USRE38555EExpiredUtility

Continuous chain caster and method

Assignee: HUNTER DOUGLAS IND BVPriority: Nov 14, 1995Filed: Nov 13, 1996Granted: Jul 13, 2004

Est. expiryNov 14, 2015(expired)· nominal 20-yr term from priority

Inventors:Curt Braun Christopher A. Romanowski Bobby B. Speed Pieter F. Post

B22D 11/0608

PatentIndex Score

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References

Claims

Abstract

A continuous chain caster has upper and lower mold assemblies comprising endless belts and chains traveling at synchronized speeds. The mold assemblies meet to form a mold channel which is filled with molten metal from a headbox and feed tip. As the molten metal passes through the mold channel, the metal solidifies into the shape of the mold channel. Each belt is positioned outside the corresponding chain so that the smooth surface of the belt defines the surface of the mold channel thereby preventing the formation of fins between mold blocks which make up the chain, protecting the chain blocks, and neutralizing deformations in the chain blocks. The upper and lower blocks of the chains have protrusions at opposite ends which engage the opposing blocks to form the sides of the mold channel. By sliding the chains relative to each other, the width of the mold channel is adjustable. Further, the gauge of the mold channel is adjustable over the length of the channel by tilting one mold assembly relative to the other, so that the gauge at one end of the caster is greater than at the other end of the caster. In this embodiment, the protrusions are replaced with retractable legs which are held against the opposing block with a resilient member. The legs move in and out of slots in the blocks as the gauge of the channel mold is decreased and increased respectively.

Claims

exact text as granted — not AI-modified

What is claimed is:

1. A continuous caster comprising:
a headbox;
a tip;
a mold channel having a depth defined between two endless chain assemblies each having a chain;
the headbox and tip being positioned at an opening to the mold channel to supply molten metal from the headbox to the mold channel;
each chain having a protrusion at an opposite side of the chains defining a width of the mold channel therebetween;
a means for adjusting the depth of the mold channel along the length of the mold channel so that an exit depth of the mold channel is less than an opening depth of the mold channel; and
at least one of the endless chain assemblies being moveable relative to the other to adjust the width of the mold channel.

2. The caster according to claim 1 further comprising two endless belt assemblies each corresponding to one of the chain assemblies and wherein each belt assembly has a belt which operates externally of the corresponding chain assembly to create a smooth mold channel which produces a cast product without fins.

3. The caster according to claim 2 wherein the belts have widths equal to the width of the mold channel.

4. The caster according to claim 2 wherein the belts have widths greater than the width of the mold channel to adjust the width of the mold channel without changing the belts.

5. The caster according to claim 2 further comprising a tensioning mechanism attached to the belt to tighten and hold the belt against the chain.

6. The caster according to claim 2 further comprising a coating of a heat resistant material on the belts acting as a mold release, non-wetting agent, and heat transfer moderator.

7. The caster according to claim 2 further comprising a first external means for cooling associated with one of the belts and one of the chains, and a second external means for cooling associated with the other belt and the other chain.

8. The caster according to claim 1 wherein the chain assemblies are moveable with respect to each other to adjust the width of the mold channel and to maintain the molten metal centrally in the chain caster.

9. The caster according to claim 1 wherein the mold channel extends over a length between an opening and an exit, and the caster further comprises:
at least one of the chain assemblies comprises a plurality of mold blocks; and
each mold block comprises at least one slot positioned near an end of the block, at least one leg slidably received in the slot defining sides of the mold channel, and at least one biasing member interposed between a base of the slot and the leg to bias the leg against an opposing surface to maintain the sides of the mold channel during a depth adjustment.

10. The caster according to claim 9 wherein both chain assemblies comprise mold blocks, and the slots of each mold block of one of the chain assemblies are on the same side opposite the slots of the mold blocks of the other chain assembly.

11. The caster according to claim 9 wherein each mold block comprises a backup extension located adjacent the slot and outwardly from the leg, and the extension engaging the leg to support it.

12. The caster according to claim 1 wherein the depth is adjusted so that the chains converge toward an exit of the mold channel.

13. The caster according to claim 1 A continuous caster comprising:

a headbox;

a tip;

a mold channel having a depth defined between two endless chain assemblies each having a chain;

the headbox and tip being positioned at an opening to the mold channel to supply molten metal from the headbox to the mold channel;

each chain having a protrusion at an opposite side of the chains defining a width of the mold channel therebetween;

a means for adjusting the depth of the mold channel along the length of the mold channel so that an exit depth of the mold channel is less than an opening depth of the mold channel; and

at least one of the endless chain assemblies being moveable relative to the other to adjust the width of the mold channel;

wherein at least one of the chain assemblies comprises an endless chain having a plurality of mold blocks, an upstream drive pulley pushing the chain into a casting region of the carts, and a downstream drag pulley having a drag generator hindering rotation to compress the chain in the casting region and push the mold blocks together to reduce finning.

14. The caster according to claim 13 further comprising an upstream drive coupled to the upstream drive pulley and a drag drive coupled to the downstream drag pulley, and wherein the upstream drive is more powerful than the drag drive.

15. The caster according to claim 14 wherein the upstream drive is 6 kW and the drag drive is 2 kW.

16. The caster according to claim 13 wherein the mold blocks comprise interlocking mold blocks.

17. A method for continuous casting of a cast product having a width and a depth on a chain caster having two mold assemblies with chains forming a mold channel, the method comprising:
continuously melting a metal alloy;
continuously introducing the molten metal alloy into the mold channel with a headbox and a tip;
moving at least one of the mold assemblies relative to the other in a direction substantially transverse to a direction of travel of the metal alloy through the mold channel to adjust any one of the width and depth of the cast product; and
converging one mold assembly relative to the other mold assembly in a direction of travel of the metal alloy through the mold channel to compensate for metal shrinkage and casting pressure regulation along the length and width of the mold channel.

18. The method according to claim 17 further comprising sliding at least one of the mold assemblies relative to the other to adjust the width of the cast product.

19. The method according to claim 17 further comprising sliding both mold assemblies equal distances relative to each other in opposite directions substantially transverse to the direction of travel of the metal alloy to adjust the width of the cast product.

20. The method according to claim 17 , wherein the mold assemblies have a belt, further comprising changing the belt on the mold assemblies.

21. The method according to claim 17 , wherein the mold assemblies have an endless belt, further comprising:
translating the endless belt of the assemblies through a closed belt path covering the entire width of the mold channel; and
translating the chains of the assemblies through a closed chain path inside the closed belt path.

22. The method according to claim 21 wherein each belt defines a portion of the mold channel and has a width greater than a width of the mold channel, the method further comprising heating portions of each belt not in contact with the metal alloy.

23. The method according to claim 21 further comprising tensioning each belt.

24. The method according to claim 17 further comprising:
tilting at least one mold assembly relative to the other; and
converging the mold assemblies toward the exit of the mold channel.

25. The method according to claim 17 wherein the chains comprise mold blocks, the method further comprising:
pressing a plurality of slidable upper legs held in slots of the mold blocks of one of the mold assemblies against opposing mold blocks of the other mold assembly with resilient members;
pressing a plurality of slidable lower legs held in slots of the mold blocks of the other mold assembly against opposing mold blocks of the one mold assembly with resilient members and at an opposite side of the one mold assembly from the upper legs; and
tilting one of the mold assemblies relative to the other to adjust the depth of the mold channel.

26. The method according to claim 25 wherein tilting one of the mold assemblies comprises tilting one of the mold assemblies to decrease the depth of the mold channel at an exit of the mold channel and compressing the resilient members near the exit of the mold channel.

27. The method according to claim 17 further comprising: A method for continuous casting of a cast product having a width and a depth on a chain caster having two mold assemblies with chains forming a mold channel the method comprising:

continuously melting a metal alloy;

continuously introducing the molten metal alloy into the mold channel with a headbox and a tip;

moving at least one of the mold assemblies relative to the other in a direction substantially transverse to a direction of travel of the metal alloy through the mold channel to adjust any one of the width and depth of the cast product;

converging one mold assembly relative to the other mold assembly in a direction of travel of the metal alloy through the mold channel to compensate for metal shrinkage and casting pressure regulation along the length and width of the mold channel;

rotating upstream pulleys with a drive in directions such that the upstream pulleys are pushing the chains into a casting region of the chain caster; and
hindering rotation of downstream pulleys with a drag generator such that the upstream pulleys and the downstream pulleys are pressing a plurality of mold blocks connected to the chains together in the casting region.

28. The method according to claim 17 27 further comprising compressing the chains in the casting region so that there are no gaps between the mold blocks of the chains.

29. A continuous caster comprising:
a headbox;
a tip;
a mold channel defined between two endless chain assemblies each having a chain;
the headbox and tip being positioned at an opening to the mold channel to supply molten metal from the headbox through the tip to the mold channel;
each chain having a protrusion at an opposite side of the chains defining a width of the mold channel therebetween;
at least one of the endless chain assemblies comprises a plurality of mold blocks being moveable relative to the other to adjust the width of the mold channel, an upstream drive pulley pushing the chain in the mold channel and a downstream drag pulley having a drag generator hindering rotation to compress the chain in the mold channel and push the mold blocks together to reduce finning; and
each mold block comprises at least one slot positioned near an end of the block, at least one leg slidably received in the slot defining sides of the mold channel, and at least one biasing member interposed between a base of the slot and the leg to bias the leg against an opposing surface to maintain the sides of the mold channel during a depth adjustment.

30. A method for compensating for volumetric changes of a metal alloy to prevent undesirable deformation as the metal alloy cools during a continuous casting process on a chain caster having upper and lower mold assemblies forming a mold channel extending over a length and having a depth, exit, and opening, the method comprising:
pressing a plurality of slidable upper legs held in slots of the mold blocks of the upper mold assembly against opposing mold blocks of the lower mold assembly with resilient members;
pressing a plurality of slidable lower legs held in slots of the mold blocks of the lower mold assembly against opposing mold blocks of the upper mold assembly with resilient members and at an opposite side of the upper mold assembly from the upper legs; and
tilting one of the mold assemblies relative to the other to adjust the depth of the mold channel;

rotating upstream pulleys with a drive in directions such that the upstream pulleys are pushing the mold assemblies into a casting region of the chain caster; and

hindering rotation of downstream pulleys with a drag generator such that the upstream pulleys and the downstream pulleys are pressing a plurality of the mold blocks connected to the mold assemblies together in the casting region.

31. A continuous chain caster having a casting region, the caster including:
a plurality of mold assemblies forming a mold channel therebetween; and
at least one mold assembly comprising an endless chain having a plurality of interlocking mold blocks, an upstream drive pulley pushing the chain into the casting region, and a downstream drag pulley having a drag generator hindering rotation to compress the chain in the casting region and push the mold blocks together to reduce finning.

32. A method for continuous casting of products on a chain caster having a casting region and two chain assemblies each having an upstream pulley and a downstream pulley to drive a chain comprised of a plurality of interlocking mold blocks and the chain assemblies forming a mold channel therebetween, the method comprising:
rotating the upstream pulleys with a drive in directions such that the pulleys are pushing the chains into the casting region; and
hindering rotation of the downstream pulley with a drag generator such that the upstream pulleys and downstream pulleys are pressing the mold blocks together in the casting region.

33. A continuous non- vertical caster for casting a non - ferrous metal or an alloy thereof to a predetermined width and depth comprising:

a headbox;

a tip;

two opposed endless mold assemblies that can each travel along a closed path and that cooperate to define a mold channel between them; the mold channel having a feed opening and an exit and a casting region therebetween, and the metal or alloy, in a molten state, being able to move in the mold channel in a direction of travel between the feed opening and the exit; the mold channel having a depth that is defined between the two opposed mold assemblies; at least one of the mold assemblies having a plurality of mold blocks; the headbox and tip being positioned at the feed opening to supply the metal or alloy, in the molten state, from the headbox through the tip into the mold channel;

a side dam on an opposite side of each mold assembly defining respective sides and a width of the mold channel between the side dams;

adjusting means for changing the position of one of the endless mold assemblies relative to the other in at least one of two orthogonal directions transverse to the direction of travel to adjust any one of the width and the depth of the mold channel and thereby to adjust any one of the width and the depth of the metal or alloy in the molten state moving through the mold channel; and

internal cooling means in the mold blocks to cool the mold blocks to solidify the metal or alloy in the mold channel;

wherein at least one of the mold assemblies further comprises an upstream drive pulley pushing the mold blocks into the casting region and a downstream drag pulley having a drag generator hindering rotation to compress the mold assembly in the casting region and push the mold blocks together to reduce finning.

34. The caster of claim 33 wherein external cooling means also cool the mold blocks to solidify the metal or alloy in the mold channel.

35. The caster of claim 33 comprising first adjusting means for changing the position of one of the endless mold assemblies relative to the other in a first of the two orthogonal directions to adjust the width of the mold channel.

36. The caster of claim 35 , wherein both mold assemblies are supported for movement at an equal distance in opposite directions with respect to each other when adjusting the width of the mold channel so as to enable the metal to be maintained centrally in the caster.

37. The caster of claim 35 , further comprising second adjusting means for changing the position of one of the endless mold assemblies relative to the other in a second of the two orthogonal directions to adjust the depth of the mold channel.

38. The caster of claim 37 , wherein the second adjusting means can change the depth of the mold channel lengthwise of the mold channel so that the depth of the mold channel at the exit is less than the depth of the mold channel at the feed opening thereby providing a convergence of the mold toward the exit.

39. The caster of claim 38 wherein the second adjusting means can change the depth of the mold channel to maintain the convergence of the mold assemblies.

40. The caster of claim 37 wherein when the second adjusting means changes the position of one of the assemblies in said second of the two orthogonal directions the extent to which each side can dam extends from its mold assembly is adjusted automatically.

41. The caster of claim 40 wherein the side dam from each mold assembly in defining the depth of the mold channel extends only to the other mold assembly.

42. The caster of claim 40 wherein each mold block comprises at least one slot positioned near a side of the block, at least one side dam slidably received in the slot and defining a side of the mold channel and at least one biasing member interposed between a base of the slot and the side dam to bias the side dam against an opposing surface to maintain the side of the mold channel during any one of a width and a depth adjustment.

43. The caster of claim 42 wherein the slots of the mold blocks of one of the mold assemblies are on the same side but are on the opposite side from the slots of the mold blocks of the other mold assembly.

44. The caster of claim 43 wherein each mold block comprises a backup extension located adjacent the slot and outwardly from the side dam and the extension engages the side dam to support it.

45. The caster of claim 43 wherein the side dam from each mold assembly in defining the depth of the mold channel extends only to the other mold assembly.

46. The caster of claim 45 wherein a first one of the endless mold assemblies can travel along a first closed path, a second one of the mold assemblies can travel along a second closed path wherein the second closed path at least in part extends in close proximity to the first closed path and wherein the first one of the mold assemblies and the second one of the mold assemblies each have a substantially flat surface to form a rectangular mold channel between them.

47. The caster of claim 42 wherein a first one of the endless mold assemblies can travel along a first closed path, a second one of the mold assemblies can travel along a second closed path wherein the second closed path at least in part extends in close proximity to the first closed path and wherein the first one of the mold assemblies and the second one of the mold assemblies each have a substantially flat surface to form a rectangular mold channel between them.

48. The caster of claim 47 yet further comprising two endless belts each traveling around and parallel to one of the mold assemblies and each traveling between the two mold assemblies to provide between the endless belts a smooth mold channel which can produce a cast product without fins in the regions contacted by the belts.

49. The caster of claim 48 still further comprising external cooling means to cool both the mold blocks and the endless belts to solidify the metal or alloy in the mold channel.

50. The caster of claim 49 wherein the external cooling means to cool both the mold blocks and the endless belts are the same external cooling means.

51. The caster of claim 49 wherein the endless belts have widths greater than the width of the mold channel so that the width of the mold channel can be adjusted without changing the belts.

52. The caster of claim 46 yet further comprising two endless belts each traveling around and parallel to one of the mold assemblies and each traveling between the two mold assemblies to provide between the endless belts a smooth mold channel which can produce a cast product without fins in the regions contacted by the belts.

53. The caster of claim 52 still further comprising external cooling means to cool both the mold blocks and the endless belts to solidify the metal or alloy in the mold channel.

54. The caster of claim 53 wherein the external cooling means to cool both the mold blocks and the endless belts are the same external cooling means.

55. The caster of claim 54 wherein the endless belts have widths greater than the width of the mold channel so that the width of the mold channel can be adjusted without changing the belts.

56. A method for continuous non- vertical casting of a non - ferrous metal or an alloy thereof to a predetermined width and depth wherein two opposed endless mold assemblies each having a plurality of mold blocks and traveling along a closed path cooperate to define a mold channel between them; the mold channel having a feed opening and an exit and a casting region therebetween and the metal or alloy in a molten state being able to move in the mold channel in a direction of travel between the feed opening and the exit;

the method comprising the steps of:

melting the metal or alloy;

introducing the metal or alloy in a molten state into the feed opening;

translating the mold assemblies along closed paths along the direction of travel between them;

cooling the mold blocks internally to solidify the metal or alloy in the mold channel;

moving the mold assemblies relative to one another in one of two orthogonal directions substantially transverse to the direction of travel to adjust any one of the width and the depth of the mold channel and thereby to adjust any one of the width and the depth of the metal or alloy in the molten state moving through the mold channel;

rotating upstream pulleys with a drive and direction such that the upstream pulleys are pushing at least one of the mold assemblies into a casting region; and

hindering rotation of downstream pulleys with a drag generator such that the upstream pulleys and the downstream pulleys are pressing a plurality of mold blocks together in the casting region.

57. The caster of claim 56 wherein external cooling means also cool the mold blocks to solidify the metal or alloy in the mold channel.

58. The method of claim 56 further comprising a step of adjusting the width of the mold channel by sliding at least one of the mold assemblies to move it relative to the other in the direction transverse to the direction of travel of the metal or alloy.

59. The method of claim 58 further comprising a step of adjusting the width of the mold channel by sliding each of the mold assemblies an equal distance in opposite directions transverse to the direction of travel whereby the metal or alloy remains centered in the caster.

60. The method of claim 59 further comprising the step of tilting the mold assemblies relative to one another so that they converge in the direction of travel to compensate for metal shrinkage and provide casting pressure regulation along the length and width of the mold channel in the direction of travel.

61. The method of claim 60 wherein each mold assembly extends as far as the other mold assembly transverse to the direction of travel and includes a projecting side dam defining a side of the mold channel; and wherein the side dam of each mold assembly during the step of tilting the mold assemblies relative to one another extends towards and is pressed against the other mold assembly.

62. The method of claim 60 wherein each side dam of one of the mold assemblies is pressed against the other mold assembly by a resilient member between the side dam and the one mold assembly.

63. The method of claim 56 further comprising the steps of:

pressing a plurality of slidable upper side dams held in slots of the mold blocks of an upper one of the mold assemblies against the mold blocks of a lower one of the mold assemblies with resilient members between the upper side dams and the mold blocks of the upper mold assembly;

pressing a plurality of slidable lower side dams held in slots of the mold blocks of the lower mold assembly against the mold blocks of the upper mold assembly with resilient members between the lower side dams and the mold blocks of the lower mold assembly; the lower and upper side dams being on opposite sides of the mold channel; and

tilting the mold assemblies relative to one another to adjust the depth of the mold channel along the direction of travel.

64. The method of claim 63 wherein the step of tilting the mold assemblies relative to one another decreases the depth of the mold channel at the exit of the mold channel and compresses the resilient members near the exit.

65. The method of claim 56 further comprising the step of translating opposed endless belts through closed belt paths along the direction of travel and over the width of the mold channel; the closed path of each mold assembly being within the closed belt path of one of the endless belts.

66. The method of claim 65 wherein external cooling means cool both the mold blocks and the endless belts to solidify the metal or alloy in the mold channel.

67. The method of claim 66 wherein the same external cooling means cool both the mold blocks and the endless belts.

68. The method of claim 65 wherein a step of adjusting the width of the mold channel includes a step of changing the width of the opposed endless belts.

69. The caster of claim 13 wherein the caster is a non- vertical caster.

70. The method of claim 27 wherein the chain caster is a non- vertical chain caster.

71. The caster of claim 29 where in the caster is a non- vertical caster.

72. The method of claim 30 wherein the chain caster is a non- vertical chain caster.

73. The method of claim 27 wherein the case product is a non- ferrous metal or alloy.

74. The method of claim 30 wherein the metal alloy is non- ferrous.

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