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1. WO1987004376 - PROCEDE ET APPAREIL DE MOULAGE D'ARTICLES

Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

[ EN ]

Ha'ving described specific preferred embodiments of the invention, the following is claimed:

1. A mold for use in casting a plurality of articles, said mold comprising a plurality of article molds disposed in an array having an open central portion, each of said article molds having an article mold cavity with a
configuration corresponding to the configuration of one of the articles, molten metal distribution means for
conducting molten metal to each of said article mold cavities, said molten metal distribution means including a primary distribution system separate from said article molds and having a pluality of passages for conducting molten metal, a plurality of separable joint means
connected in fluid communication with said article mold cavities and with said passages in said primary
distribution system for conducting a flow of molten metal from said primary distribution system at a plurality of locations and for enabling relative movement to occur between said array of article molds and said primary distribution system after said article mold cavities have been filled with molten metal, baffle plate means disposed in the central portion of the array of article molds for retarding heat transmission from said article molds, and support means disposed in the central portion of the array of article molds and extending between said baffle plate -34- eans "and said primary distribution system for supporting said baffle plate means from said primary distribution system and for holding said baffle plate means against movement relative to said primary distribution system during relative movement between the array of article molds and said primary distribution system.

2. A mold as set forth in claim 1 wherein said molten metal distribution means includes a secondary distribution system connected to said article molds for movement
therewith relative to said primary distribution system, said secondary distribution system including a distribution channel extending around an upper end portion of the array of article molds, said distribution channel having a plurality of openings connected in fluid communication with said article mold cavities, said distribution channel being outwardly of and extending around said support means during at least a portion of the relative movement between the array of article molds and said primary distribution system.

3. A mold as set forth in claim 2 wherein said joint means connects said primary distribution system in fluid communication with said secondary distribution system at a plurality of locations along said distribution channel.

4." A mold as set forth in claim 1 wherein said baffle plate means has a generally circular configuration, said support means extending axially upwardly from said baffle plate means to said primary distribution system to support said baffle plate means independently of supports
extending radially from said baffle plate means through the array of article molds.

5. A mold as set forth in claim 1 wherein said primary distribution system includes a pour cup and a plurality of runners extending outwardly from said pour cup toward upper end portions of said article molds, said support means including a support member having a lower end portion connected to said baffle plate means and an upper end portion connected to said pour cup, said support member being at least partially surrounded by the array of article molds .

6. A mold as set forth in claim 1 wherein said primary distribution system, baffle plate means and support means are formed as one piece of ceramic material.

7. A mold as set forth in claim 1 wherein said article molds are disposed in a circular array, said mold further including an annular base interconnecting lower end portions of said article molds and circumscribing said baffle plate means, said annular base having bottom surface means for engaging a chill plate, said baffle plate means being disposed in a central opening in said annular base to block exposure of said surface areas of said article molds to the chill plate prior to relative movement between the array of article molds and said primary distribution system, said baffle plate means being spaced from the central opening in said annular base to expose lower surface areas of said article molds to the chill plate after relative movement between the array of article molds and said primary distribution system.

8. A mold as set forth in claim 1 wherein said molten metal distribution means further includes a secondary distribution sytem connected to upper end portions of each of said article molds and connected in fluid communication with said primary distribution system by said joint means, said secondary distribution system including a hollow annular distribution ring which is connected in fluid communication with each of said article mold cavities, said annular distribution ring having an axial extent which- is substantially greater than its radial extent to facilitate the transfer of heat to said distribution ring.

9. A mold as set forth in claim 1 further including surface means disposed between said article molds to eliminate open space between adjacent article molds and thereby retard the transfer of heat at locations between adjacent article molds.

10. A method of casting a plurality of articles, said method comprising the steps of providing a plurality of article molds disposed in an array having an open central portion, providing a primary distribution system which is separate from the article molds, conducting a flow of molten metal from the primary distribution system to cavities in the article molds to fill the cavities in the article molds with molten metal, separating the article molds and primary distribution system by providing relative movement between the article molds and primary distribution system, retarding the transmission of heat from the article molds with a baffle plate disposed in the central portion of the array of article molds, and supporting the baffle plate from the primary distribution system during the relative movement between the article molds and primary distribution system.

11. A method as set forth in claim 10 further
including the step of providing a secondary distribution sytem which defines an annular chamber connected in fluid communication with each of the cavities in the article molds, said step of conducting a flow of molten metal from the primary distribution system to cavities in the article molds "including conducting a flow of molten metal from the primary distribution system to the annular chamber in the secondary distribution system, said step of separating the article molds and the primary distribution system including separating the primary and secondary distribution systems by providing relative movement between them.

12. A method as set forth in claim 10 wherein said step of conducting a flow of molten metal from the primary distribution system to the cavities in the article molds includes filling the primary distribution system with molten metal and emptying the primary distribution system of molten metal before providing .relative movement between the article molds and primary distribution system.

13. A method as set forth in claim 10 wherein the step of supporting the baffle plate from the primary distribution system includes transmitting force from the baffle plate to the primary distribution system along a path through the central portion of the array of article molds.

14. A method as set forth in claim 10 further
including the steps of providing a furnace housing, providing a chill plate, supporting the article molds on the chill plate, providing relative movement between the furnace housing and chill plate to position the article molds in the furnace housing, connecting the primary distribution system with the furnace housing, thereafter, performing said step of conducting a flow of molten metal from the primary distribution system to cavities in the article molds, said step of separating the article molds and primary distribution system including separating the furnace housing and chill plate while supporting the primary distribution system from the furnace housing and supporting the article molds on the chill plate.

15. A ceramic mold for use in casting a plurality of articles, said mold comprising a plurality of article molds disposed in an annular array having an open central portion, each of said article molds having an article mold cavity with a configuration corresponding to the
configuration of one of the articles, molten metal
distribution means for conducting molten metal to each of said article mold cavities, said molten metal distribution means including a primary distribution system separate from said article molds and a secondary distribution system connected to said article molds, said primary distribution system including a pour cup disposed in a coaxial relationship with the circular array of article molds and a plurality of runners extending outwardly from said pour cup, said secondary distribution system including an annular distribution ring separate from said runners and disposed at a first axial end portion of and coaxial with the annular array of article molds, said annular distribution ring being formed as one piece with said article molds and having an annular cavity connected in fluid communciation with said article mold cavities, joint means connecting said runners and said distribution ring in fluid communication for conducting a flow of molten metal from said primary distribution system to said secondary distribution system and for enabling said
secondary distribution system and array of article molds to be moved away from said primary distribution system after said article mold have been filled with molten metal.

16. A ceramic mold as set forth in claim 15 further including an annular ceramic base disposed at a second axial end portion of and coaxial with the annular array of article molds, said annular base being formed as one piece with said article molds and having annular bottom surface means for engaging a chill plate, said article mold
cavities being disposed between said annular base and said annular distribution ring.

17. A ceramic mold as set forth in claim 15 further including a baffle plate disposed adjacent to the second axial end portion of and coaxial with the annular array of article molds, and a support member interconnecting said baffle plate and said pour cup to hold said baffle plate against movement relative to said pour cup during movement of said article molds away from said primary distribution system.

18. A ceramic mold as set forth in claim 15 further including a surface means interconnecting said article molds to form a solid annular wall having an inside diameter equal to or less than the inside diameter of said annular distribution ring and an outside diameter equal to or greater than the outside diameter of said annular distribution ring.

19. An apparatus for use in casting a plurality of articles, said apparatus comprising furnace means for supplying heat to a mold receiving chamber in said furnace means, a plurality of article molds at least partially disposed in said mold receiving chamber, each of said article molds having a mold cavity with a configuration corresponding to the configuration of one of the articles, molten metal distirbution means for conducting molten metal to each of the article mold cavities, said molten metal distribution means including a primary distribution system at least partially disposed in said mold receiving chamber and separate from said article molds, said primary distribution system including a pour cup for receiving molten metal and a plurality of passages for conducting olteri metal away from said pour cup, connector means for connecting said primary distribution system with said furnace means, a plurality of separable joint means
connected in fluid communication with said article mold cavities and with said passages in said primary
distribution system for conducting a flow of molten metal from said primary distribution system at a plurality of locations and for enabling relative movement to occur between said article molds and said primary distribution system, and means for providing relative movement between said article molds and said furnace means while said connector means holds said primary distribution system against movement relative to said furnace means to
separate said article molds from said mold receiving chamber while at least a portion of said primary
distribution system remains in said mold receiving chamber,

20. An apparatus as set forth in claim 19 further including support means supporting said plurality of article molds while said article molds are in the mold receiving chamber in said furnace means, and post means separate from said article molds and extending from said pour cup for transmitting forces induced by -the pouring of molten metal into said pour cup to said support means.

21. An apparatus as set forth in claim 20 further including baffle means connected with an end portion of said post means opposite from said pour cup for retarding heat trnsmisssion from said mold receiving chamber in said furnace means during separation of said article molds from said mold receiving chamber .

22. An apparatus as set forth in claim 19 wherein said pour cup includes a base portion and an extension portion extending; upwardly from said base portion, said connector means being disposed in engagement with said extension portion of said pour cup to connect said primary distribution system with said furnace means.

23. An apparatus as set forth in claim 19 wherein said furnace means includes means for defining an opening, said pour cup extending through said opening so that an upper end portion of said pour cup is disposed outside of the mold receiving chamber in said furnace means, said connector means being disposed in engagement with said upper end portion of said pour cup.

24. An apparatus as set forth in claim 19 wherein said article molds are disposed in a circular array having an open central portion, said apparatus further including baffle means disposed in the central portion of the array of article molds for retarding heat transmission from said mold receiving chamber in said furnace means.

25. An apparatus as set forth in claim 24 further including means for connecting said baffle means with said furnace means to hold said baffle means against movement relative to said furnace means during separation of said article molds from the chamber in said furnace means.

26. An apparatus as set forth in claim 25 wherein said baffle means includes a surface which faces toward said upper wall of said furnace means and has a greater reflectivity than the surfaces of said article molds.

27. An apparatus as set forth in claim 19 wherein said molten metal distribution means includes a secondary distribution system connected to said article molds, said secondary distribution system including a distribution channel having a plurality of openings connected in fluid communication with said article mold cavities, said joint means connecting said primary distribution system in fluid communication with said secondary distribution system at a plurality of locations along said distribution channel.

28. An apparatus as set forth in claim 19 wherein said primary distribution system is formed of a material which is capable of being repeatedly used to conduct molten metal.

29-. An apparatus as set forth in claim 19 wherein said article molds are disposed in an annular array having an open central portion, said pour cup being disposed adjacent to a first axial end portion of the annular array of article molds and being disposed in a coaxial relationship with the annular array of article molds, said apparatus further including a ceramic baffle plate disposed adjacent to the second axial end portion of and coaxial with the annular array of article molds, and means interconnecting said baffle plate and said primary distribution system to hold said baffle plate against movement relative to said primary distribution system.

30. An apparatus as set forth in claim 29 wherein said means interconnecting said baffle plate and said primary distribution system transmits forces from said primary distribution system to said baffle plate during a pouring of molten metal into said pour cup, said baffle plate includes surface means for transmitting forces from said baffle plate to said means for providing relative movement between said article molds and said furnace means.

31. An apparatus as set forth in claim 30 wherein said means interconnecting said baffle plate and said primary distribution system includes a single support post
extending between said baffle plate and said pour cup.

32. A method of casting a plurality of articles, said method comprising the steps of providing a mold having a plurality of article molds disposed in an array having an open central portion, a primary distribution system connected in fluid communication with cavities in the article molds and a baffle disposed in the central, portion of the array of article molds, moving the mold into a chamber in a furnace, connecting the primary distribution system with the furnace, connecting the baffle with the furnace, thereafter, pouring molten metal into the primary distribution system, conducting a flow of molten metal from the primary distribution system to the cavities in the article molds, thereafter, moving the article molds at least part way out of the chamber in the furnace while maintaining the primary distribution system and baffle stationary in the chamber in the furnace, and retarding the' radiation of heat from the chamber in the furnace with the baffle during performance of said step of moving the article molds out of the chamber in the furnace.

33. A method as set forth in claim 32 wherein said steps of connecting the primary distribution system and baffle with the furnace includes connecting the primary distribution system to the furnace and supporting the baffle from the primary distribution system.

34. A method as set forth in claim 32 wherein the primary distirbution system includes a pour cup and a plurality of passages for conducting molten metal from the pour cup, said step of connecting the primary distribution system with the furnace includes moving an end portion of the pour cup through an opening in a wall of the furnace and engaging the end portion of the pour cup to hold the pour cup against movement relative to the wall of the furnace.

35. A method as set forth in claim 34 wherein said step of connecting the baffle with the furnace includes supporting the baffle from the pour cup after having performed said step of connecting the pour cup with the furnace.

36. A method as set forth in claim 32 wherein said step of moving the article molds out of the chamber in the furnace includes separating the article molds from the primary distribution system.

37. A method as set forth in claim 32 further including the steps of moving the article molds back into the furnace, disconnecting the baffle and primary
distribution system from the furnace, and moving the article molds, baffle and primary distribution system together out of the chamber in the furnace.

38". A method as set forth in claim 32 further
including the steps of supporting the article molds on a support member during the performance of said step of pouring of molten metal into the primary distribution system, transmitting forces induced by the pouring molten metal into the primary distribution system to the baffle, and transmitting pouring induced forces from the baffle to the support member .

39. A method as set forth in claim 32 wherein the step of providing a mold includes providing a secondary distribution system fixedly connected with said article molds, said step of conducting a flow of molten metal to the cavities in the article molds including conducting a flow of molten metal from the primary distribution system to the secondary distribution system and conducting a flow of molten metal from the secondary distribution system to the article mold cavities, said step of moving the article molds out of the chamber in the furnace including lowering the article molds to a level at which the secondary distribution system is lower than the baffle.

40. A method comprising the steps of providing a furnace having a mold receiving chamber, mounting in the furnace chamber a primary distribution system which includes a pour cup and a plurality of passages extending outwardly from the pour cup, providing a plurality of mold structures each of which includes a plurality of article molds and a secondary distribution system which includes a distribution channel connected in fluid communication with article mold cavities in the article molds, moving a first one of the plurality of mold structures into the furnace chamber with the secondary distribution system of the first mold structure disposed adjacent to the primary distribution system, pouring molten metal into the pour cup of the primary distribution system, conducting a plurality of streams of molten metal from the pour cup through the passages in the primary distribution system to the channel in the secondary distribution system of the first mold structure, conducting molten metal from the distribution channel in the secondary distribution system of the first mold structure to the article mold cavities in the article molds of the first mold structure, emptying the passages in the primary distribution system of molten metal, thereafter, moving the first mold structure out of the furnace chamber, moving a second one of the plurality of mold structures into the furnace chamber with the secondary distribution system of the second mold structure adjacent to the primary distribution system, again pouring molten metal into the pour cup of the primary distribution system, conducting a plurality of streams of molten metal from the pour cup through the passages in the primary distribution system to the channel in the secondary
distribution system of the second mold structure to the article mold cavities -in the article molds of the second mold structure, emptying the passages in the primary distribution system of molten metal, and, thereafter, moving the second mold structure out of the furnace.

41. A method as s;et forth in claim 40 further
including the step of providing a baffle plate which is fixedly connected with the primary distribution system, said step of moving a first one of the mold structures into the furnace chamber including moving the secondary distribution system and article mold cavities of the first one of the mold structures upwardly past the baffle plate, said step of moving the first one of the mold structures out of the furnace chamber including moving the article mold cavities and secondary distribution system of the second one of the mold structures downwardly past the baffle plate, said step of moving a second one of the mold structures into the furance chamber including moving the secondary distribution system and article mold cavities of the second one of the mold structures upwardly past the baffle plate, said step of moving the second one of the mold structures out of the furnace chamber including moving the article mold cavities and secondary distribution system of the second one of the mold structures downwardly past the baffle plate.

42. A method as set forth in claim 41 wherein said step of moving a first one of the plurality of mold structures into the furnace chamber includes placing the first one of the mold structures on a support member disposed outside of the furnace chamber and moving the support member and first mold structure toward the furnace chamber, said step of moving a second one of the mold structures into the furnace chamber includes placing the second one of the mold structures on the support member outside of the furnace chamber and moving the support member and the second mold structure toward the furnace chamber , said method further including the steps of transmitting forces induced by the pouring of molten metal into the pour cup with the first mold structure in the furnace chamber and transmitting forces induced by the pouring of molten metal into the pour cup with the second mold structure in the furnace chamber through the baffle plate to the support member.

43. An apparatus for use in casting a plurality of articles, said apparatus comprising furnace means for supplying heat to a mold receiving chamber in said furnace means, a support member movable toward and away from said furnace means, a plurality of article molds disposed on said movable support member in an annular array, each of said article molds having a cavity with a configuration corres"ponding to the configuration of one of the articles, drive means for moving said support member toward said furnace means to move said article molds into the chamber in said furnace means and for moving said support member away from said furnace means to withdraw said article molds from the chamber in said furnace means, a primary distribution system for receiving molten metal and
directing the molten metal toward article molds, said primary distribution system being disposed adjacent to a first axial end portion of the annular array of article molds when said article molds are in the chamber in said furnace means, baffle means disposed adjacent to a second axial end portion of the annular array of article molds when said article molds are in the chamber in said furnace means for retarding heat transmission from the chamber in said furnace means during withdrawal of said article molds from the chamber in said furnace means, said baffle means having a lower side surface area disposed in abutting engagement with said support member when said article molds are in the chamber in said furnace means, and means extending between said baffle means and said primary distribution system for transmitting forces from said primary distribution system to said baffle means to press the lower side surface area on said baffle means against said support member to at least partially support said primary distribution system during the receiving. of molten metal in said primary distribution system.

44'. An apparatus as set forth in claim 43 further including connector means for connecting said primary distribution system with said furnace means to withdrawal of said primary distribution system from the chamber in said furnace means during withdrawal of said article molds from the chamber in said furnace means.

45. An apparatus as set forth in claim 43 wherein said means extending between said baffle means and said primary distribution system supports said baffle means from said primary distribution system during withdrawal of said article molds from the chamber in said furnace means.

46. An apparatus as set forth in claim 43 further including a secondary distribution system connected to said article molds and movable therewith during movement of said support member toward and away from said furnace means, said secondary distribution system being connected in fluid communication with each of the article mold cavities, and a plurality of joint means connected in fluid communication with said primary and secondary distribution systems for conducting a flow of metal therebetween at a plurality of locations and for enabling relative movement to occur between said primary and secondary distribution systems.

47". An apparatus as set forth in claim 43 wherein said means extending between said baffle means and said primary distribution system includes a post having an upper end portion connected to said primary distribution system and a lower end portion connected to said baffle means .

48. An apparatus as set forth in claim 43 wherein said primary distriburion system, baffle maans, and post are formed as one piece of ceramic material.

49. An apparatus as set forth in claim 43 further including an annular base disposed in engagement with said support member and interconnecting lower end portions of said article molds, said annular base circumscribing said baffle means when said article molds are in the chamber in said furnace means.

50. An apparatus as set forth in claim 43 wherein said primary distribution system includes a pour cup having a base portion and an extension potion extending upwardly from said base portion, said apparatus further including connector means disposed in engagement with said extension portion of said pour cup to connect said primary distribution system with said furnace means.

51. A mold for use in casting a plurality of articles, said mold comprising a plurality of article molds disposed in an annular array having an open central portion, each of said article molds having an article mold cavity with a configuration corresponding to the configuration of one of the articles, molten metal distribution means for conducting molten metal to each of said article mold cavities, said molten metal distribution means including a primary distribution system separate from said article molds and a secondary distribution system connected to said article molds, said primary distribution system including a pour cup disposed in a coaxial relationship with the circular array of article molds and a plurality of runners extending outwardly from the pour cup, said secondary distribution system including an annular distribution ring separate from said runners and disposed at a first axial end portion of and coaxial with the annular array of article molds, said annular distribution ring being formed as one piece with said article molds and having an annular cavity connected in fluid communciation with said article mold cavities, joint means connecting said runners and said distribution ring in fluid communication for conducting a flow of molten metal from said primary distribution system to said secondary distribution system and for enabling said secondary distribution system and array of article molds to be moved away from said primary distribution system after said article mold cavities have been filled with molten metal.

and baffle plate means disposed at a second axial end portion of and coaxial with the annular array of article molds for retarding heat transmission from said article molds, said baffle plate means being separate from said article molds to enable said article molds to be moved relative to said baffle plate means.

52. A mold as set forth in claim 51 further including support means disposed in the central portion of the array of article molds and extending between said baffle plate means and said primary distribution system for supporting said baffle plate means.

53. An apparatus as set forth in claim 51 further including surface means interconnecting said article molds to form a solid annular wall.

54. A mold as set forth in claim 51 further including an annular base plate disposed at the second axial end portion of and coaxial with the array of article molds, said annular base plate being formed as one piece with said article molds.

55. An apparatus as set forth in claim 51 wherein said pour cup includes a base section and an extension section which is formed separately from said base section and connected to said base section.

56". In an apparatus for casting metal forms, said apparatus being adapted to establish controlled heating zones, the combination comprising:
an induction heating source;
a mold assembly in the form of an annular array of individual molds, adapted to receive heat energy on the outer and inner surfaces of said array and adapted to move in a predetermined direction;
a liquid metal distribution means adapted to separably and matingly engage said mold assembly into which said liquid metal is poured, said distribution means retarding the entry of radiant energy to the interior of the annular array of molds when said distribution means is in metal pouring communication with said mold assembly;
a first heating zone defined by said induction heat source with said mold assembly and distribution means disposed therein;
a second zone in which the temperature is less than in said first zone;
baffle means fixedly secured to said distribution means forming a separation between said first and second zones to restrict the flow of radiant energy emanating from said first zone from entering said second zone;
means for moving said mold assembly from said first zone to said second zone;
means for retaining said distribution means stationary in said first zone during movement of said mold assembly to effect the separation of said mold assembly from said distribution means when said mold assembly begins its movement toward said second zone to expose the inner surface of said mold assembly to the radiant energy while in said first zone to maintain the metal in its liquid state, said mold assembly being rapidly cooled in said second zone;
whereby said combination produces a high
temperature gradient for each unit of length along at least a portion of said mold assembly.

57. An apparatus as set forth in claim 56 wherein said baffle means is disposed in a central portion of said annular array of molds during movement of said mold
assembly from said first zone to said second zone.

58. An apparatus as set forth in claim 56 wherein said baffle means is connected with said distribution means by a post disposed in a coaxial relationship with said
distribution means.

59. An apparatus as set forth in claim 56 wherein said means for retaining said distribution means stationary includes means for connecting said distribution means with said induction heating source.

60". An apparatus as set forth in claim 56 wherein said baffle means cooperates with said mold assembly and
induction heating means to establish and maintain
essentially horizontal isotherms in said first and second zones adjacent to said baffle means during movement of said mold assembly from said first zone to said second zone.