Pattern Making Patents (Class 164/45)
  • Patent number: 9511990
    Abstract: A method of fabricating a micromechanical part in a single-piece made of a synthetic carbon-allotrope includes forming a substrate which includes the negative cavity for the micromechanical part to be fabricated, coating the negative cavity of the substrate with a layer of the synthetic carbon allotrope in a thickness of between 0.2 ?m and 20 ?m, the thickness being less than the depth of the negative cavity, removing from the substrate a larger thickness than the thickness of the deposited layer, so as to leave a limited thickness of the layer of material in the negative cavity, and removing the substrate so as to release the single-piece micromechanical part formed in the negative cavity comprising an external surface of comparable roughness to that of the substrate.
    Type: Grant
    Filed: January 5, 2012
    Date of Patent: December 6, 2016
    Assignee: Nivarox-FAR S.A.
    Inventors: Pierre Cusin, David Richard, Philippe Dubois
  • Patent number: 9364889
    Abstract: Various techniques are provided for creating fugitive foam patterns for use in investment casting operations. In certain illustrative embodiments, a fugitive foam pattern is assembled from independently formed portions. A first section is formed in a mold. Once cured, a mating surface of the first section is exposed to the cavity of a second mold and the section is formed. The second section integrally adheres to the first section. The process is repeated as necessary. In alternative embodiments, a channel is created in a foam pattern using a temporary core that is removed without chemical leaching. The core material comprises water-soluble materials, acid-soluble materials, low-melting point materials, or a combination thereof. A pattern may also be created by inserting foam around a core that remains with the foam pattern.
    Type: Grant
    Filed: January 4, 2013
    Date of Patent: June 14, 2016
    Assignee: IC PATTERNS, LLC
    Inventors: Anil R. Chaudhry, Robert Dzugan, Richard M. Harrington, Faurice D. Neece, Nipendra P. Singh, Travis Westendorf
  • Patent number: 9132476
    Abstract: A multi-wall gas turbine airfoil (192) and method of forming same using a casting core (150) having a monolithic body configured to define a pressure side wall (12), a suction side wall (14), and a third wall (16). The casting core is formed around a fugitive insert (96) during a single pour casting process.
    Type: Grant
    Filed: October 31, 2013
    Date of Patent: September 15, 2015
    Assignee: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Ching-Pang Lee, Gary B. Merrill
  • Publication number: 20150132139
    Abstract: A foundry core for manufacturing a blade of a turbomachine including a tip section offset, including a core element for forming various internal cavities, the core element including a leading-edge cavity internal core, central cavity internal cores, and a trailing-edge cavity internal core. The internal core for the central cavity adjacent to the internal core for the trailing-edge cavity includes a bulge extending toward the core for the leading-edge cavity.
    Type: Application
    Filed: February 12, 2013
    Publication date: May 14, 2015
    Applicant: SNECMA
    Inventors: Huu-Thanh Tran, Michael Hansom, Christian Bariaud, Patrice Eneau
  • Publication number: 20150121957
    Abstract: The present invention relates to a nail ornament having a base substrate and a plurality of three-dimensional ornaments attached to the base substrate in that the lower surface of the base substrate is configured to substantially conform to a nail and the plurality of ornaments are embedded in the upper surface of the base substrate. Recesses are formed in the upper surface of the base substrate and the plurality of three-dimensional ornaments fits into the recesses. The lower surface of the base substrate is curved such that the lower surface substantially conforms to a contour of a nail when placed in contact with the nail.
    Type: Application
    Filed: November 1, 2013
    Publication date: May 7, 2015
    Inventor: Brandon LEE
  • Patent number: 8936068
    Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.
    Type: Grant
    Filed: April 15, 2011
    Date of Patent: January 20, 2015
    Assignees: Siemens Energy, Inc., Mikro Systems, Inc.
    Inventors: Ching-Pang Lee, Gary B. Merrill, Andrew J. Burns
  • Publication number: 20140290892
    Abstract: Refractory slurry for use in coating a foam cluster to provide a foam pattern for lost foam casting is provided. The slurry includes a catalyst capable of catalyzing reactions for vaporizing the foam cluster. A foam pattern with a refractory coating including the catalyst and processes for preparing the foam pattern and using the foam pattern are also provided.
    Type: Application
    Filed: March 24, 2014
    Publication date: October 2, 2014
    Applicant: General Electric Company
    Inventors: Zhaoping WU, Brian Victor MOORE, Michael Douglas ARNETT, Dejia WANG, Junyoung PARK, Yanfei GU, Qi ZHAO
  • Publication number: 20140284016
    Abstract: A method for creating undercut features in a wax pattern in an investment casting process is disclosed. The method comprises designing a tooling that includes a mold for an object with an aperture and a core corresponding in size and shape of the aperture. Then, the mold is used to injection mold a pattern for the object, wherein the pattern includes an opening corresponding to the aperture. Next, a plug from the core of the tooling is injection molded using the mold. The plug is press-fitted into the opening of the pattern and the opening of the pattern is sealed with the plug.
    Type: Application
    Filed: April 16, 2014
    Publication date: September 25, 2014
    Applicant: COORSTEK MEDICAL LLC d/b/a IMDS
    Inventor: Stephen Vander Wal
  • Publication number: 20140262108
    Abstract: A method of making a radial pattern assembly is disclosed. The method includes forming a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between an outer surface of the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.
    Type: Application
    Filed: March 14, 2013
    Publication date: September 18, 2014
    Applicant: Hitchiner Manufacturing Co., Inc.
    Inventors: Michael R. Hanrahan, Skip L. Patteuw
  • Patent number: 8833430
    Abstract: A method of forming a nanostructured surface, including providing an original nanostructured surface having an array of high aspect ratio structures formed on a planar substrate; forming a negative replica mold of the original nanostructured surface, where the negative replica mold includes a flexible material; deforming the negative replica mold; and using the deformed negative replica mold to form a deformed replica of the original nanostructured surface, where the deforming step is performed at least one of before, during, or after introducing a material for forming the deformed replica into the negative replica mold.
    Type: Grant
    Filed: June 26, 2009
    Date of Patent: September 16, 2014
    Assignee: President and Fellows of Harvard College
    Inventors: Joanna Aizenberg, Boaz Pokroy
  • Patent number: 8720527
    Abstract: A method for manufacturing a cast product having a photographic relief image thereon is disclosed. The method includes steps of capturing a photographic image as a digital grayscale image, converting the digital grayscale image to a series of instructions for operating a laser engraving machine; laser engraving a pattern material to provide a pattern having a photographic relief image therein corresponding to the digital grayscale image and having a relief depth of about 0.030 inch to about 0.080 inch, wherein the relief depth refers to the maximum relief distance within the photographic relief image, and wherein the photographic relief image exhibits a true resolution corresponding to at least about 80 dpi; creating a mold cavity in sand using the laser engraved substrate; and casting a metallic material in the mold cavity to provide a cast product having the photographic relief image therein.
    Type: Grant
    Filed: March 25, 2012
    Date of Patent: May 13, 2014
    Assignee: Cold Springs Granite Company
    Inventors: Samuel Emerson Shepherd, Chad David Althaus
  • Patent number: 8702394
    Abstract: An air boost device such as a turbocharger, wherein the compressor wheel thereof 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. The compressor wheel improves low cycle fatigue, withstands high temperatures and temperature changes, and permits operation at high boost pressure ratio while, on the other hand, having low weight, low inertial drag, and high responsiveness.
    Type: Grant
    Filed: January 24, 2008
    Date of Patent: April 22, 2014
    Assignee: BorgWarner, Inc.
    Inventors: David Decker, Stephen I. Roby
  • Publication number: 20140102656
    Abstract: A casting core assembly includes a metallic core and a ceramic core. A protuberant portion of a metallic core is received in a compartment of the ceramic core.
    Type: Application
    Filed: October 12, 2012
    Publication date: April 17, 2014
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Tracy A Propheter-Hinckley, Eric A Hansen
  • Patent number: 8689855
    Abstract: A tire vulcanizing mold manufacturing method for manufacturing of a mold including a vent mechanism, and a tire vulcanizing mold manufactured using such method are disclosed. Blades each with anchor portions are mounted on a plaster mold with only the anchor portions embedded in the plaster mold. A portion of each blade mounted on the plaster mold is covered with a cover layer made of a destructible fire-resistant material. Molten metal is poured over a surface of the plaster mold to cast a mold to which the shape of the surface is transferred and in which each blade is buried. The anchor portions protruding from the surface of the mold are removed, and the cover layer is removed to form a slit around the blade. A vent opening forming member is removed to form a vent opening. The slit and the vent opening communicate with each other.
    Type: Grant
    Filed: April 10, 2012
    Date of Patent: April 8, 2014
    Assignee: The Yokohama Rubber Co., Ltd.
    Inventor: Kenji Enokido
  • Publication number: 20140090383
    Abstract: A casting, mold and method for producing a casting are disclosed. The casting may have an area of small thermal mass and an area of large thermal mass. The method may comprise providing a casting having a work product and an appendage engaged to, and suspended over, the work product between the area of small thermal mass and the area of large thermal mass, and controllably cooling the work product using the appendage.
    Type: Application
    Filed: June 27, 2013
    Publication date: April 3, 2014
    Inventor: Bradley T. Duelm
  • Patent number: 8678071
    Abstract: A lightweight metal mold having a necessary rigidity is realized. Firstly, an original pattern of an evaporative pattern is formed by machining an evaporative material block. The original pattern includes a three-dimensional mesh structure including a plurality of bar-shaped parts and connecting points that connect ends of the bar-shaped parts and are distributed in a three-dimensional space, and a plurality of block parts having fixed relative positional relationship by being fixed to the three-dimensional mesh structure. Then, at least a portion of at least one or more of the bar-shaped parts composing the original pattern is removed, and replaced with a tube member. Then, a full-mold casting is performed by using the evaporative pattern having the replaced tube member. Positional relationship of the block parts in which surfaces, etc. necessary for the metal mold are formed is fixed by the three-dimensional mesh structure, and the necessary rigidity is secured.
    Type: Grant
    Filed: January 28, 2011
    Date of Patent: March 25, 2014
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Hirotake Sueta, Kiyoshi Kameyama, Atsushi Takemoto, Tatsuya Watarai, Hitoshi Akimoto, Masaki Yamashita
  • Patent number: 8678073
    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: August 22, 2007
    Date of Patent: March 25, 2014
    Assignee: Howmet Corporation
    Inventors: Richard S. Jakus, Kurt R. Swartz
  • Patent number: 8678769
    Abstract: A compressor impeller and a method of manufacturing the compressor impeller. The magnesium alloy compressor impeller as a die-cast part comprises a hub shaft part, a hub disk part having a hub surface extending from the hub shaft part in the radial direction, and a plurality of vane parts disposed on the hub surface. The impeller can be manufactured by a die-cast method in which a magnesium alloy heated to a liquidus temperature or higher is supplied into molds with cavities corresponding to the shape of the impeller for a filling time of 1 sec. or shorter, a pressure of 20 MPa or higher is applied to the magnesium alloy in the cavities, and the pressurized state is maintained for a time of 1 sec. or longer.
    Type: Grant
    Filed: February 21, 2006
    Date of Patent: March 25, 2014
    Assignees: Hitachi Metals Precision, Ltd., Hitachi Metals, Ltd.
    Inventors: Yasuhiro Kubota, Hirokazu Itoh, Mikio Sasaki
  • Publication number: 20140079542
    Abstract: A casting mold assembly comprises an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.
    Type: Application
    Filed: September 14, 2012
    Publication date: March 20, 2014
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Steven J. Bullied, Carl R. Verner, Steven D. Porter, James B. Park
  • Patent number: 8656981
    Abstract: A root portion 7a of a sipe blade 7 that protrudes from a surface 12a of a plaster casting mold 12 is coated with a coating layer 10 of an easily collapsible refractory material. A string-shaped exhaust hole forming member 11 of a casting refractory material is attached to the sipe blade 7 so as to be in contact with the coating layer 10. Molten metal M is poured onto the surface 12a of the plaster casting mold 12 in this state so as to cast a mold with the shape of the surface 12a transferred thereon and with the root portion 7a of the sipe blade 7 cast therein. The coating layer 10 is thereafter removed to form a slit around the root portion 7a of the sipe blade 7. The exhaust hole forming member 11 is also removed to form an exhaust hole communicating with the outside of the piece. Therefore, the slit and the exhaust hole communicate with each other. In this way, a mold provided with an exhaust mechanism can be simply produced.
    Type: Grant
    Filed: July 20, 2011
    Date of Patent: February 25, 2014
    Assignee: The Yokohama Rubber Co., Ltd.
    Inventor: Kenji Enokido
  • Patent number: 8636050
    Abstract: The invention relates to a method of fabricating a micromechanical part made of a single piece material. According to the invention, the method includes the following steps: a) forming a substrate which includes the negative cavity for said micromechanical part to be fabricated; b) forming a sacrificial layer on one portion of the substrate; c) depositing particles on the substrate intended to form a germ ination layer; d) removing the sacrificial layer so as to selectively leave one portion of the substrate free of any particles; e) depositing a layer of material by chemical vapour phase deposition so that the material is exclusively deposited where the particles remain; f) removing the substrate to release the micromechanical part formed in said negative cavity.
    Type: Grant
    Filed: February 2, 2012
    Date of Patent: January 28, 2014
    Assignee: Nivarox-FAR S.A.
    Inventors: Pierre Cusin, David Richard, Philippe Dubois
  • Publication number: 20130333855
    Abstract: An investment casting process wherein the wax pattern tool (42) is flexible to provide compliant support for an enclosed ceramic core (10) and to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. Positioning pins (106) may extend from the flexible tool to make compliant contact against the core during the wax injection step. The pins may cooperate with a pedestal (128) formed on the core to support the core along multiple axes during wax injection, thereby allowing a higher wax injection pressure without damage to the core.
    Type: Application
    Filed: May 3, 2013
    Publication date: December 19, 2013
    Inventors: GARY B. MERRILL, Allister Williams James, Kevin C. Sheehan, Benjamin E. Heneveld, Iain Alasdair Fraser
  • Patent number: 8591787
    Abstract: A method of creating a foam pattern comprises mixing a polyol component and an isocyanate component to form a liquid mixture. The method further comprises placing a temporary core having a shape corresponding to a desired internal feature in a cavity of a mold and inserting the mixture into the cavity of the mold so that the mixture surrounds a portion of the temporary core. The method optionally further comprises using supporting pins made of foam to support the core in the mold cavity, with such pins becoming integral part of the pattern material simplifying subsequent processing. The method further comprises waiting for a predetermined time sufficient for a reaction from the mixture to form a foam pattern structure corresponding to the cavity of the mold, wherein the foam pattern structure encloses a portion of the temporary core and removing the temporary core from the pattern independent of chemical leaching.
    Type: Grant
    Filed: June 7, 2011
    Date of Patent: November 26, 2013
    Assignee: IC Patterns, LLC
    Inventors: Anil R. Chaudhry, Robert Dzugan, Richard M. Harrington, Faurice D. Neece, Nipendra P. Singh, Travis Westendorf
  • Publication number: 20130309098
    Abstract: A turbocompressor rotor for a turbocompressor for compressing process gas has a rotor body which makes contact with the process gas and which is produced entirely from a stainless steel material including 0.3 to 1.2% carbon and 12 to 19% chromium, wherein the steel material includes the alloy X39CrMo17-1.9. A process for producing such a turbocompressor rotor by casting includes manufacturing a casting model corresponding to the geometry of the rotor body by rapid technology and producing a casting mold using the casting model, or manufacturing a casting mold corresponding to the negative geometry of the rotor body by rapid technology, introducing the liquid steel material into the casting mold to form a cast workpiece as the rotor body, and finishing the turbocompressor rotor with the rotor body.
    Type: Application
    Filed: February 1, 2012
    Publication date: November 21, 2013
    Inventor: Ralf Bode
  • Patent number: 8511366
    Abstract: A method for spray forming a metal component (11, 17, 21, 27) having an elongated open channel (10, 20, 22, 28) therein comprises firstly spray forming a layer (8, 19, 24) of the desired metal onto a deposition substrate (2), placing then an elongated spray blocking object (9, 18, 26, 29) on the already sprayed layer for forming the channel, and continuing then the spray forming process until the desired total thickness of the component is achieved. According to the present invention, the spray blocking object is a strip (18, 26, 29), the cross-sectional profile of the strip being fully open in the direction of an axis (a) in a cross-sectional plane of the strip, and the strip is placed on the already deposited layer (8, 19, 24) with said axis directed substantially parallel to the direction of the incident metal spray (6).
    Type: Grant
    Filed: August 30, 2006
    Date of Patent: August 20, 2013
    Assignee: Valtion teknillinen tutkimuskeskus
    Inventor: Yunfeng Yang
  • Publication number: 20130174996
    Abstract: Various techniques are provided for creating fugitive foam patterns for use in investment casting operations. In certain illustrative embodiments, a fugitive foam pattern is assembled from independently formed portions. A first section is formed in a mold. Once cured, a mating surface of the first section is exposed to the cavity of a second mold and the section is formed. The second section integrally adheres to the first section. The process is repeated as necessary. In alternative embodiments, a channel is created in a foam pattern using a temporary core that is removed without chemical leaching. The core material comprises water-soluble materials, acid-soluble materials, low-melting point materials, or a combination thereof. A pattern may also be created by inserting foam around a core that remains with the foam pattern.
    Type: Application
    Filed: January 4, 2013
    Publication date: July 11, 2013
    Applicant: FOPAT LLC
    Inventor: FOPAT LLC
  • Publication number: 20130168035
    Abstract: A casting assembly for manufacturing a lock of a railcar coupler includes drag and cope portions of a first mold that defines exterior surfaces of the lock, wherein the first mold comprises a first molding material. The casting assembly also includes a second mold formed of a second molding material. The second mold defines a cavity with an interior surface that substantially complements an exterior surface of the first mold. A down sprue is formed in the second mold. A gating system is formed in the second mold that and is in fluid communication with the down sprue. An in-gate is formed in the second mold and is in fluid communication with the gating system and the first mold.
    Type: Application
    Filed: December 28, 2011
    Publication date: July 4, 2013
    Inventors: F. Andrew Nibouar, Jerry R. Smerecky, Kelly S. Day, Nick Salamasick
  • 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
  • Patent number: 8424585
    Abstract: A method and apparatus for creating a pattern of an item of manufacture, the method and apparatus including the use of a mold frame, mold, mold core, injection frame and injection core to create patterns of items of manufacture for investment casting.
    Type: Grant
    Filed: March 4, 2011
    Date of Patent: April 23, 2013
    Assignee: James Avery Craftsman, Inc.
    Inventor: Aaron Hansen
  • Patent number: 8397790
    Abstract: A method of manufacture of a wax model of an annular bladed turbomachine stator assembly includes in succession the positioning, in a mold, of a core intended to form the impression of a cavity of a blade of the assembly, the injection of a wax in the mold, and the removal of the wax model fitted with the core from the mold. The core is manufactured in metal and is positioned such that its radially internal end is housed in the portion of the mold defining the blade including the cavity, away from the radially internal end of this portion of the mold.
    Type: Grant
    Filed: September 30, 2010
    Date of Patent: March 19, 2013
    Assignee: SNECMA
    Inventors: Christian Bariaud, Yannick Collin, Eric Herzer, David Mathieu
  • 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
  • Publication number: 20120186769
    Abstract: A method and apparatus for creating a pattern of an item of manufacture, the method and apparatus including the use of a mold frame, mold, mold core, injection frame and injection core to create patterns of items of manufacture for investment casting.
    Type: Application
    Filed: March 4, 2011
    Publication date: July 26, 2012
    Inventor: Aaron Hansen
  • Publication number: 20120180972
    Abstract: A method of manufacture of a wax model of an annular bladed turbomachine stator assembly includes in succession the positioning, in a mould, of a core intended to form the impression of a cavity of a blade of the assembly, the injection of a wax in the mould, and the removal of the wax model fitted with the core from the mould. The core is manufactured in metal and is positioned such that its radially internal end is housed in the portion of the mould defining the blade including the cavity, away from the radially internal end of this portion of the mould.
    Type: Application
    Filed: September 30, 2010
    Publication date: July 19, 2012
    Applicant: SNECMA
    Inventors: Christian Bariaud, Yannick Collin, Eric Herzer, David Mathieu
  • Publication number: 20120156044
    Abstract: A bi-cast turbine rotor disk and method of forming the same are provided. The disk includes a ring and a blade. The ring comprises a superalloy that includes a plurality of elements, and the blade extends from the ring. The blade comprises a non-metallic ceramic matrix composite, and at least one element from the superalloy of the ring is diffused into the non-metallic ceramic matrix composite of the blade.
    Type: Application
    Filed: December 20, 2010
    Publication date: June 21, 2012
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventor: Milton Ortiz
  • Patent number: 8196640
    Abstract: A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).
    Type: Grant
    Filed: July 1, 2011
    Date of Patent: June 12, 2012
    Assignee: Mikro Systems, Inc.
    Inventors: John R. Paulus, Michael P. Appleby
  • Publication number: 20120118015
    Abstract: The present invention relates to a process to produce hollow jewelry article and hollow jewelry articles produced in accordance with the said process. The process comprises a joining least two predetermined wax portions into a wax model and casting the said wax model into a partially or fully hollow jewelry article.
    Type: Application
    Filed: November 19, 2008
    Publication date: May 17, 2012
    Applicant: Jewelex India Pvt. Ltd.
    Inventor: Arvind Soni
  • Publication number: 20120112604
    Abstract: A manufacturing method of an ultrasonic probe that has a signal foil made of a copper foil patterned by an additive method is provided. The manufacturing method includes preparing a base material and forming an insulating layer on a surface of the material, patterning the insulating layer by exposure, development, and peeling according to a lithographic technique, forming a cavity reaching an upper surface of the base material in the insulating layer along the patterning, forming a signal foil by performing plating in the cavity in the order of copper plating and solder plating, and demolding the formed signal foil from the cavity.
    Type: Application
    Filed: October 14, 2011
    Publication date: May 10, 2012
    Applicant: NIHON DEMPA KOGYO CO., LTD.
    Inventor: Yasunobu HASEGAWA
  • 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
  • Publication number: 20120055647
    Abstract: In the castings of a turbine element, a sheet casting core is assembled to a feedcore. The sheet casting core and feedcore are placed in a die. A sacrificial pattern material is molded over the casting core and feedcore to form a pattern including an airfoil. The sheet casting core extends from at or adjacent a trailing edge of the airfoil. The sheet casting core has a first array of open areas and a second array of portions interspersed with the open areas. A first portion of the die has a third array of projections contacting the second array.
    Type: Application
    Filed: November 10, 2011
    Publication date: March 8, 2012
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: P. Brennan Reilly, Lea D. Kennard
  • Publication number: 20120031579
    Abstract: A method for producing a negative mold for casting a turbine blade with a blade platform and at least one fastening element for fastening the turbine blade to a blade fixture is provided. The surface of the fastening element of a platform surface is located at a distance opposite of the blade platform. A wax model of the turbine blade to be produced is produced, a negative model of the turbine blade is created based on the wax model after the wax model has hardened and the wax model is melted out after completion of the negative mold. During hardening and/or during storage and/or during transport of the wax model at least one spacer is arranged between the platform surface of the blade platform and the opposite surface of the fastening element of the wax model.
    Type: Application
    Filed: March 31, 2010
    Publication date: February 9, 2012
    Inventors: Fathi Ahmad, Winfried Esser
  • Patent number: 8100165
    Abstract: An investment casting core combination includes a metallic casting core and a ceramic feedcore. A first region of the metallic casting core is embedded in the ceramic feedcore. A mating edge portion of the metallic casting core includes a number of projections. The first region is along at least some of the projections. A number of recesses span gaps between adjacent projections. The ceramic feedcore includes a number of compartments respectively receiving the metallic casting core projections. The ceramic feedcore further includes a number of portions between the compartments and respectively received in the metallic casting core recesses.
    Type: Grant
    Filed: November 17, 2008
    Date of Patent: January 24, 2012
    Assignee: United Technologies Corporation
    Inventors: Justin D. Piggush, Karl A. Mentz, Richard H. Page, Jesse R. Christophel, Ricardo Trindade
  • 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: 8066052
    Abstract: A casting includes a wall thickness check feature for measuring thickness of a wall second aside an in-wall cooling passageway. The thickness is determined by observing the existence and/or size of an opening formed by the feature. The casting is cast from a pattern including portions forming the feature. To manufacture the pattern, a pattern-forming die is assembled with a ceramic feedcore and a refractory metal core (RMC). The assembling leaves an inlet portion of the RMC engaged to the ceramic feedcore and leaves an outlet portion of the RMC engaged to the die. A pattern-forming material is molded in the die at least partially over the ceramic feedcore and RMC. The die is disengaged from the pattern-forming material. The assembling engages a stepped projection of the RMC with a mating surface of the die.
    Type: Grant
    Filed: June 7, 2007
    Date of Patent: November 29, 2011
    Assignee: United Technologies Corporation
    Inventor: Michael F. Blair
  • Patent number: 8056603
    Abstract: A method for producing a casting die by simple work without requiring any high work skill in which the working days required for producing the casting die can be shortened greatly. A die model suitably employed in this production method, an NC processing system and a processing robot are also provided.
    Type: Grant
    Filed: September 19, 2007
    Date of Patent: November 15, 2011
    Assignees: Kamiita Seiki Seisakusho Co., Ltd., Mold Technical Office Co., Ltd.
    Inventors: Seiji Omata, Toshio Iwasawa
  • Publication number: 20110247859
    Abstract: The manufacture of a submillimetric grid includes the production of a mask having submillimetric openings, referred to as a network mask, on the main face, from a solution of colloidal nanoparticles with a given glass transition temperature Tg, the drying of the masking layer at a temperature below the Tg; the formation of the electroconductive grid from the network mask including in this order: deposition of at least one electroconductive material, referred to as grid material, having an electricity resistivity of less than 10?5 ohm.cm; removal of the masking layer, revealing the mother grid; optional deposition, by electrodeposition, of an electroconductive material, referred to as overgrid material, the surface subjacent to the mother grid then being dielectric; a detachment, of the mother grid or the overgrid, of a thickness of at least 500 nm. The invention also relates to the detached grid.
    Type: Application
    Filed: September 25, 2009
    Publication date: October 13, 2011
    Inventors: Georges Zagdoun, Bernard Nghiem, Emmanuel Valentin, Eddy Royer
  • 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: 7958932
    Abstract: A foam material comprises a liquid polymer and a liquid isocyanate which is mixed to make a solution that is poured, injected or otherwise deposited into a corresponding mold. A reaction from the mixture of the liquid polymer and liquid isocyanate inside the mold forms a thermally collapsible foam structure having a shape that corresponds to the inside surface configuration of the mold and a skin that is continuous and unbroken. Once the reaction is complete, the foam pattern is removed from the mold and may be used as a pattern in any number of conventional casting processes.
    Type: Grant
    Filed: July 3, 2008
    Date of Patent: June 14, 2011
    Assignee: Fopat LLC
    Inventors: Anil R. Chaudhry, Robert Dzugan, Richard M. Harrington, Faurice D. Neece, Nipendra P. Singh