax runner that has been formed into a wax tree and additional wax runners are affixed in the same manner.
    Type: Grant
    Filed: November 26, 2002
    Date of Patent: June 28, 2005
    Assignee: MPI Incorporated
    Inventors: Richard Ludwig, Stephen Derby, Raymond H. Puffer, Jr., Bruce S. Phipps
  • Patent number: 6904949
    Abstract: A method of making an air boost device, wherein a compressor wheel incorporated therein is re-designed to permit die inserts (20), which occupy the air passage and define the blades (4, 5) during a process of forming a wax pattern (21) of a compressor wheel, to be pulled without being impeded by the blades. This modified blade design enables the automated production of wax patterns (21) using simplified tooling. These wax patterns (21) can be used in a large-scale investment casting process, and produce an economical cast titanium compressor wheel which performs aerodynamically at high boost pressure/RPM.
    Type: Grant
    Filed: September 12, 2003
    Date of Patent: June 14, 2005
    Assignee: BorgWarner, Inc.
    Inventors: David Decker, Stephen I. Roby
  • Patent number: 6892789
    Abstract: A lost wax molding system has a re-usable, collapsible, chain-linked mesh exoskeleton, one or more inserts to be placed within the interior surface of the mesh exoskeleton to exert outward pressure on the mesh exoskeleton thereby creating a pre-formed, rigid, three-dimensional shape, a waterproof sleeve sized to cover the outer surface of the three-dimensional shape, and a base sized to seal said waterproof sleeve forming an investment mold container.
    Type: Grant
    Filed: December 6, 2002
    Date of Patent: May 17, 2005
    Inventor: Michael Boyle
  • Patent number: 6886621
    Abstract: A sprue structure is specifically designed to facilitate the rapid filling of molded polystyrene patterns with molten metal. It comprises a down sprue and parallel columnar members that are connected to the down sprue. The flow of molten metal is initially downward through the first columnar member and then it reverses direction to flow upwardly through second and third columnar members so that the patterns to be cast receive molten metal as it travels upwardly through the second and third columnar members. This decreases the amount of pyrolyzation products that could otherwise flow through in-gates and into the patterns to be cast.
    Type: Grant
    Filed: August 29, 2002
    Date of Patent: May 3, 2005
    Assignee: Brunswick Corp.
    Inventors: William G. Hesterberg, Dean A. Wickman, Thomas D. Blum, Howard W. Beumler, Jr.
  • Patent number: 6880618
    Abstract: Method of making a subcutaneous melt flow-channel in the surface of a fugitive foam pattern used in lost-foam casting process. After a refractory skin has been formed on the surface of a foam pattern, a strip of the skin is treated so as to cause the foam underlying the strip to recede from the strip and leave a groove in its stead. Suitable treatments include (1) heating the strip, or (2) applying a foam solvent thereto that soaks through the skin. In each case, the treatment is such as to cause the foam underlying the treated strip to soften and recede from the strip.
    Type: Grant
    Filed: July 15, 2003
    Date of Patent: April 19, 2005
    Assignee: General Motors Corporation
    Inventors: David Douglas Goettsch, Bob Ross Powell, Jr.
  • Patent number: 6857461
    Abstract: A method of producing reticular structures, particularly metallic reticular structures, as well as a device suitable for the production thereof. The method and device enable continuous and/or automated production of such structures, and particularly, large-scale automated production of large-dimensioned reticular structures. A reticulated foam pre-structure is placed into a first container and infiltrated with a refractory material. After solidification, the mold formed by the refractory material is removed from the first container and the foam pre-structure stripped from the mold. The mold is then pre-heated and placed into a second container and infiltrated with a molten substance that forms the reticular structure when solidified. The filled mold may be covered with a solid jacket as a means of controlling the rate and progression of solidification of the molten substance to form a fine-grained, bubble-free structure.
    Type: Grant
    Filed: February 20, 2002
    Date of Patent: February 22, 2005
    Inventors: Dieter Girlich, Juergen Schaedlich-Stubenrauch
  • Publication number: 20040256072
    Abstract: A wax runner is provided having risers along the edge of the surface which is melted to attach the wax gates of wax patterns to the wax runner. The risers prevent the flow of molten wax over the edge of the wax runner. In addition to the risers or separately, at least one locator extends from both ends of the wax runners, the locators are aligned with one another and assure a constant distance between the ends of the wax runner and the wax pattern being affixed to it. The locators further provide a fixed reference point.
    Type: Application
    Filed: June 20, 2003
    Publication date: December 23, 2004
    Inventors: Raymond H. Puffer, Bruce S. Phipps, Daniel Walczyk, Rory MacKean, Jason Chalfant
  • Publication number: 20040173334
    Abstract: According to the invention a light metal cylinder liner with a surface which facilitates the connection with the surrounding cast material may be produced, whereby the cylinder liner is produced by means of a lost-foam method with a form for production of the cast foam model having a structured surface with height variations of 0.8 to 5 mm, said structuring being for example grooves or longitudinal elevations.
    Type: Application
    Filed: April 26, 2004
    Publication date: September 9, 2004
    Inventors: Karlheinz Bing, Frank Winger
  • Patent number: 6766850
    Abstract: A method of casting including forming a shell mold around a pattern fabricated from an expendable material and then removing the expendable material from the shell mold. The shell mold is located within a housing such that an inlet port of the shell mold communicates with an opening in the housing. A supporting material is provided and substantially fills an open volume between an external surface of the shell mold and an interior surface of the housing. A molten material is then pressure cast through the inlet port and into the shell mold. The invention includes a mold assembly and a casting system useful in practicing the disclosed method.
    Type: Grant
    Filed: December 27, 2001
    Date of Patent: July 27, 2004
    Assignee: Caterpillar Inc
    Inventors: Gerald A. Gegel, David Weiss
  • Publication number: 20040134634
    Abstract: A method of making a ceramic shell mold comprises repeatedly coating a fugitive pattern of an article to be cast with a ceramic slurry layer and applying on the ceramic slurry layer a refractory stucco to form a plurality of ceramic slurry layers and stucco layers on the pattern wherein at least one of the stucco layers is formed by applying discontinuous stucco fiber bundles held together in the bundles by a fugitive binder, which is removed during subsequent firing of the shell mold at elevated temperature.
    Type: Application
    Filed: November 13, 2003
    Publication date: July 15, 2004
    Inventors: Xi Yang, Boyd A. Mueller
  • Publication number: 20040108090
    Abstract: A lost wax molding system has a re-usable, collapsible, chain-linked mesh exoskeleton, one or more inserts to be placed within the interior surface of the mesh exoskeleton to exert outward pressure on the mesh exoskeleton thereby creating a pre-formed, rigid, three-dimensional shape, a waterproof sleeve sized to cover the outer surface of the three-dimensional shape, and a base sized to seal said waterproof sleeve forming an investment mold container.
    Type: Application
    Filed: December 6, 2002
    Publication date: June 10, 2004
    Inventor: Michael Boyle
  • Publication number: 20040108089
    Abstract: A method for producing a golf club head consists of preparing at least two wax models for the golf club head; combining the at least two wax models; coating the combined wax models with a layer of sand mortar to form a sand mortar mold; removing the wax from the sand mortar mold; pouring molten liquid into the sand mortar mold; breaking the sand mortar mold to leave a metal golf club head. The metal golf club head is further cut off any surplus metal and polished to complete a one-piece metal golf club head.
    Type: Application
    Filed: December 4, 2002
    Publication date: June 10, 2004
    Inventors: Bernard Cheng, Hsiao-Kun Chen, Tony Chen, May Lin
  • Patent number: 6739376
    Abstract: A method for producing a golf club head includes preparing at least two wax models for the golf club head; combining the at least two wax models; coating the combined wax models with a layer of sand mortar to form a sand mortar mold; removing the wax from the sand mortar mold; pouring molten liquid into the sand mortar mold; breaking the sand mortar mold to leave a metal golf club head. The metal golf club head is further cut off any surplus metal and polished to complete a one-piece metal golf club head.
    Type: Grant
    Filed: December 4, 2002
    Date of Patent: May 25, 2004
    Assignee: Advanced International Multitech Co., Ltd.
    Inventors: Bernard Cheng, Hsiao-Kun Chen, Tony Chen, May Lin