US4633929A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for producing metal castings
Assignee: PAC POLYMER Inc A CORP OF
•
Filing: 1985-10-16
•
Granted: 1987-01-06
•
Expires: 2005-10-16
Abstract
Abstract Metal castings having reduced residual carbon ash and surface flaws are produced by an evaporative pattern casting process, in which an organic foam pattern is vaporized upon contact with a molten metal leaving a metal replica of the pattern. The organic foam used in this process comprises a polymer formed by polymerizing CO 2 with one or more oxirane compounds.
Inventors
- 👤 Joseph G. Santangelo
- 👤 James J. Weber
- 👤 Richard G. Sinclair
- 👤 Richard D. Tenaglia
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 12:48
CPC Classifications
B; B22; B22C; B22C9/00; B22C9/02; B22C9/04; C; C08; C08J; C08J9/00; C08J9/04; C08J9/12; C08J9/14; C08J9/141; B22C7/00; B22C7/02; B22C7/023; C08J9/28; C08J2369/00
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
94 words
A method for reducing residual carbon ash and surface flaws on metal castings produced by an evaporative pattern casting process in which an organic foam is shaped into a particular pattern to be reproduced by molten metal, said foam pattern being embedded in a support medium, whereby when said foam is subsequently contacted with molten metal whereby the organic foam vaporizes leaving a metal replica of the foam pattern in the support medium, said method comprising: using an organic foam comprising a polymer formed by polymerizing CO 2 with one or more oxirane compounds.
Claim 2
Independent Claim
94 words
A method for reducing residual carbon ash and surface flaws on metal castings produced by an evaporative pattern casting process in which an organic foam is shaped into a particular pattern to be reproduced by molten metal, said foam pattern being embedded in a support medium, whereby when said foam is subsequently contacted with molten metal whereby the organic foam vaporizes leaving a metal replica of the foam pattern in the support medium, said method comprising: using an organic foam comprising a polymer formed by polymerizing CO 2 with one or more oxirane compounds.
Claim 3
Dependent Claim
26 words
The method in accordance with claim 1 wherein said oxirane compounds are selected from the group consisting of ethylene oxide and propylene oxide and mixtures thereof.
Claim 4
Dependent Claim
18 words
The method in accordance with claim 1 wherein said polymer has a molecular weight of at least 5,000.
Claim 5
Dependent Claim
21 words
The method in accordance with claim 1 wherein said organic foam has a glass transition temperature of at least 20° C.
Claim 6
Dependent Claim
17 words
The method in accordance with claim 1 wherein said organic foam has a density between 0.01-0.9 g/cc.
Claim 7
Dependent Claim
21 words
The method in accordance with claim 1 wherein said organic foam is synthesized from said polymer by a freeze-drying foaming method.
Claim 8
Dependent Claim
15 words
The method in accordance with claim 1 wherein said support medium is loose, unbonded sand.
Claim 9
Dependent Claim
14 words
The method in accordance with claim 1 wherein said molten metal is grey iron.
Claim 10
Independent Claim
162 words
A method for reducing residual carbon ash and surface flaws on metal castings produced by an evaporative pattern casting process in which an organic foam is shaped into a particular pattern to be reproduced by molten metal, said foam pattern being embedded in a support medium, whereby when said foam is subsequently contacted with molten metal, the organic form vaporizes leaving a metal replica of the foam pattern in the support medium, said method comprising: using an organic foam comprising a polymer formed by polymerizing CO 2 and one or more oxirane compounds having the general formula: ##STR4## wherein R 1 is selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , C 4 H 9 , C 6 H 5 and C 6 H 11 ; R 2 is selected from the group consisting of H and CH 3 ; or R 1 and R 2 together form a six-member ring.
Claim 11
Independent Claim
162 words
A method for reducing residual carbon ash and surface flaws on metal castings produced by an evaporative pattern casting process in which an organic foam is shaped into a particular pattern to be reproduced by molten metal, said foam pattern being embedded in a support medium, whereby when said foam is subsequently contacted with molten metal, the organic form vaporizes leaving a metal replica of the foam pattern in the support medium, said method comprising: using an organic foam comprising a polymer formed by polymerizing CO 2 and one or more oxirane compounds having the general formula: ##STR4## wherein R 1 is selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , C 4 H 9 , C 6 H 5 and C 6 H 11 ; R 2 is selected from the group consisting of H and CH 3 ; or R 1 and R 2 together form a six-member ring.
Claim 12
Dependent Claim
12 words
The method in accordance with claim 9 wherein R 2 is H.
Claim 13
Dependent Claim
22 words
The method in accordance with claim 10 wherein R 1 is selected from the group consisting of H and CH 3 .
Claim 14
Dependent Claim
18 words
The method in accordance with claim 9 wherein said polymer has a molecular weight of at least 5,000.
Claim 15
Dependent Claim
17 words
The method in accordance with claim 9 wherein said organic foam has a density between 0.02-0.05 g/cc.
Claim 16
Independent Claim
156 words
A method for reducing residual carbon ash and surface flaws on metal castings produced by an evaporative pattern casting process in which an organic foam is shaped into a particular pattern to be reproduced by molten metal, said foam pattern being embedded in a support medium, whereby when said foam is subsequently contacted with molten metal, the organic foam vaporizes leaving a metal replica of the foam pattern in the support medium, said method comprising: using an organic foam comprising a polymer having covalently linked units of the general structural formula: ##STR5## wherein R 1 is selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , C 4 H 9 , C 6 H 5 and C 6 H 11 ; R 2 is selected from the group consisting of H and CH 3 ; or R 1 and R 2 together form a six-member ring.
Claim 17
Independent Claim
156 words
A method for reducing residual carbon ash and surface flaws on metal castings produced by an evaporative pattern casting process in which an organic foam is shaped into a particular pattern to be reproduced by molten metal, said foam pattern being embedded in a support medium, whereby when said foam is subsequently contacted with molten metal, the organic foam vaporizes leaving a metal replica of the foam pattern in the support medium, said method comprising: using an organic foam comprising a polymer having covalently linked units of the general structural formula: ##STR5## wherein R 1 is selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , C 4 H 9 , C 6 H 5 and C 6 H 11 ; R 2 is selected from the group consisting of H and CH 3 ; or R 1 and R 2 together form a six-member ring.
Claim 18
Dependent Claim
12 words
The method in accordance with claim 14 wherein R 2 is H.
Claim 19
Dependent Claim
22 words
The method in accordance with claim 15 wherein R 1 is selected from the group consisting of H and CH 3 .
Claim 20
Dependent Claim
18 words
The method in accordance with claim 14 wherein said polymer has a molecular weight of at least 5,000.
Claim 21
Dependent Claim
17 words
The method in accordance with claim 14 wherein said organic foam has a density between 0.02-0.05 g/cc.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-01-05 | 1990-07-07 | 1991-01-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-01-05 | 1994-07-07 | 1995-01-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-01-05 | 1998-07-07 | 1999-01-06 | $7700.00 | Window Closed / Lapsed |