US2008093043A1PendingUtilityA1

Method and casting media composition for creating foam sacrificial parts and investment models

37
Individually held — no corporate assignee on recordPriority: Oct 20, 2006Filed: Oct 20, 2006Published: Apr 24, 2008
Est. expiryOct 20, 2026(~0.2 yrs left)· nominal 20-yr term from priority
Inventors:Victor Joyner
B22C 7/023
37
PatentIndex Score
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Claims

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.

Claims

exact text as granted — not AI-modified
1 . A casting medium composition, comprising:
 a compound selected from the class of compounds comprised of cold setting foams, and   a compound selected from the class of compounds which solidify when subjected to radiation.   
   
   
       2 . A casting medium composition as defined in  claim 1 , wherein:
 said compound selected from the class of compounds comprised of cold setting foams is limited to compounds which vaporize when subjected to temperatures normally encountered in the lost wax process during burnout.   
   
   
       3 . A casting medium composition as defined in  claim 1 , wherein:
 said compound selected from the class of compounds which solidify when subjected to radiation is limited to compounds which leave very little residue when subjected to temperatures normally encountered in the lost wax process during burnout.   
   
   
       4 . A casting medium composition as defined in  claim 1 , wherein:
 said compound selected from the class of compounds comprised of cold setting foams is limited to compounds which leave very little residue when subjected to temperatures normally encountered in the lost wax process during burnout.   
   
   
       5 . A casting medium composition as defined in  claim 1 , wherein:
 said compound selected from the class of compounds which solidify when subjected to radiation is limited to compounds which vaporize when subjected to temperatures normally encountered in the lost wax process during burnout.   
   
   
       6 . A casting medium composition, comprising:
 a fluid casting medium selected from the class of compounds which solidify when subjected to radiation, and   a foaming agent.   
   
   
       7 . A casting medium composition as defined in  claim 6 , wherein:
 said fluid casting medium is limited to compounds which vaporize when subjected to temperatures normally encountered in the lost wax process during burnout.   
   
   
       8 . A casting medium composition as defined in  claim 6 , wherein:
 said fluid casting medium is limited to compounds which leave very little residue when subjected to temperatures normally encountered in the lost wax process during burnout   
   
   
       9 . A casting medium composition as defined in  claim 6 , wherein:
 said foaming vaporizes when subjected to temperatures normally encountered in the lost wax process during burnout.   
   
   
       10 . A casting medium composition as defined in  claim 6 , wherein:
 said foaming agent leaves very little residue when subjected to temperatures normally encountered in the lost wax process during burnout   
   
   
       11 . A casting medium composition as defined in  claim 6 , comprising:
 a hot melt casting medium.   
   
   
       12 . A method for creating a sacrificial pattern for lost wax casting, including the steps of:
 partially filling a master mold with a cold setting foam casting compound mixed with a compound which solidifies when subjected to radiation;   waiting for said casting compound within said master mold to mature through the foaming process until said master mold is filled to the point where all details within said master mold have been completely filled with foam; and   hardening said foam by subjecting said foam to catalysis initiating radiation.   
   
   
       13 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 12 , including the step of:
 removing said matured foam from said master mold before said step of hardening said foam by subjecting said foam to catalysis initiating radiation.   
   
   
       14 . A method for creating a sacrificial pattern for lost wax casting, including the steps of:
 mixing a foaming agent with a casting medium that solidifies when subjected to radiation;   partially filling a master mold with said casting medium mix;   waiting for said casting medium mix within said master mold to matured through the foaming process until said master mold is filled to the point where all details within said master mold have been completely filled with foam; and   hardening said foam by subjecting said foam to catalysis initiating radiation.   
   
   
       15 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 14 , including the step of:
 removing said matured foam from said master mold before said step of hardening said foam by subjecting said foam to catalysis initiating radiation.   
   
   
       16 . A method for creating a sacrificial pattern for lost wax casting, including the steps of:
 mixing a blowing agent with a hot melt casting medium that contains a compound that solidifies when subjected to radiation;   partially filling a master mold with said hot melt casting medium mix before the foaming process is completed;   waiting for said hot melt casting medium mix within said master mold to matured through the foaming process until said master mold is filled to the point where all details within said master mold have been completely filled with foam; and   hardening said foam by subjecting said foam to curing radiation.   
   
   
       17 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 16 , including the steps of:
 cooling said matured foam in said master mold; and   hardening said matured foam by subjecting it to catalysis initiating radiation.   
   
   
       18 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 16 , including the steps of:
 hardening said matured foam by subjecting it to catalysis initiating radiation; and   cooling said matured foam in said master mold.   
   
   
       19 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 16 , including the steps of:
 cooling said matured foam in said master mold;   removing said cooled matured foam said master mold; and   hardening said cooled matured foam by subjecting it to catalysis initiating radiation.   
   
   
       20 . A method for creating a sacrificial pattern for lost was casting as defined by claim,  16 , wherein said blowing agent is a compressed gas. 
   
   
       21 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 12 , including the step of:
 removing said matured foam from said master mold after said step of hardening said foam by subjecting said foam to catalysis initiating radiation.   
   
   
       22 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 12  wherein said step of hardening said foam by subjecting said foam to catalysis initiating radiation is accomplished while said foam is in a liquid state before said sacrificial pattern is removed from said master mold. 
   
   
       23 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 12 , wherein said step of partially filling a master mold with a cold setting foam casting compound mixed with a compound which solidifies when subjected to radiation is preceded by the steps of:
 selecting said cold setting foam casting compound from the class of compounds which vaporize when subjected to temperatures normally encountered in the lost wax process during burnout,   selecting said compound which solidifies when subjected to radiation from the class of compounds which reduce to a very small amount of residue when subjected to temperatures normally encountered in the lost wax process during burnout, and   mixing together said selected cold setting foam casting compound and said selected compound which solidifies when subjected to radiation.   
   
   
       24 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 12 , wherein said step of partially filling a master mold with a cold setting foam casting compound mixed with a compound which solidifies when subjected to radiation is preceded by the steps of:
 selecting said cold setting foam casting compound from the class of compounds which reduce to a very small amount of residue when subjected to temperatures normally encountered in the lost wax process during burnout,   selecting said compound which solidifies when subjected to radiation from the class of compounds which vaporize when subjected to temperatures normally encountered in the lost wax process during burnout, and   mixing together said selected cold setting foam casting compound and said selected compound which solidifies when subjected to radiation.   
   
   
       25 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 12 , wherein said step of partially filling a master mold with a cold setting foam casting compound mixed with a compound which solidifies when subjected to radiation is preceded by the steps of:
 selecting said cold setting foam casting compound from the class of compounds which vaporize when subjected to temperatures normally encountered in the lost wax process during burnout,   selecting said compound which solidifies when subjected to radiation from the class of compounds which vaporize when subjected to temperatures normally encountered in the lost wax process during burnout, and   mixing together said selected cold setting foam casting compound and said selected compound which solidifies when subjected to radiation.   
   
   
       26 . A method for creating a sacrificial pattern for lost wax casting as defined by  claim 12 , wherein said step of partially filling a master mold with a cold setting foam casting compound mixed with a compound which solidifies when subjected to radiation is preceded by the steps of:
 selecting said cold setting foam casting compound from the class of compounds which reduce to a very small amount of residue when subjected to temperatures normally encountered in the lost wax process during burnout,   selecting said compound which solidifies when subjected to radiation from the class of compounds which reduce to a very small amount of residue when subjected to temperatures normally encountered in the lost wax process during burnout, and   mixing together said selected cold setting foam casting compound and said selected compound which solidifies when subjected to radiation.

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