US010307818B1

( 12 ) United States Patent Vohl et al .

( 10 ) Patent No . : US 10 , 307 , 818 B1 ( 45 ) Date of Patent : Jun . 4 , 2019

( 54 ) AIR SET SAND MOLDING APPARATUS ( 71 ) Applicant : Wisconsin Aluminum Foundry

Company , Manitowoc , WI ( US )

4 , 553 , 581 A * 11 / 1985 Uppgren et al . . . . . . . B22C 15 / 24 164 / 16

5 , 101 , 881 A * 4 / 1992 Hunter B22C 7 / 04 164 / 239

2006 / 0108087 Al * 5 / 2006 Kaneto et al . . . . . . . . . . . B22C 15 / 08 164 / 37 ( 72 ) Inventors : Mark Vohl , Manitowoc , WI ( US ) ;

Steve Van Ess , Manitowoc , WI ( US ) FOREIGN PATENT DOCUMENTS ( 73 ) Assignee : Wisconsin Aluminum Foundry

Company , Manitowoc , WI ( US ) KR KR KR

20020077266 A 20020082707 A 20130087138 A 2011115348 AL

10 / 2002 10 / 2002

8 / 2013 9 / 2011 ( * ) Notice : WO Subject to any disclaimer , the term of this

patent is extended or adjusted under 35 U . S . C . 154 ( b ) by 0 days . OTHER PUBLICATIONS

( 21 ) Appl . No . : 15 / 853 , 335 International Search Report with Written Opinion for related Appli cation No . PCT / US2018 / 059730 dated Feb . 22 , 2019 ( 12 pages ) .

( 22 ) Filed : Dec . 22 , 2017 * cited by examiner

Primary Examiner — Kevin P Kerns ( 74 ) Attorney , Agent , or Firm — Michael Best & Friedrich LLP

( 51 ) Int . Ci . B22C 17 / 02 ( 2006 . 01 ) B22C 13 / 02 ( 2006 . 01 ) U . S . CI . CPC . . . . . . . . . . . . . . B22C 17 / 02 ( 2013 . 01 ) ; B22C 13 / 02

( 2013 . 01 ) Field of Classification Search CPC . . . . . . . . . . . . . . . B22C 17 / 00 ; B22C 17 / 02 USPC . . . . . . . . . 164 / 37 , 169 , 180 , 187 , 191 , 213 , 237 ,

164 / 238 , 241 See application file for complete search history .

( 58 ) Tiel

( 56 ) References Cited U . S . PATENT DOCUMENTS

1 , 772 , 463 A * 8 / 1930 Loudenslager et al .

( 57 ) ABSTRACT An air set molding apparatus configured to form a sand mold , the apparatus includes a pattern mounting plate including an ejection pin aperture , a molding flask on the pattern mounting plate , the molding flask having a closed lower end and an open upper end . The molding flask including an ejection pin aperture in the closed lower end , an ejection pin movable relative to the pattern mounting plate and the molding flask , the ejection pin movable through the ejection pin aperture of the pattern mounting plate and the ejection pin aperture of the molding flask between a lowered position and a raised position . As the ejection pin moves from the lowered position to the raised position , the ejection pin lifts the sand mold through the open upper end of the molding flask .

2 , 822 , 590 A * 2 / 1958 Hines . . . . . . . . . . . . . . .

B22C 11 / 00 164 / 238

B22C 9 / 20 164 / 137

3 , 089 , 207 A 4 , 210 , 194 A *

5 / 1963 Miller 7 / 1980 Cina et al . B22C 9 / 123

164 / 16 16 Claims , 6 Drawing Sheets

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US 10 , 307 , 818 B1

AIR SET SAND MOLDING APPARATUS FIG . 3 is a perspective view of the air set molding apparatus of FIG . 1 with a molding flask removed and

BACKGROUND ejection pins in a raised position . FIG . 4 is a perspective view of the air set molding

The present invention relates to an air set sand molding 5 apparatus with side panels removed and the ejection pins in apparatus . a lowered position . Mold patterns are used to for making sand molds , which FIG . 5 is a perspective view of the air set molding

include sand mold patterns , sand mold parts , and sand mold machine of FIG . 4 but with the ejection pins in the raised cores used in the metal casting process . A pattern is formed position . in the sand mold and casting fluid is poured into the sand 10 FIG . 6 is a perspective view of the air set molding mold . The sand mold can be formed using a method referred machine of FIG . 1 with a sand mold in a raised position . to as air set molding . In air set molding , a mixture of sand , FIG . 7 is a perspective view of a portion of the air set a resin , and a catalyst is poured into a molding flask that molding machine of FIG . 1 . includes a pattern . The pattern is at least a portion of the cast Before any embodiments of the invention are explained in tooling or part . The mixture cures in the molding flask to 15 detail , it is to be understood that the invention is not limited create the sand mold . The cured sand mold must be removed in its application to the details of construction and the from the molding flask , which presents many challenges . To arrangement of components set forth in the following remove the sand mold , the molding flask is turned over or upside down so that the sand mold drops out of the molding description or illustrated in the following drawings . The flask by gravity . However , this often times damages the sand 20 invention is capable of other embodiments and of being mold or the sand mold does not fall out of the molding flask practiced or of being carried out in various ways . by gravity . If the sand mold does not fall out of the molding flask , the user often times hits the molding flask to urge the DETAILED DESCRIPTION sand mold out of the molding flask . Hitting the molding flask ( e . g . , with a hammer ) can damage the molding flask and / or 25 FIG . 1 illustrates an air set sand molding apparatus 10 that the sand mold . The molding flask is intended to be used is used to create or form a sand mold 14 ( FIG . 6 ) of a pattern multiple times . Dropping the sand mold by gravity can 12 . Air set sand molding is also referred to as and includes damage the sand mold . pepset sand molding , all - core sand molding , dry sand mold

ing , no - bake sand molding , chemically bonded sand mold SUMMARY 30 ing , and the like .

As will be discussed below , the air set molding apparatus In one embodiment , the invention provides an air set 10 automatically and easily removes a cured sand mold 14

molding apparatus configured to form a sand mold , the ( FIG . 6 ) from a molding flask 16 with very low risk of apparatus includes a pattern mounting plate including an damage to the mold 14 and the molding flask 16 . The sand ejection pin aperture , a molding flask on the pattern mount - 35 mold 14 can include sand mold pattern , sand mold part , sand ing plate , the molding flask having a closed lower end and mold core , and the like . an open upper end . The molding flask including an ejection Referring to FIG . 1 , the air set sand molding apparatus 10 pin aperture in the closed lower end , an ejection pin movable includes a pattern mounting plate 18 , a frame 20 , and the relative to the pattern mounting plate and the molding flask , molding flask 16 . The pattern mounting plate 18 has a top the ejection pin movable through the ejection pin aperture of 40 side and a bottom side . The molding flask 16 is supported on the pattern mounting plate and the ejection pin aperture of the top side of the plate 18 . As best seen in FIG . 3 , the pattern the molding flask between a lowered position and a raised mounting plate 18 includes several ejection pin apertures 22 . position . As the ejection pin moves from the lowered posi - The ejection pin apertures 22 extend all the way through the tion to the raised position , the ejection pin lifts the sand mold plate 18 , that is through the top and bottom sides of the plate through the open upper end of the molding flask . 45 18 . The apertures 22 are arranged in rows 24 and columns

In another embodiment the invention provides an air set 26 to form a grid like pattern on the plate 18 . molding apparatus configured to form a sand mold , the The frame 20 supports the pattern mounting plate 18 apparatus includes a pattern mounting plate including an above the floor at a convenient working height for the user . ejection pin aperture , an ejection plate movable relative to For example , in some embodiments , the frame 20 holds the the pattern mounting plate between a lowered position and 50 plate 18 about 30 to 40 inches above the floor . The frame 20 a raised position , and an ejection pin coupled to the ejection includes supports 30 and panels 32 . The panels 32 are plate for movement with the ejection plate between the removably coupled to the supports 30 to that the user can lowered position and the raised position . The ejection pin is access components within the frame 20 and hidden by the movable through the ejection pin aperture of the pattern panels 32 . mounting plate as the ejection plate moves from the lowered 55 Referring to FIGS . 1 and 2 , the molding flask 16 includes position to the raised position to lift the sand mold away a lower end or bottom wall 36 and sidewalls 38 that extend from the pattern mounting plate . up from the lower end 36 . Upper ends of the sidewalls 38

Other aspects of the invention will become apparent by define and open upper end 40 of the molding flask 16 . consideration of the detailed description and accompanying Molding flask ejection pin apertures 42 extend through the drawings . 60 bottom wall or lower end 36 of the molding flask 16 . In the

illustrated embodiment , four apertures 42 extend through the BRIEF DESCRIPTION OF THE DRAWINGS bottom wall 36 of the molding flask 16 . In other embodi

ments , fewer or more than four apertures 42 extend through FIG . 1 is a perspective view of an air set molding the wall 36 . The apertures 42 of the molding flask each align

apparatus according to one embodiment of the invention . 65 with one of the ejection pin apertures 22 of the plate 18 to FIG . 2 is a top view of the air set molding apparatus of form a generally continuous through hole or through aper

FIG . 1 . ture .

US 10 , 307 , 818 B1

The pattern 12 is located inside the molding flask 16 to create a level surface 70 ( see FIG . 6 ) on top of the mold . below the open upper end 40 of the molding flask 16 . In the The mixture is given time to cure and harden . Then , the user illustrated embodiment , the pattern 12 is formed in the moves the ejection plate 50 toward the raised position ( see bottom wall 36 of the flask 16 and then the sidewalls 38 are FIGS . 3 and 6 ) using the drive 62 and associate control attached to the bottom wall 36 . In other embodiments , the 5 system . As the ejection plate 50 moves to the raised position , sidewalls 38 can be already or permanently attached to the the ejection pins 50 pass through the apertures 22 of the plate bottom wall 36 . In other embodiments , the pattern 12 can be 18 and the apertures 42 of the flask 16 and move to a raised separate component that is set on the bottom wall 36 rather position . The pins 50 raise or lift the sand mold 14 out of the than being integrally formed in the bottom wall 36 . The flask 16 as shown in FIG . 6 . That is , the sand mold 14 is ejection pin apertures 42 of the molding flask 16 are located 10 raised above the open upper end 40 of the molding flask 16 . outside the part pattern 12 . That is , the apertures 42 form no As discussed above , the ejection pins 52 that lift the sand part of the part pattern 12 and do not interfere with the part mold 14 are outside the perimeter of the pattern 12 . There pattern 12 . Rather , the apertures 42 are located through the flat area of the bottom wall 36 . fore , the pins 52 lift and press against a flat part 76 of the

Referring to FIGS . 4 . 5 . and 7 , the air set sand molding 15 sand mold 14 , which is a waste portion , and the pins 52 do apparatus 10 further includes an ejection plate 50 and not press against the cavity created by the pattern 12 in the ejection pins 52 that are raised and lowered by the ejection mold pattern 14 . The pins 52 pressing against the cavity plate 50 . The ejection plate 50 is underneath or adjacent the created by the pattern 12 may damage the sand mold 14 or bottom side of the pattern mounting plate 18 . The ejection otherwise create undesirable surface features on the final plate 50 is located inside the frame 20 and panels 32 ( FIG . 20 product created by the mold . The user can then easily lift or 1 ) . The ejection plate 50 is movable up and down relative to otherwise move the sand mold 14 to another location the plate 18 and frame 20 between a lowered position ( FIG . because the mold has be lifted out of the flask 16 . 4 ) and a raised position ( FIG . 5 ) . It should be understood that The air set sand molding apparatus 10 and ejection system the lowered position illustrated in FIG . 4 is just one possible can easily be reconfigured for use with a different molding lowered position of the ejection plate 50 . The ejection plate 25 flasks and patterns simply by moving the location of the 50 may be further lowered so that the ejection pins 52 do not ejection pins 52 on the ejection plate 50 . The pins 52 are extend at all beyond the top of the mounting plate 18 . uncoupled or removed from the ejection plate pin apertures However , in one embodiment , the lowered position is set so 58 and repositioned into different apertures 58 depending on that upper ends 54 of pins 52 are flush with the top of the the shape and size of the new pattern and molding flask . The bottom wall 36 of the molding flask 16 . Therefore , the upper 30 pattern mounting plate 18 also has several pin apertures 22 , ends 54 of the pins 52 extend slightly beyond the top of the as discussed above , so that the pins 52 can pass through the mounting plate 18 ( e . g . , the thickness of bottom wall 36 ) . plate 18 to lift the sand mold as discussed above .

The ejection plate 50 includes several ejection pin aper Thus , the invention provides , among other things , an air tures 58 . The ejection pin apertures 58 are arranged in set molding apparatus that automatically and easily removes columns and rows similar to the pattern mounting plate 18 . 35 the sand mold from the molding flask with very low risk of The location of the apertures 58 of the ejection plate 50 damage to the sand mold and the molding flask . Various relate or match up with the location of the apertures 22 of the features and advantages of the invention are set forth in the mounting plate 18 . That is , each of the apertures 58 of the following claims . ejection plate 50 lines up with one of the apertures 22 of the mounting plate 18 . The pin apertures 58 of the ejection plate 40 What is claimed is : 50 are sized to receive an ejection pin 52 to couple the 1 . An air set molding apparatus configured to form a sand ejection pin 52 for movement up and down with the ejection mold , the apparatus comprising : plate 50 related to the pattern mounting plate 18 . For a pattern mounting plate including an ejection pin aper example , in one embodiment , the pin apertures 58 are blind ture ; bores , not through bores , in the plate 50 to support the pins 45 a molding flask on the pattern mounting plate , the mold 52 for movement with the plate 50 . In other embodiments , ing flask having a closed lower end and an open upper the pins 52 have an interference fit with the apertures 58 . end , the molding flask including an ejection pin aper

The air set sand molding apparatus 10 further includes a ture in the closed lower end ; drive 62 that moves the ejection plate 50 between the raised an ejection pin movable relative to the pattern mounting and lowered position . The illustrated drive 62 includes 50 plate and the molding flask , the ejection pin movable hydraulic cylinders 64 that raise the plate 50 and allow the through the ejection pin aperture of the pattern mount plate 50 to be lowered when desired . A double rack and ing plate and the ejection pin aperture of the molding pinion system 66 is utilized to ensure that plate 50 is raised flask between a lowered position and a raised position , and lowered in a level and even manner and so that one part wherein as the ejection pin moves from the lowered of the plate 50 does not raise or lower at a different rate . It 55 position to the raised position , the ejection pin lifts the should be understood that the drive 62 is just one of many sand mold through the open upper end of the molding possible drive devices that could be used to raise and lower flask , further comprising an ejection plate , the ejection the ejection plate 50 . In other embodiments , other suitable plate movable relative to the pattern mounting plate drives can be used , such as electric motors , pneumatic or between a lowered position and a raised position , pressurized air , etc . 60 wherein the ejection pin is coupled to the ejection plate

In operation , the ejection plate 50 starts in the lowered for movement with the ejection plate relative to the position so that the upper ends 54 of the ejection pins 52 are pattern mounting plate , and wherein movement of the about flush with the bottom wall 36 of the molding flask 16 . ejection plate from the lowered position to the raised The user fills the molding flask 16 with a mixture of sand , position moves the ejection pin from the lowered catalyst , resin , and an activator . The mixture fills in around 65 position to the raised position through the ejection pin the part pattern 12 while the user typically strikes the apertures of the molding flask and the pattern mounting mixture off using the sidewalls 38 of the flask 16 as a guide plate .

US 10 , 307 , 818 B1

2 . The air set molding apparatus of claim 1 , wherein the 13 . The air set molding apparatus of claim 9 , where the pattern mounting plate includes a plurality of ejection pin pattern mounting plate includes a top side and bottom side apertures . and the ejection pin aperture of the pattern mounting plate

3 . The air set molding apparatus of claim 2 , wherein the extends through the top and bottom sides , further compris pattern mounting plate includes at least ten ejection pin 5 ing a molding flask wherein the molding flask is set on the apertures . top side of the pattern mounting plate and the ejection plate

4 . The air set molding apparatus of claim 3 , wherein the is adjacent the bottom side of the pattern mounting plate . at least ten ejection pin apertures are arranged in rows and 14 . The air set molding apparatus of claim 13 , wherein the columns . ejection plate includes an ejection pin aperture that receives 5 . The air set molding apparatus of claim 2 , further 10 " the ejection pin to couple the ejection pin to the ejection comprising at least four ejection pins movable between plate for movement relative to the pattern mounting plate . lowered and raised positions , wherein the pattern mounting plate includes more ejection pin apertures than the apparatus 15 . The air set molding apparatus of claim 14 , wherein the

ejection plate includes at least ten ejection pin apertures has ejection pins . 6 . The air set molding apparatus of claim 1 . where the 15 arranged in rows and columns , wherein the pattern mounting

pattern mounting plate includes a top side and bottom side plate includes at least ten ejection pins in apertures arranged and the ejection pin aperture of the pattern mounting plate in rows and columns that relate to the rows and columns of extends through the top and bottom sides , wherein the the ejection pin apertures of the ejection plate . molding flask is set on the top side of the pattern mounting 16 . An air set molding apparatus configured to form a plate and the ejection plate is adjacent the bottom side of the 20 sand mold , the apparatus comprising : pattern mounting plate . a pattern mounting plate including a plurality of ejection

7 . The air set molding apparatus of claim 6 , wherein the pin apertures arranged in rows and columns ; ejection plate includes an ejection pin aperture that receives a molding flask on the pattern mounting plate , the mold the ejection pin to couple the ejection pin to the ejection ing flask having a closed lower end and an open upper plate for movement relative to the pattern mounting plate . 25 end , the molding flask including first and second ejec

8 . The air set molding apparatus of claim 7 , wherein the tion pin apertures in the closed lower end ; ejection plate includes at least ten ejection pin apertures first and second ejection pins movable relative to the arranged in rows and columns , wherein the pattern mounting pattern mounting plate and the molding flask , the first plate includes at least ten ejection apertures arranged in rows and second ejection pins movable through ejection pin and columns that relate to the rows and columns of the 30 apertures of the pattern mounting plate and the first and ejection pin apertures of the ejection plate . second ejection pin apertures of the molding flask 9 . An air set molding apparatus configured to form a sand between a lowered position and a raised position , mold , the apparatus comprising :

a pattern mounting plate including an ejection pin aper an ejection plate , the ejection plate movable relative to the ture ; 35 pattern mounting plate between a lowered position and

an ejection plate movable relative to the pattern mounting a raised position , wherein the first and second ejection plate between a lowered position and a raised position ; pins are coupled to the ejection plate for movement and with the ejection plate and wherein movement of the

an ejection pin coupled to the ejection plate for movement ejection plate between the lowered and raised positions with the ejection plate between the lowered position 40 moves the first and second ejection pins between the and the raised position , the ejection pin movable lowered position to the raised position through the through the ejection pin aperture of the pattern mount ejection pin apertures of the molding flask and the ing plate as the ejection plate moves from the lowered pattern mounting plate , position to the raised position to lift the sand mold away where the pattern mounting plate includes a top side and from the pattern mounting plate . 45 a bottom side and the ejection pin apertures of the

10 . The air set molding apparatus of claim 9 , wherein the pattern mounting plate extend through the top and pattern mounting plate includes a plurality of ejection pin bottom sides , wherein the molding flask is set on the apertures . top side of the pattern mounting plate and the ejection

11 . The air set molding apparatus of claim 9 , wherein the plate is adjacent the bottom side of the pattern mount pattern mounting plate includes at least ten ejection pin 50 ing plate , apertures arranged in rows and columns . wherein as the first and second ejection pins move from 12 . The air set molding apparatus of claim 11 , further the lowered position to the raised position , the first and comprising at least four ejection pins movable between second ejection pins lift the sand mold through the open lowered and raised positions , wherein the pattern mounting plate includes more ejection pin apertures than the apparatus 55 upper end of the molding flask . has ejection pins .