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Title: Foam patterns

Patent ·
OSTI ID:1109104
; ; ; ; ;

A method of creating a foam pattern comprises mixing a polyol component and an isocyanate component to form a liquid mixture. The method further comprises placing a temporary core having a shape corresponding to a desired internal feature in a cavity of a mold and inserting the mixture into the cavity of the mold so that the mixture surrounds a portion of the temporary core. The method optionally further comprises using supporting pins made of foam to support the core in the mold cavity, with such pins becoming integral part of the pattern material simplifying subsequent processing. The method further comprises waiting for a predetermined time sufficient for a reaction from the mixture to form a foam pattern structure corresponding to the cavity of the mold, wherein the foam pattern structure encloses a portion of the temporary core and removing the temporary core from the pattern independent of chemical leaching.

Research Organization:
IC Patterns, LLC (Miamisburg, OH)
Sponsoring Organization:
USDOE
DOE Contract Number:
FC36-04GO14332
Assignee:
IC Patterns, LLC (Miamisburg, OH)
Patent Number(s):
8,591,787
Application Number:
13/154,667
OSTI ID:
1109104
Country of Publication:
United States
Language:
English

References (17)

Method for molding composite structural plastic and objects molded thereby patent February 2002
Process of forming multi piece vaporizable pattern for foundry castings patent December 1980
Investment casting method utilizing polymeric casting patterns patent April 1998
Method of Making an Electroformed Mold Having Heat Transfer Conduits and Foam Polyurethane Foundation patent March 1973
Production of Moulds patent July 1973
Ceramic shell moulds, manufacture and use patent April 1987
Resin transfer molding core and preform patent July 1991
Method of preparing disappearing model patent November 1994
Method of producing a golf club head patent March 1987
Molding system and article patent August 1983
Composite casting method patent July 1994
Investment casting patterns and method patent November 2002
Pattern for use in lost pattern foundry process patent October 1989
Process for making a multiple non-pneumatic tire patent October 1997
Reaction injection molding apparatus patent March 1991
Removing lost foam pattern coating residue from a casting patent June 2005
No-bake process for preparing foundry shapes for casting low melting metal castings patent January 1991

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37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY