US6820677B2
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of making a spray formed article
Assignee: Ford Global Technologies LLC
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Filing: 2002-08-20
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Granted: 2004-11-23
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Expires: 2022-08-20
Abstract
Abstract A method of making a spray formed article includes the steps of providing a sand pattern and spraying metal material toward the sand pattern to form the desired article. The sand pattern is made from a sand molding composition comprising refractory materials and binder. The refractory material comprises at least about 15 weight percent alumina, based on the total weight of the refractory material.
Inventors
- 👤 Grigoriy Grinberg
- 👤 David Robert Collins
- 👤 Matthew M. Shade
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 01:13
CPC Classifications
B; B22; B22D; B22D23/00; B22D23/003
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
93 words
A method of making a spray formed article, the method comprising the steps of: providing a sand pattern that has an inverse of at least a portion of the surface of a desired spray formed article, the spray forming pattern being the cured product of a sand molding composition comprising refractory material and binder, the refractory material comprising at least about 15 weight percent alumina, based on the total weight of the refractory material; and spraying metallic material against the sand pattern to form a desired spray formed article on the sand pattern.
Claim 2
Independent Claim
93 words
A method of making a spray formed article, the method comprising the steps of: providing a sand pattern that has an inverse of at least a portion of the surface of a desired spray formed article, the spray forming pattern being the cured product of a sand molding composition comprising refractory material and binder, the refractory material comprising at least about 15 weight percent alumina, based on the total weight of the refractory material; and spraying metallic material against the sand pattern to form a desired spray formed article on the sand pattern.
Claim 3
Dependent Claim
37 words
A method as set forth in claim 1 wherein the step of providing a sand pattern comprises making a model of the desired spray formed article and constructing the sand pattern as the inverse of the model.
Claim 4
Dependent Claim
36 words
A method as set forth in claim 2 wherein the step of constructing the sand pattern comprises depositing a sand molding composition over the model and curing the sand molding composition to form the sand pattern.
Claim 5
Dependent Claim
29 words
A method as set forth in claim 3 wherein the refractory material is present in the sand molding composition in an amount of about 75 to 98 weight percent.
Claim 6
Dependent Claim
37 words
A method as set forth in claim 4 wherein the alumina is present in the sand molding composition in an amount of about 1 to 85 weight percent, based on the total weight of the refractory material.
Claim 7
Dependent Claim
37 words
A method as set forth in claim 5 wherein the alumina is present in the sand molding composition in an amount of about 25 to 40 weight percent, based on the total weight of the refractory material.
Claim 8
Dependent Claim
43 words
A method as set forth in claim 5 wherein the binder comprises an inorganic binder which is present in the sand molding composition in an amount of about 2 to 25 weight percent, based on the total weight of the sand molding composition.
Claim 9
Dependent Claim
16 words
A method as set forth in claim 5 wherein the binder comprises an inorganic, water-soluble binder.
Claim 10
Dependent Claim
14 words
A method as set forth in claim 8 wherein the binder comprises sodium silicate.
Claim 11
Dependent Claim
45 words
A method as set forth in claim 3 wherein the sand molding composition further comprises a catalyst which is present in the sand molding composition in an amount of about 0.2 to 2.5 weight percent, based on the total weight of the sand molding composition.
Claim 12
Dependent Claim
24 words
A method as set forth in claim 10 wherein the curing of the sand molding composition takes place without the addition of any heat.
Claim 13
Dependent Claim
18 words
A method as set forth in claim 3 wherein the curing of the sand molding composition requires heat.
Claim 14
Dependent Claim
21 words
A method as set forth in claim 5 wherein the refractory material has an average particle size of about 25-400 microns.
Claim 15
Dependent Claim
30 words
A method as set forth in claim 8 further comprising separating the sand pattern from the desired article, wherein the step of separating comprises exposing the sand pattern to water.
Claim 16
Dependent Claim
29 words
A method as set forth in claim 1 wherein the refractory material comprises about 85 to 15 weight percent silica sand and about 15 to 85 weight percent alumina.
Claim 17
Dependent Claim
45 words
A method as set forth in claim 15 wherein the sand molding composition further comprises a catalyst which is present in the sand molding composition in an amount of about 0.2 to 2.5 weight percent, based on the total weight of the sand molding composition.
Claim 18
Dependent Claim
16 words
A method as set forth in claim 1 wherein the spray formed article comprises a tool.
Claim 19
Independent Claim
217 words
A method of making a spray formed article, the method comprising the steps of: providing a sand pattern that has an inverse of at least a portion of the surface of a desired spray formed article, the spray forming pattern being the cured product of a sand molding composition comprising refractory material present in the sand molding composition in an amount of about 75 to 98 weight percent, based on the total weight of the sand molding composition, an inorganic, water-soluble binder present in the sand molding composition in an amount of about 2 to 25 weight percent, based on the total weight of the sand molding composition, and catalyst present in the sand molding composition in an amount of about 0.2 to 2.5 weight percent, based on the total weight of the sand molding composition, wherein the refractory material has an average particle size of about 25-400 microns and comprises silica sand and at least about 15 weight percent alumina, based on the total weight of the refractory material, wherein the alumina has a smaller average particle size than the silica sand; spraying metallic material against the sand pattern to form a desired spray formed article on the sand pattern; and separating the sand pattern from the desired article by exposing the sand pattern to water.
Claim 20
Independent Claim
217 words
A method of making a spray formed article, the method comprising the steps of: providing a sand pattern that has an inverse of at least a portion of the surface of a desired spray formed article, the spray forming pattern being the cured product of a sand molding composition comprising refractory material present in the sand molding composition in an amount of about 75 to 98 weight percent, based on the total weight of the sand molding composition, an inorganic, water-soluble binder present in the sand molding composition in an amount of about 2 to 25 weight percent, based on the total weight of the sand molding composition, and catalyst present in the sand molding composition in an amount of about 0.2 to 2.5 weight percent, based on the total weight of the sand molding composition, wherein the refractory material has an average particle size of about 25-400 microns and comprises silica sand and at least about 15 weight percent alumina, based on the total weight of the refractory material, wherein the alumina has a smaller average particle size than the silica sand; spraying metallic material against the sand pattern to form a desired spray formed article on the sand pattern; and separating the sand pattern from the desired article by exposing the sand pattern to water.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2007-11-23 | 2008-05-24 | 2008-11-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2011-11-23 | 2012-05-24 | 2012-11-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2015-11-23 | 2016-05-24 | 2016-11-23 | $7700.00 | Window Closed / Lapsed |