Including Recycling Of Process Material Patents (Class 164/5)
  • Patent number: 11065676
    Abstract: What are described is a process for producing casting molds, cores and mold base materials regenerated therefrom, a mixture for combination with a solution or dispersion comprising waterglass for production of casting molds and/or cores, a molding material mixture, a mold base material mixture, and a casting mold or a core. What is also described is the corresponding use of an amount of particulate sheet silicates having a d90 of less than 45 ?m or a corresponding mixture as additive for production of a molding material mixture comprising waterglass and particulate amorphous silicon dioxide, which is cured by chemical reaction of constituents of the molding material mixture with one another, in the production of a casting mold or a core, to facilitate the breakdown and/or to increase the regeneratability of the casting mold or core.
    Type: Grant
    Filed: April 5, 2018
    Date of Patent: July 20, 2021
    Assignee: HÜTTENES-ALBERTUS CHEMISCHE WERKE GESELLSCHAFT MIT BESCHRÄNKTER HAFTUNG
    Inventors: Lukas Mirko Reinold, Maria Schweinefuss, Christian Lustig
  • Patent number: 10967421
    Abstract: A method of reusing core sand includes crushing a core used for casting into granules, the core includes water glass as a binder, and the water glass includes water-soluble water glass and water-insoluble water glass; heating the core; detaching the water glass from the core sand; and separating and collecting the core sand from a mixture of the water glass and the core sand.
    Type: Grant
    Filed: April 17, 2020
    Date of Patent: April 6, 2021
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Yamashita, Hirotsune Watanabe, Masashi Morikawa
  • Patent number: 10906088
    Abstract: A method of forming a dry molding sand additive may include recovering a non-sand fraction from a foundry waste material and adding the non-sand fraction to a dry molding sand additive formulation to form a dry molding sand additive. Adding the non-sand fraction to the dry molding sand additive formulation may reduce the amount of fresh clay and carbon to produce the dry molding sand additive. A method of forming a molding sand additive may include recovering a waste molding sand additive composition having a clay or carbon content differing from a desired clay and carbon content, recycling the waste molding sand additive as a raw material in production of a fresh molding sand additive, and adjusting the amount of fresh clay or carbon added during production of the fresh molding sand additive to achieve the desired clay and carbon content.
    Type: Grant
    Filed: August 11, 2016
    Date of Patent: February 2, 2021
    Assignee: IMERYS USA, INC.
    Inventors: Victor Lafay, Jeremy Tibbs, Felicia Daniels, Brian Burns
  • Patent number: 10493466
    Abstract: One or more techniques and/or systems are disclosed for producing beneficial re-use sand from foundry sand. Foundry sand can be collected from a mold making operation, and/or from the casting removal and cleaning process. The collected sand product can be cleaned and separated into a clay and carbon mixture, and a beneficial re-use sand. The collected sand product can be cleaned by mixing with water, and subjecting the resulting mix to a hydrocyclone at appropriate flow rates. The hydrocyclone can separate the mix into a carbon, clay and water mix for re-use, and a wet sand mix. Water can be separated from the wet sand and reused, and the resulting sand can be used as beneficial re-use sand.
    Type: Grant
    Filed: February 26, 2018
    Date of Patent: December 3, 2019
    Assignee: KB FOUNDRY SERVICES, LLC
    Inventor: Mark Pine
  • Patent number: 10041890
    Abstract: A method of manufacturing a core for casting a component can include manufacturing a core for at least partially forming an internal passage architecture of a component with a material including radiopaque particles. A method can include removing a material including radio opaque particles from an internal passage architecture of a component; and inspecting the component via radiographic imaging at gamma/X-ray wavelengths to detect residual material. A core for use in casting an internal passage architecture of a component can include a material with radiopaque particles dispersed therein.
    Type: Grant
    Filed: August 4, 2015
    Date of Patent: August 7, 2018
    Assignee: United Technologies Corporation
    Inventors: James Tilsley Auxier, Lea Kennard Castle
  • Patent number: 9987637
    Abstract: A process for refining sand for use as frac sand includes the steps of passing the sand through a first fines separation stage to remove fine particles of contaminant from the sand, reducing the water content of the sand (such as to less than 20%), passing the sand into an attrition scrubber unit containing moving blades to delaminate clay and other contaminants from the sand grains, passing the sand from the attrition scrubber unit through a second fines separation stage to separate fine contaminants from the sand, and dewatering the resulting sand product in a further dewatering stage.
    Type: Grant
    Filed: August 24, 2017
    Date of Patent: June 5, 2018
    Assignee: CDE Global Limited
    Inventors: Anthony Convery, Glenn Sloan
  • Patent number: 9724754
    Abstract: There are provided a method of manufacturing an aluminum product and a method of manufacturing an aluminum brake caliper each using die casting, for improving flow and run of molten metal during casting and enhancing productivity and quality. In a method of manufacturing an aluminum product provided with opposing portions opposed to each other with a hollow portion interposed in between, and connecting portions connecting the opposing portions at two sides thereof, the method includes a die casting step of performing casting by pouring molten metal of an aluminum alloy from a gate for the molten metal formed in one of the opposing portions via the connecting portions and a bridge connecting the two opposing portions, and a bridge removing step of removing the bridge.
    Type: Grant
    Filed: December 4, 2012
    Date of Patent: August 8, 2017
    Assignee: NIPPON LIGHT METAL COMPANY, LTD.
    Inventors: Shinya Sato, Takaaki Ikari
  • Patent number: 8985184
    Abstract: For regenerating the sand, which is obtained from sand molds and/or sand cores, which are produced from the sand and soluble glass as a binder and are used in metal casting, the sand obtained from the sand molds and/or sand cores is subjected to a mechanical regeneration stage and a thermal regeneration stage. During or after the mechanical regeneration stage, the obtained sand is mixed with a hardener for soluble glass.
    Type: Grant
    Filed: February 24, 2014
    Date of Patent: March 24, 2015
    Assignee: Bayerische Motoren Werke Aktiengesellschaft
    Inventors: Harald Schwickal, Matthias Huebner
  • Publication number: 20140166226
    Abstract: For regenerating the sand, which is obtained from sand molds and/or sand cores, which are produced from the sand and soluble glass as a binder and are used in metal casting, the sand obtained from the sand molds and/or sand cores is subjected to a mechanical regeneration stage and a thermal regeneration stage. During or after the mechanical regeneration stage, the obtained sand is mixed with a hardener for soluble glass.
    Type: Application
    Filed: February 24, 2014
    Publication date: June 19, 2014
    Applicant: Bayerische Motoren Werke Aktiengesellschaft
    Inventors: Harald SCHWICKAL, Matthias HUEBNER
  • Patent number: 8631854
    Abstract: With a continuous casting method for producing preliminary profiles, in particular double T preliminary profiles, the downwardly flowing cooling water is pushed out of the internal curve of the preliminary profile strand (3) via the profile flanges and discharged using water nozzles (21, 22) aligned substantially to the crossover from the bar (4) to the respective flange (5, 6) by means of the diverting water delivered via the water nozzles (21, 22). In this way the excessive cooling caused by downwardly running cooling water is largely avoided in the internal curve of the preliminary profile strand.
    Type: Grant
    Filed: March 5, 2010
    Date of Patent: January 21, 2014
    Assignee: SMS Concast AG
    Inventors: Christian Dratva, Klaus Von Eynatten
  • Patent number: 8071664
    Abstract: Compositions comprising (1) a refractory and/or a binder, and (2) bis-cyclopentadienyl iron cyclopentadienyl manganese tricarbonyl, derivatives thereof, and mixtures thereof.
    Type: Grant
    Filed: January 26, 2009
    Date of Patent: December 6, 2011
    Assignee: ASK Chemicals L.P.
    Inventors: Ronald C. Aufderheide, Michael T. Brown, Jorg Kroker, Xianping Wang
  • Publication number: 20100173767
    Abstract: The invention relates to a method for regenerating used foundry sand, which is contaminated with soluble glass, wherein: used foundry sand is provided, which is tainted with a binding agent made of the soluble glass, to which a particle-shaped metal oxide is added; and the used foundry sand is subjected to a thermal treatment, wherein the foundry sand is heated to a temperature of at least 200° C., thereby obtaining regenerated foundry sand. The invention further relates to regenerated foundry sand, as that obtained from using the method.
    Type: Application
    Filed: February 19, 2008
    Publication date: July 8, 2010
    Inventors: Diether Koch, Jens Müller, Marcus Frohn
  • Publication number: 20100038826
    Abstract: A method and apparatus for forming a sheet are disclosed. A melt is cooled and a sheet is formed on the melt. This sheet has a first thickness. The sheet is then thinned from the first thickness to a second thickness using, for example, a heater or the melt. The cooling may be configured to allow solutes to be trapped in a region of the sheet and this particular sheet may be thinned and the solutes removed. The melt may be, for example, silicon, silicon and germanium, gallium, or gallium nitride.
    Type: Application
    Filed: August 11, 2009
    Publication date: February 18, 2010
    Applicant: VARIAN SEMICONDUCTOR EQUIPMENT ASSOCIATES INC.
    Inventors: Peter L. Kellerman, Frederick Carlson, Frank Sinclair
  • Patent number: 7438119
    Abstract: A system for reclaiming sand from a casting process includes a chamber having an inlet, an outlet, and a plurality of baffles defining a circuitous path for the sand therebetween, a heating element for providing heat to the chamber, and a fluidizing distributor for directing the sand through the chamber. A method of reclaiming waste sand also is provided.
    Type: Grant
    Filed: March 18, 2005
    Date of Patent: October 21, 2008
    Assignee: Consolidated Engineering Company, Inc.
    Inventors: Paul M. Crafton, James L. Lewis, Jr., Ian French, Shanker Subramanian, James R. Garrett
  • Patent number: 7290583
    Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply fluid to the castings for heat treating the castings and degrading the sand cores for removal from the castings.
    Type: Grant
    Filed: March 9, 2005
    Date of Patent: November 6, 2007
    Assignee: Consolidated Engineering Company, Inc.
    Inventors: Scott P. Crafton, Paul M. Crafton, Volker R. Knobloch, James L. Lewis, Jr., Ian French, Franz Ruegg
  • Patent number: 7284593
    Abstract: The invention relates to a method for collecting and evacuating run-off water from the inner arc of the strand guide (8) of a beam blank casting machine, according to which the cast strand (2) is solidified and the required dissipation of heat is achieved, among other things, by sprayed water, whereby run-off water can also collect on the inner arc of the strand (2). The run-off water is collected using a suction head (1). The run-off water that is collected in the suction head is fluidized using fluidizers or momentum inhibitors. The fluidized water is sucked off and the water-air mixture is split into water and air in a separation device. The invention also relates to a device for carrying out said method, comprising at least one suction device that is arranged or can be driven along the strand guide (8), said suction device having an attachable suction head (1) and being equipped with fluidizers. The suction device (4) is driven along the beam blank preliminary section (9) by means of manipulators (7).
    Type: Grant
    Filed: March 11, 2003
    Date of Patent: October 23, 2007
    Assignee: SMS Demag AG
    Inventors: Dirk Letzel, Josef Kockentiedt, Thomas Fest, Jürgen Friedrich, Adolf-Gustav Zajber
  • Patent number: 7275582
    Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply heat to the castings for heat treating the castings and dislodging the sand cores for removal from the castings.
    Type: Grant
    Filed: October 16, 2003
    Date of Patent: October 2, 2007
    Assignee: Consolidated Engineering Company, Inc.
    Inventors: Scott P. Crafton, Paul M. Crafton, Volker R. Knobloch, James L. Lewis, Jr., Ian French
  • Patent number: 7252134
    Abstract: Various systems and apparatuses for processing a metal casting are provided.
    Type: Grant
    Filed: June 27, 2005
    Date of Patent: August 7, 2007
    Assignee: Consolidated Engineering Company, Inc.
    Inventors: Scott P. Crafton, Paul M. Crafton, Ian French, Jim Garrett
  • Patent number: 7147034
    Abstract: Apparatus for use in reclaiming particulate material from bonded particulate material comprises an outer compartment arranged substantially concentrically about an inner compartment, means in one compartment for breaking up the bonded particulate material and means in the other compartment for removing the binder, and means for transferring broken up material from one compartment to the other.
    Type: Grant
    Filed: April 5, 2002
    Date of Patent: December 12, 2006
    Assignee: Clayton Thermal Processes Limited
    Inventor: Christopher Clayton
  • Patent number: 7140418
    Abstract: A continuous metallic strip casting plant comprising an ingot mould, a device for the evacuation of casting wastes formed by a trolley which can host two chests. The trolley is located below the ingot mould and on the trolley is deposited the full chest in the free space next to the spare empty chest. The trolley is then moved and the spare empty chest is fixed under the ingot mould. A metal waste evacuation method is also described.
    Type: Grant
    Filed: July 10, 2003
    Date of Patent: November 28, 2006
    Assignee: Danieli & C. Officine Meccaniche S.p.A.
    Inventors: Brian W. Botham, Andrea De Luca, Edi Faggiani, Alfredo Poloni, Nuredin Kapaj
  • Patent number: 7073557
    Abstract: A method of drying a sand mold mixture containing moisture includes restraining the sand mold mixture and exposing the sand mold mixture to a vacuum. The vacuum flashes off the moisture within the sand mold mixture thereby drying the sand mold mixture to create a solidified sand mold. The restraining member prevents voids from forming in the sand mold during exposure to the vacuum.
    Type: Grant
    Filed: February 18, 2004
    Date of Patent: July 11, 2006
    Assignee: Hormel Foods, LLC
    Inventors: Daniel L. Franklin, Richard M. Herreid
  • Patent number: 7011133
    Abstract: A filter material for molten aluminum, the material subsequently dissolvable in molten aluminum to recover aluminum captured therein.
    Type: Grant
    Filed: February 2, 2004
    Date of Patent: March 14, 2006
    Inventor: C. Edward Eckert
  • Patent number: 6929670
    Abstract: An apparatus for the separation of sand from an air stream in a thermal sand removal oven is disclosed. The preferred embodiment of the apparatus comprises a plurality of members comprising two planar members joined to form “V” shaped members. The vertex of the “V” shape points generally in the direction of the air current. The apparatus is installed in the recirculated air stream of a thermal sand removal oven, in a location between the sand molds and the air circulation means. The present invention is also installed in ovens containing metal castings containing sand cores, and ovens containing metal castings both encased in a sand mold and containing a sand core.
    Type: Grant
    Filed: January 25, 2002
    Date of Patent: August 16, 2005
    Assignee: Can-Eng Furnaces Ltd.
    Inventors: Mohamed S. Hamed, Alan Van Geyn
  • Patent number: 6926063
    Abstract: A method for conditioning cooled used moulding sand retaining moulding sand binder in a mixer (1), wherein the cooled used moulding sand is heated to at least a minimum temperature, moisturized by providing water or water vapor through holes in an agitator and subsequently cooled in the mixer from the minimum temperature using the effect of a vacuum.
    Type: Grant
    Filed: September 6, 2000
    Date of Patent: August 9, 2005
    Assignee: Maschinenfabrik Gustav Eirich
    Inventors: Paul Eirich, Hubert Eirich, Walter Eirich
  • Patent number: 6923239
    Abstract: The use of green sand is eliminated by replacing green sand molds with all core sand assemblies that provide, during casting, both the internal and external surfaces of a casting, such as a cylinder head or engine block. In the process, a mold is formed from the same core sand that is used to form the core elements defining the internal passageways of the casting. A mold-core carrier is constructed with downwardly converging sides that hold assembled mold and core elements together, without fasteners, during transportation and pouring of the molten iron alloy into the mold-core assembly and the cooling period to form the casting. After the casting is formed, the core sand from both the mold elements and core elements is recovered, and may be recycled and processed to form further mold elements or core elements or both.
    Type: Grant
    Filed: September 2, 2003
    Date of Patent: August 2, 2005
    Assignee: International Engine Intellectual Property Company, LLC
    Inventors: Billy J. Cagle, Paul E. Flick, Arthur D. Parks, Edward A. Reelfs
  • Patent number: 6920911
    Abstract: Sand mold for shaping molten metal cast into the mold. The mold includes sand, a thermally oxidizable polymer amongst the grains of the sand, and a catalyst coating on the gains for promoting the thermal oxidation and breakdown of the polymer in the course of removing the sand from the casting and/or reclaiming the sand for reuse. The catalyst coating adheres so tenaciously to the grains of sand that the sand can withstand repeated casting and sand reclamation cycles without the need to replenish the catalyst.
    Type: Grant
    Filed: November 7, 2003
    Date of Patent: July 26, 2005
    Assignee: General Motors Corporation
    Inventors: Nicholas Edward Sargent, June-Sang Siak, Mei Cai
  • Patent number: 6901990
    Abstract: A method and system of processing castings is provided in which one or more castings are deposited into a mobile furnace and moved from one station to another of a multi-station casting processing system. The interior of the mobile furnace is heated so as to maintain the temperature of the casting within a desired range of temperatures. The multi-station casting processing system may include a casting machine, a fluidized bed and a quench tank. The method may include transferring a casting into the mobile furnace and moving the furnace from one station to another.
    Type: Grant
    Filed: July 17, 2003
    Date of Patent: June 7, 2005
    Assignee: Consolidated Engineering Company, Inc.
    Inventors: Robert Howard, Paul M. Crafton, Scott P. Crafton, James L. Lewis, Jr., Volker R. Knobloch
  • Patent number: 6860313
    Abstract: A device for preparing moulding sand. The device includes a mixer configured to operate under at least a partial vacuum and at least one feeder to introduce components to be mixed. An inlet in the mixer is of sufficient size to allow rapid introduction of the components into the mixer from the feeder. The combination of large inlet opening and a pressure differential between the mixer and the feeder significantly reduces the time required to fill the mixer. In addition, the presence of the pressure differential made possible by the vacuum in the mixer reduces the likelihood that airborne contaminants resident in the mixer will migrate outside the mixer. Optional moveable conveyor chutes minimize contact of airborne contaminants with adjacent equipment, while optional mixing tools facilitate the introduction of powdered additives into the mixer.
    Type: Grant
    Filed: June 16, 2001
    Date of Patent: March 1, 2005
    Assignee: Maschinenfabrik Gustav Eirich GmbH & Co. KG
    Inventors: Uwe Greissing, Dieter Adelmann, Paul Eirich, Herbert Durr, Winfried Diem
  • Publication number: 20040261969
    Abstract: The invention provides a method with which high-quality complex-shaped castings can be manufactured and with which, after the end of the casting process, the casting mould parts can be easily removed out of or from the casting without any risk.
    Type: Application
    Filed: August 16, 2004
    Publication date: December 30, 2004
    Inventors: Bernhard Stauder, Walter Gintner
  • Patent number: 6834706
    Abstract: Sand, bentonite clay and organics recovered as foundry waste from a green sand mold foundry are reclaimed for reuse in making new green sand molds and mold cores by a multi-step process involving both hydraulic and mechanical separation steps.
    Type: Grant
    Filed: February 4, 2003
    Date of Patent: December 28, 2004
    Assignee: Foundry Advanced Clay Technologies, L.L.C.
    Inventors: Robert C. Steele, Allen James Huff
  • Publication number: 20040134633
    Abstract: Apparatus for use in reclaiming particulate material from bonded particulate material comprises an outer compartment arranged substantially concentrically about an inner compartment, means in one compartment for breaking up the bonded particulate material and means in the other compartment for removing the binder, and means for transferring broken up material from one compartment to the other.
    Type: Application
    Filed: October 3, 2003
    Publication date: July 15, 2004
    Inventor: Christopher Clayton
  • Patent number: 6725899
    Abstract: Disclosed are an apparatus for and a method of reclaiming molding sand capable of increasing a recycling efficiency of used molding sand and of highly enhancing the purity of a reclaimed molding sand. By crushing a lump of molding sand segregated from a molding box, used molding sand can be formed. In order to remove coking agents sticking on a surface of the used molding sand, an impeller disposed in a rotatable grinding drum is rotated after charging the used molding sand into a casing in which the rotatable grinding drum is disposed. The coking agents sticking on the surface of the used molding sand are removed due to collision and a mutual frictional rolling contact between the used molding sand and the rotatable grinding drum with the aid of rotational force of the impeller after having accomplished charging the used molding sand toward the impeller.
    Type: Grant
    Filed: October 25, 2002
    Date of Patent: April 27, 2004
    Assignee: Kiwon Metal Co., Ltd.
    Inventor: Jeon Rae Jo
  • Patent number: 6712119
    Abstract: A method and apparatus are provided to process collected sand. This method and apparatus allow the moisture content to be adjusted and the addition of a binder to be facilitated to renew the collected sand as casting sand for future use. Also, defective castings are prevented when they are made by a main mold using the renewed casting sand. The sand-collecting means can be compact. The method is performed and the apparatus is operated by separating a main mold of green sand, after casting is conducted, into parts unaffected and affected by the molten metal heat, adjusting the moisture content of the part unaffected by molten metal heat for use as facing sand in the next main mold making, and adding a binder and adjusting the moisture content of the part affected by the molten metal heat for use as back sand in making the next main mold.
    Type: Grant
    Filed: August 30, 2002
    Date of Patent: March 30, 2004
    Assignee: Sintokogio, Ltd.
    Inventors: Shigeaki Yamamoto, Kuniyasu Mori, Ryoji Kanayama, Hisashi Harada, Hiroaki Tokita, Kazuo Sugimoto, Takehiko Matsumoto, Hiroyasu Makino, Yasunori Yoshida
  • Publication number: 20040050527
    Abstract: A temperature control unit for raw molding sand or resin-coated sand for a shell mold according to the present invention comprises a heat exchanger (A) consisting of a spiral hollow tube allowing heat carrier to flow, and a gas distribution tube assembly for making powder flow (B) for supplying gas to cause the flow of molding sand or resin-coated sand for a shell mold. Furthermore, a temperature control apparatus according to the present invention comprises a reservoir for raw molding sand or resin-coated sand for a shell mold, and said temperature control unit provided in said reservoir.
    Type: Application
    Filed: September 17, 2002
    Publication date: March 18, 2004
    Inventors: Motoyoshi Yamazaki, Tomio Kuwatani, Masanao Tokoro
  • Patent number: 6691765
    Abstract: A system and method for producing foundry quality sand from non-conventional starting materials through the combination of oolitization and classification. Incoming particulate matter is first directed into a controlled energy attrition unit where the particles are made to collide with one another. Such collisions clean and round the particles by chipping away surface projections and coatings without crushing the particles. The particle stream is then directed through a multi-fraction classifier where it is separated into two or more useable grades of foundry sand. An air classifier is preferred for the classification stage.
    Type: Grant
    Filed: August 7, 2001
    Date of Patent: February 17, 2004
    Assignee: Noram Technology, Ltd.
    Inventors: Robert E. Sparks, Kenneth Hillel Peter Harris
  • Patent number: 6672367
    Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply heat to the castings for heat treating the castings and dislodging the sand cores for removal from the castings.
    Type: Grant
    Filed: January 31, 2002
    Date of Patent: January 6, 2004
    Assignee: Consolidated Engineering Company, Inc.
    Inventors: Scott P. Crafton, Paul M. Crafton, Volker R. Knobloch, James L. Lewis, Jr., Ian French
  • Patent number: 6651819
    Abstract: Apparatus for removing debris from a fluidized sand bed. One or more troughs extend radially from a vertical shaft. Associated with each trough is a perforated chute. The apparatus is placed into the fluidized bed of sand, and rotated. As the apparatus rotates, the perforated chute sifts, or separates, debris from the fluidized sand. That is, the fluidized sand flows through the perforations, but the debris does not. When the apparatus is removed from the fluidized bed, the debris tumbles down the chute, into the troughs, if it has not already done so, and is captured.
    Type: Grant
    Filed: July 6, 2001
    Date of Patent: November 25, 2003
    Assignee: General Electric Company
    Inventors: Rick Allen Burnett, Bradley Howard Foreman
  • Patent number: 6644381
    Abstract: The use of green sand is eliminated by replacing green sand molds with all core sand assemblies that provide, during casting, both the internal and external surfaces of a casting, such as a cylinder head or engine block. In the process, a mold is formed from the same core sand that is used to form the core elements defining the internal passageways of the casting. A mold-core carrier is constructed with tapered sides that hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period to form the casting. Although the carrier sides can use a refractory liner, preferably the sides are made of replaceable sheet metal backed by an open structural framework to enhance cooling of the casting. After the casting is formed, the core sand from both the mold elements and the core elements is recovered, and may recycled and processed to form further mold elements or core elements or both.
    Type: Grant
    Filed: June 30, 2000
    Date of Patent: November 11, 2003
    Assignee: International Engine Intellectual Property Company, LLC
    Inventors: Billy J. Cagle, Paul E. Flick, Arthur D. Parks, Edward A. Reelfs
  • Publication number: 20030205351
    Abstract: Precision castings requiring a fine finish and having complex internal geometries can be produced by casting a semi-solid thixotropic metal alloy within or about a melt-away metal component in the form of a core and/or a die insert that has a lower melting point than the solid-to-semi-solid transition temperature of the thixotropic alloy The thixotropic alloy may be cast, e.g., by thixocasting, rheocasting, sub liquidus casting. Then, after the alloy solidifies to form a casting with a captured melt-away component, the component is melted from the casting, preferably using a liquid bath. Process robustness, speed, and versatility can be enhanced by coating the component with a thin, uniform, abrasion-resistant, and thermally resistant coating that prevents excessive heat from being transferred to the component from the alloy and that prevents the component from alloying with the casting.
    Type: Application
    Filed: May 15, 2003
    Publication date: November 6, 2003
    Applicant: Chipless Metals, LLC
    Inventor: James A. Buckley
  • Publication number: 20030201091
    Abstract: Cooling and dust exhaustion plant for foundry sand, comprising:
    Type: Application
    Filed: April 30, 2002
    Publication date: October 30, 2003
    Inventor: Bartolomeo Tosco
  • Publication number: 20030145972
    Abstract: Sand, bentonite clay and organics recovered as foundry waste from a green sand mold foundry are reclaimed for reuse in making new green sand molds and mold cores by a multi-step process involving both hydraulic and mechanical separation steps.
    Type: Application
    Filed: February 4, 2003
    Publication date: August 7, 2003
    Inventors: Robert C. Steele, Allen James Huff
  • Patent number: 6595267
    Abstract: A tumbling unit such as a casting shake-out unit, rotary media drum, sand reclaimer or the like, is provided. The tumbling unit includes a cylindrical outer shell and a cylindrical inner shell. The inner liner is formed of a series of interfitting segments. The segments each have an inner surface, an outer surface, side edges, a front edge, a back edge, and a vane extending from the outer surface. The side edges of the segments have a groove formed therein which extends the length of said the edges. The grooves of neighboring segments define channel between the segments. A pin or liner lock key is received in the channel to urge the neighboring segments apart to form a tight interfit among the segments in a row of the liner. The retaining pin has a body having side surfaces, a top surface, and a bottom surface. A hole extends through the pin body and receives a dowel, which is sized to extend from opposite sides of said pin body.
    Type: Grant
    Filed: August 8, 2001
    Date of Patent: July 22, 2003
    Assignee: Didion Manufacturing Company
    Inventors: Michael S. Didion, Charles J. Didion
  • Patent number: 6591891
    Abstract: Given green sand is obtained by a mixing operation that is carried out for a short period of time. Discarded sand is supplied as supplementary sand to a sand processing line, so that molding sand can be recycled. Green sand for a molding is used for facing sand or the pocket sand. Bentonite-covered sand is made by mixing reproduced sand, new sand, and discarded sand or any or all of them. The bentonite-covered sand is added to collected sand to supplement it. Also, the bentonite-covered sand is mixed with water, and used for facing sand or the pocket sand.
    Type: Grant
    Filed: January 14, 2002
    Date of Patent: July 15, 2003
    Assignee: Sintokogio Ltd.
    Inventors: Ryoji Kanayama, Yasunori Yoshida, Kuniyasu Mori, Kazuo Sugimoto, Yukikazu Ando
  • Publication number: 20030079851
    Abstract: Disclosed are an apparatus for and a method of reclaiming molding sand capable of increasing a recycling efficiency of used molding sand and of highly enhancing the purity of a reclaimed molding sand. By crushing a lump of molding sand segregated from a molding box, used molding sand can be formed. In order to remove coking agents sticking on a surface of the used molding sand, an impeller disposed in a rotatable grinding drum is rotated after charging the used molding sand into a casing in which the rotatable grinding drum is disposed. The coking agents sticking on the surface of the used molding sand are removed due to collision and a mutual frictional rolling contact between the used molding sand and the rotatable grinding drum with the aid of rotational force of the impeller after having accomplished charging the used molding sand toward the impeller.
    Type: Application
    Filed: October 25, 2002
    Publication date: May 1, 2003
    Inventor: Jeon Rae Jo
  • Patent number: 6554049
    Abstract: Sand, bentonite clay and organics recovered as foundry waste from a green sand mold foundry are reclaimed for reuse in making new green sand molds and mold cores by a multi-step process involving both hydraulic and mechanical separation steps.
    Type: Grant
    Filed: May 15, 2001
    Date of Patent: April 29, 2003
    Assignee: Foundry Advanced Clay Technologies, L.L.C.
    Inventors: Robert C. Steele, Allen James Huff
  • Patent number: 6554050
    Abstract: Irregularly shaped mold-core assemblies are retained for casting within a thin-wall container by solid particulate material. In the process, the mold and core elements are formed from the core sand. After the mold and core elements, both of which are formed from core sand, are assembled, the assembly is placed in a container large enough to provide space around the assembled mold and core elements, and solid particulate material is placed in the space around the mold-core assembly to hold the assembled mold and core elements together during pouring of the molten iron alloy into the mold-core assembly and the cooling period, during which the molten iron alloy solidifies to form the casting. After the casting is formed, the solid particles and the core sand from the mold elements and core elements are recovered, processed and reused in further casting operations.
    Type: Grant
    Filed: June 28, 2002
    Date of Patent: April 29, 2003
    Assignee: International Engine Intellectual Property Company, L.L.C.
    Inventors: Edward A. Reelfs, Billy J. Cagle, Paul T. Cody, D. Gary Wildrick, II
  • Publication number: 20030037899
    Abstract: A method and apparatus are provided to process collected sand. This method and apparatus allow the moisture content to be adjusted and the addition of a binder to be facilitated to renew the collected sand as casting sand for future use. Also, defective castings are prevented when they are made by a main mold using the renewed casting sand. The sand-collecting means can be compact. The method is performed and the apparatus is operated by separating a main mold of green sand, after casting is conducted, into parts unaffected and affected by the molten metal heat, adjusting the moisture content of the part unaffected by molten metal heat for use as facing sand in the next main mold making, and adding a binder and adjusting the moisture content of the part affected by the molten metal heat for use as back sand in making the next main mold.
    Type: Application
    Filed: August 30, 2002
    Publication date: February 27, 2003
    Inventors: Shigeaki Yamamoto, Kuniyasu Mori, Ryoji Kanayama, Hisashi Harada, Hiroaki Tokita, Kazuo Sugimoto, Takehiro Matsumoto, Hiroyasu Makino, Yasunori Yoshida
  • Patent number: 6523597
    Abstract: A recovery method of a compact disc includes the steps of: crushing a compact disc; b) placing the crushed compact disc into a stripping solution, so that the metallic layer is separated from the plastic base plates of the crushed compact disc; c) filtering the plastic base plates from the stripping solution; d) recovering the metal; and e) recovering the plastic base plates. Thus, the waste compact disc may be recovered and reused, thereby preventing incurring an environmental pollution.
    Type: Grant
    Filed: August 30, 2001
    Date of Patent: February 25, 2003
    Inventor: Cheng-Shu Chen
  • Publication number: 20030029592
    Abstract: Sand, bentonite clay and organics recovered as foundry waste from a green sand mold foundry are reclaimed for reuse in making new green sand molds and mold cores by a multi-step process involving both hydraulic and mechanical separation steps.
    Type: Application
    Filed: May 15, 2001
    Publication date: February 13, 2003
    Inventors: Robert C. Steele, Allen J. Huff
  • Patent number: 6516863
    Abstract: Apparatus and methods for preparing foundry sand mixes, using a pre-mix tank to pre-mix water and particulate bond material to make a water/bond slurry, then feeding the slurry to a mullor or other foundry sand mixer. The slurry is received in the mullor/mixer, mixed with return sand, and then discharged for use in making foundry molds. Preferably, the particulate bond material is added to the pre-mix tank as a falling stream of such particles, and a disperse spray of water is projected onto the particles with sufficient gentleness to not deleteriously distract the particles from their downward path.
    Type: Grant
    Filed: July 3, 2002
    Date of Patent: February 11, 2003
    Assignee: New Ideas, LLC
    Inventor: Duane Alan McVane