STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not Applicable REFERENCE TO A MICROFICHE APPENDIX Not Applicable

BACKGROUND OF THE INVENTION 1. FIELD OF THE INVENTION The present invention relates generally to the art of investment casting and more specifically to a method and apparatus for combining a conforming gas permeable mold within a correspondingly suitable vacuum chamber in a manner that subjects said mold to vacuum pressure while molten metal is introduced by gravity means from outside the vacuum chamber.

2. DESCRIPTION OF THE RELATED ART The basic principles and methodology of investment or"lost wax" casting have remained basically the same during the 6000 years it has been practiced. Investing a disposable pattern in a mold, eliminating the disposable pattern by burning it out, and introducing molten metal into the resultant mold cavity has never changed other than the quality of materials and equipment technology employed in the process. However, there have been many improvements made in the art during the time it has been known. Among the most important developments in modern times include the discovery that vacuum pressures applied to a gas permeable mold while molten metal is added will greatly enhance the fill out probabilities of complex shapes which otherwise depend entirely on sprue weight, elaborate conduits, venting gates, and hydrostatic pressures to completely fill out a complex mold.

Major changes in recent years have advanced vacuum assisted casting to the point where it is now standard practice to produce very complex articles, including highly detailed finished parts that require no additional machining, expensive assembly procedures, or further finishing of the cast article beyond sprue removal. Prior art examples include a wide variety of vacuum casting methods and equipment, which have proven to be successful in their intended applications. However, of the various processes heretofore used or

proposed for use, few have received commercial consideration for high production industrial applications involving the precision casting of large and complex articles or highly detailed articles.

Consequently, there exists a need for a vacuum casting method and apparatus which is versatile, relatively simple and safe in it's operation, provides consistently reliable results and is reasonably affordable and safe enough to be readily utilized by individuals as well as schools and commercial foundries. The inherent fragility of large gas permeable molds such as ceramic shell molds hinder the progress towards utilizing vacuum casting for a broader range of casting applications. The method and apparatus comprising the present invention provides the combined benefits and advantages of ceramic shell molds with the ability to more economically produce larger, and more detailed precision castings requiring only minimum rework for manufacturing a finished product.

Therefore it is the primary objective of the present invention to reinforce and strengthen ceramic shell molds in a manner that makes them self-supporting, and to provide a uniform means for said molds to be mounted and sealed within a vacuum chamber regardless of mold size, or shape, or mold type used, up to the size limitations of the particular vacuum chamber used in the process. The invention further permits molten metal to be introduced by gravity means from outside the vacuum chamber while said mold remains subjected to vacuum pressure.

It is another object of the invention to provide a method and apparatus that more efficiently drains melted pattern material from the mold during the pattern elimination process resulting in a cleaner mold at the beginning of the burnout phase, consequently reducing exposure to smoke and pollution in the workplace and to reduce undesirable emissions into the atmosphere.

It is still another object of the invention to provide a method and apparatus that furnishes a means for handling sprued patterns and finished molds safely to lessen the chance of damage while investing, drying, and setting up the mold for casting.

Other related objectives are: (a) To provide a method and apparatus that increases yield of the metal being cast by reducing the amount of metal that must be cut off the cast article in the form of sprues, gates, and risers.

(b) To provide a method and apparatus that allows thinner walled castings to be cast resulting in lighter finished articles and consequently less costly articles.

(c) To provide a method and apparatus that is applicable to the casting of a wide variety of different metals including both ferrous and nonferrous metals.

(d) To provide a method and apparatus that permits the casting of articles of varying sizes and shapes one after the other in any desired order on a single production line thereby speeding up production and reducing costs.

(e) To provide a method and apparatus that can be used to sprue and cast any number of articles of any given configuration within a single mold up to the size limitations of the vacuum casting unit being used.

(f) To provide a method and apparatus that is capable of use with a variety of different casting designs involving different types of casting molds such as poured investment molds, ceramic shell molds, multiple mold sections, inserts, disintegrable cores, and the like.

(g) To provide a method and apparatus that can be used to cast different mold types one after the other in any desired order.

(h) To provide a method and apparatus that requires fewer production man-hours to be expended due to the high quality and precise detail of the cast articles.

(i) To provide a method and apparatus that is adaptable to high production output by combining any desired number of vacuum casting chambers in successive order such as a carousel arrangement or the like.

(j) To provide a method and apparatus that is reasonably simple and safe enough for use in a home workshop or teaching facility as well as a commercial foundry and is versatile enough for smaller units to be transported and used at any convenient site such as demonstration workshops or the like.

(k) To provide an apparatus that has a long operating life and minimal maintenance requirements.

(1) To provide a method and apparatus fhat accommodates any size, type, or shape of gas permeable mold in random or any desired order up to the maximum size of the casting unit used (m) To provide a method and apparatus suitable for space manufacturing projects utilizing the natural vacuum outside the earth's atmosphere.

(n) To provide stronger, self-supported molds in order to prevent mold splitting or breakage caused by excessive stress from hydrostatic forces and vacuum pressures as molten metal is introduced into the vacuumized mold.

(o) To provide a more energy efficient casting process by allowing molds to be cast at room temperature or at lower pre-heated temperatures if preferred.

(p) To provide a method and apparatus capable of casting multiple complex shapes and configurations in a single mold thereby speeding up production and reducing costs.

From the objectives listed above, a number of advantages of my vacuum casting process become evident:

(a) Vacuum pressure subrogates gravity and hydrostatic pressures to force molten metal into all recesses of a mold cavity.

(b) A gas permeable mold suspended inside a vacuum chamber from its sprue-forming device subjects all sides of said mold to equal vacuum pressures.

(c) Outside air being drawn into a vacuum chamber through a narrow sprue and the mold walls enhances vacuum action on the molten metal as it is poured into the mold sprue and flows throughout the mold cavity.

(d) Vacuum pressure subrogates heat to keep molten metal flowing longer through a mold cavity thereby reducing the need to preheat molds before pouring.

(e) Although gas permeable molds are routinely cast by a variety of methods, the vacuum casting apparatus disclosed in my invention provides a convenient, less costly, and more efficient method of casting complex shapes.

(f) A mold confined within a vacuum chamber assures a safer workplace should a mold rupture and spill molten metal while pouring.

Further objectives and advantages of my invention will become apparent from a consideration of the drawings and ensuing description.

BRIEF SUMMARY OF THE INVENTION The present invention discloses a vacuum casting unit and a gas permeable mold, both being equipped with uniform mounting, sealing, and filling features configured to register with their corresponding counterparts. When a ready to cast gas permeable mold is set-up in an activated vacuum casting unit, molten metal is introduced into said mold by gravity means from outside the vacuum chamber while the

mold is subjected to vacuum pressure.

The vacuum casting unit consists of a vacuum tank with a means for connecting and controlling a vacuum device, and a top closure that when joined together form a vacuum chamber configured to accept a correspondingly configured gas permeable mold.

Features of the top closure include a flat sealing surface with an orifice, through which a sprue-forming device, in accordance with this invention, projects and extends a gas permeable mold's sprue, and through which molten metal is introduced into the vacuumized gas permeable mold's cavity by gravity means. The top closure further includes adjustable hanger devices that connect the gas permeable mold to the top closure and which provides the means to adjust the gas permeable mold's sealing properties from outside the vacuum chamber by lowering or raising the mold as needed to form a tighter abutment between the sealing surfaces.

The invention discloses a sprue-forming device that when combined with a disposable foundry pattern and subsequently invested together as a unit forms a gas permeable mold in accordance with this invention. Said sprue-forming device furnishes uniform sprue, mounting, and sealing features for all sizes, shapes, and mold types pertinent to this invention. The preferred embodiment of said sprue-forming device forms a structural framework that surrounds the disposable foundry pattern and carries all the weight of the mold through every step of the foundry process. Said sprue-forming device is comprised of a sprue former ring, a base plate, and other structural elements such as tie wire and connecting rods or other suitable equivalents depending upon the amount of support required for a particular application. A sprue former ring is required to be sprued and invested as an integral part of all molds utilized in this process. The sprue-forming device may be structured to the most appropriate form conditional to the disposable foundry pattern and mold type being cast, The sprue former ring is comprised of a sprue former flask, a

sealing surface, and mounting device all axially arranged and permanently fixed together. Said sprue former flask is a hollow metal cylinder, flanged at one end to form the sprue former ring's sealing surface. Set-up of a sprue former ring to a disposable pattern involves attaching a wax, or it's equivalent, sprue pattern to the disposable foundry pattern. Said wax sprue pattern is long enough to extend concentrically all the way through the sprue former flask where it is invested in place. After burning out the mold, a sprue is left through the investment that now lines the sprue former flask and through which, molten metal gravity flows into the mold cavity during casting. The exterior surface of the sprue former flask and its associated sealing surface must be kept clean and free of investment before setting the mold up in the vacuum chamber in order for the sprue former flask to slip freely through the top closure's center hole and to allow tight contact between sealing surfaces.

The aforementioned base plate, when used as part of a sprue- forming device, is positioned at the opposite end from the sprue former ring and held in place by connecting rods secured by winding tie wire around each juncture of a connecting rod with a base plate anchor bar and sprue former ring. The base plate includes a handle mount and a concentrically located drain port. A handle may be threaded into said handle mount to provide convenient handling of unwieldy molds. The drain port serves two functions. First, it provides alignment for a wax coated sprue pipe when the disposable foundry pattern is sprued* and secondly, during the pattern elimination phase it provides a conduit for melted pattern material to flow out of the mold cavity. Alignment of the sprue pipe with the base plate is assured by threading an alignment plug through the drain port. The alignment plug is a long bolt that is threaded for part of its length and smoothed to a smaller diameter for the remainder of its length. The outside diameter of the smooth part of the alignment plug allows that portion of the alignment plug to slip fit into the inside of the wax coated sprue pipe holding it firmly in place until investing is complete. After investing is complete, and when the investment is thoroughly dry, the alignment plug is

removed to facilitate pattern elimination. After burnout and before setting the gas permeable mold up in the vacuum chamber a drain plug must be threaded into the drain port which seals the drain port and will prevent molten metal from flowing straight through the mold cavity and into the vacuum chamber.

While the invention is described in connection with certain described embodiments and applications, it will be understood that it is not intended to limit the invention to these particular descriptions or uses. On the contrary, it is intended to cover all alternatives, modifications, and equivalent arrangements as may be included within the scope of this invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS Figure 1-Is an isometric view of a typical vacuum casting apparatus containing a ready to cast gas permeable mold in accordance with the present invention.

Figure 2-Shows a typical embodiment, isometric view, of a large disposable foundry pattern sprued to a sprue-forming device and ready to invest in accordance with the present invention.

Figure 3-Shows a simplified cross sectional view through a vacuum casting apparatus containing a large gas permeable mold being cast in accordance with the present invention.

Figure 4-Is an isometric view of an alternative embodiment of a sprued and ready to invest small disposable foundry pattern in accordance with the present invention.

Figure 5-Is an enlarged cross sectional view showing base plate to disposable foundry pattern connections and handle installation ready for investing in accordance with the present invention.

Figure 6-Is an enlarged cross sectional view showing drain plug

installation in drain port of a burned out and ready to cast gas permeable mold in accordance with the present invention.

Figure 7-Is an isometric view showing a typical flask mold ready for investing in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION A preferred embodiment of the present invention is illustrated in Fig. 1 (isometric view) and Fig. 3 (cross sectional view) showing a loaded and sealed vacuum casting unit 46 which when vacuumized is ready to accept molten metal into gas permeable mold 10 through mold sprue 86. Vacuumization is accomplished by activating a vacuum device (not shown) connected to vacuum pump connecting port 70.

A ready to cast gas permeable mold 10, in accordance with the present invention, is conjoined with a top closure 48 (Fig. 3) by inserting sprue former flask 22 through center hole 50 and seating sealing surface 24 against sealing surface 62 by physical abutment and latching the two parts together by attaching mounting devices 26 to adjustable hanger devices 56. Sealing surface 24 must fit flat and tight against sealing surface 62 to ensure proper vacuum pressure. A compressible seal 54 may be placed between the two sealing surfaces should either sealing surface become warped or damaged from repeated use or rough handling.

Top closure 48 along with it's conjoined gas permeable mold 10 is installed as a unit into vacuum tank 64 and secured with latching devices 60 which squeezes compressible seal 74 thereby resulting in a tight seal between top closure and vacuum tank. Air is evacuated from the vacuum chamber 66 when vacuum device (not shown) is activated. Further sealing, if needed, is accomplished by turning adjustable hanger devices 56 upward to raise the ready to cast gas permeable mold 10 and it's sealing surface 24 up tighter against sealing surface 62 inside the vacuum chamber 66. Set-up is complete and ready to cast when vacuum guage 68 indicates negative pressures exist in vacuum chamber 66. Complete vacuum is not achievable at

this point in the operation due to the vacuum drawing outside air into the mold cavity 80 through the exposed mold sprue 86 and thus through the gas permeable mold wall 84, which stabilizes low pressure in the vacuum chamber. Once no more air leaks are detected, molten metal can then be gravity poured into mold sprue 86. As molten metal 78 rises in mold cavity 80 (Fig. 3), any trapped air 82 is evacuated from mold cavity 80 through mold wall 84 of gas permeable mold 10. At the same time, vacuum pressure holds the molten metal tight against the inside wall of the mold cavity where it is held in place until solidification of the metal is complete. Vacuum pressure is maintained for a brief time after pouring to allow the molten metal to completely solidify in place thereby lessening potential shrinkage problems in the cast article (not Shown). Accidental spillage of molten metal may occur while pouring due to misalignment of the crucible (not shown) or because of overfilling of the sprue till run over occurs. Such waste metal flows into spill guard 52 where it is contained, thereby preventing molten metal from flowing into the work area and endangering those in the workplace.

The cast mold is removed from vacuum chamber 66 by opening vacuum release valve 72 and relieving vacuum pressure, then releasing latching devices 60 in order to lift top closure 48 along with the cast mold clear of vacuum tank 64 using lifting devices 58 if needed. The cast mold is then separated from top closure by disengaging adjustable hanger devices 56 from mounting devices 26.

Compressible seal 54, when used, is removed from sprue-forming device 12 and saved for future use.

The cast article (not shown) is retrieved from the mold by breaking away the ceramic shell investment 94 coating the cast article and the sprue-forming device. The investment is broken up and chipped off the sprue-forming device whereby all metal parts are sandblasted clean and reused. The cast article is further processed according to conventional foundry practices.

Figure 2 illustrates a preferred method of sprueing a large

disposable foundry pattern 14 requiring maximum structural strength and support. Metal components comprising sprue-forming device 12 form a cage that surrounds a disposable foundry pattern. Said cage supports and carries all the weight of the gas permeable mold before and after casting. Molds requiring maximum structural strength are supported by conjoining base plate 28 to sprue former ring 20 with f connecting rods 42. Said base plate forms a platform when suspended from sprue former ring 20 by connecting said base plate to said sprue former ring with connecting rods 42 and securing all joints with tie wire 44 or suitable equivalent. Said base plate is comprised of a drain port 30, a handle mount 32 (Figs. 5, and 6), and base plate anchor bars 38. Said base plate anchor bars along with sprue former ring 20 provide solid attachment points for connecting rods 42.

Molds deemed strong enough to require minimal support need only have tie wire 92 (Fig. 4), or suitable equivalent, looped loosely around, but not touching, the disposable foundry pattern 98 and secured to sprue former ring 20. Said tie wire, when invested as an integral part of a gas permeable mold, performs the same function for a gas permeable mold as the aforementioned cage. Investing is done according to conventional foundry methods.

Disposable foundry pattern configuration dictates mold requirements such as whether or not a mold is considered more suitable for a large mold set-up as Fig. 2 illustrates, a small mold set-up as shown in Fig. 4, a flask type pourable investment mold as shown in Fig. 7, or whatever mold or mold type may be used in accordance with the present invention. A sprue former ring 20 (Figs. 2,3, 4, and 7) is required to be invested as an integral part of all gas permeable molds applicable to the present invention.

Said sprue former ring incorporates a sprue former flask 22, a sealing surface 24, and a mounting device 26. Sprue former ring 20, when invested as an integral part of a gas permeable mold, provides the means for said mold to be mounted and sealed within the confines of a vacuum casting unit.

The present invention discloses a long sprue pipe 16 (Fig. 2) and a short sprue pipe 90 (Figs. 4 and 7). Said sprue pipes provide rigid support for a central sprue to which disposable foundry patterns are attached in order to create a gas permeable mold in accordance with the present invention. Said sprue pipes may be any desired length but need not be any longer than is necessary to accommodate a particular disposable foundry pattern. Coating a sprue pipe with wax, or suitable equivalent, and shaping a wax sprue pattern 76 is the first step towards setting up a typical embodiment of a sprue-forming device in accordance with the present invention.

The wax coated sprue pipe is conjoined with sprue former ring 20 by concentrically arranging the smaller diameter sprue pipe inside the larger diameter sprue former flask 22 (Fig. 3) and filling the separating space with a suitable mold material, such as pourable investment 88 (Figs. 2,3, 4, and 7). When positioning the wax coated sprue pipe inside the sprue former ring and prior to pouring investment, said sprue pipe may be adjusted lengthwise either way in the sprue former ring to allow more or less of the sprue pipe to be used for the actual sprue. Too long a sprue pipe for a particular disposable pattern is unwieldy and may impede the investing process, which is best avoided by simply selecting a shorter pipe. The two parts become firmly joined together once the pourable investment, or it's equivalent, has completely set.

Once a sprue former ring 20 and an appropriate sprue pipe 16 or 90 has been joined together with pourable investment 88 it is ready to attach a disposable foundry pattern using the usual accepted foundry methods for attachment. Only a single sprue attachment is usually all that is required for the present invention, however, for strength purposes it may be practical to add additional gates to fragile details that may be at risk for damage during the investing process. At this time, in the process, it must be determined which embodiment of the sprue-forming device is most appropriate for the particular disposable foundry pattern being cast and set-up accordingly. Investing, drying, and burnout of the mold is done according to conventional foundry practices.

The sprue pipe is a convenient handling device during the sprueing, investing, and drying process but must removed after investing is complete and before burnout.

The sprue pipe is removed by applying sufficient heat to the sprue pipe to soften it's wax coating thereby allowing the sprue pipe to be easily withdrawn from the mold sprue.

A large gas permeable mold set-up requiring all components of the previously described sprue-forming device 12 includes a drain port 30 (Figs. 5 and 6) as an integral part of base plate 28. Said drain port performs a dual function in the course of utilizing said sprue- forming device in accordance with the present invention. In one function, alignment plug 36 (Fig. 5) is threaded through drain port 30 and inserted into said sprue pipe. The outside diameter of the alignment plug is the same as the inside diameter of the sprue pipe thereby allowing the two parts to slip fit together where they hold fast, in proper alignment, until, connecting rods 42 can be positioned and used to securely join the base plate 28 to the sprue former ring 20 along with it's conjoined sprue pipe and attached disposable foundry pattern (s). The alignment plug 36 is left in place throughout the investing and mold drying process to provide greater rigidity to the assembly of parts comprising sprue-forming device 12 (Figs. 2 and 5). Said alignment plug is removed after investing, and before burnout to leave the drain port open in order for melted pattern material to drain freely from mold cavity 80 during burnout. A drain plug 34 (Fig. 6) must be threaded into said drain port 30 before the mold can be cast.

An alternative feature for sprue pipes involves drilling a plurality of drain holes 18 (Fig. 5) in sprue pipe to allow melted pattern material to flow inward into the sprue pipe and then out through drain port 30. Providing melted mold material a place to drain reduces the chance of mold cracking due to mold material expansion during pattern elimination.

Base plate 28 provides a convenient means for handling whenever

set-up as part of the sprue-forming device. A handle mount 32 (Figs. 5 and 6) allows a handle 40 (Figs. 2 and 5) to be connected to said base plate by threading said handle into said handle mount.

The handle and the sprue-forming device on the other end of the mold provides easy handling for two people to handle a large mold and also allows a mold to be laid across two saw-horses or similar support which allows the mold to be rolled to aid in investing.

Said handle is removed before placing mold in oven (not shown) for disposable pattern elimination and burnout. Mold requirements not using drain port provisions (Fig. 4) in accordance with the present invention are invested and burned out in accordance with conventional foundry practices.

An alternative embodiment (Fig. 7) shows a typical flask type investment mold set-up with sprue former ring 20 along with short sprue pipe 90, and with sprued disposable foundry pattern 106 in place and ready to introduce pourable investment (not shown) into flask 100. Generally accepted methods of investing a flask type investment mold requires a sprued disposable foundry pattern be mounted sprue down to a flat plate 102 or other suitable sprue device. A flask is placed over the pattern and sealed down to said flat plate with wax 96 or other suitable equivalent. Said wax seals the flask down to the flat plate and prevents leakage of the pourable investment as it is poured into the flask. Vent holes 104 equalize and distribute vacuum pressure more evenly to all sides of the flask and throughout the mold when the mold is subjected to vacuum pressure and ready to cast. Tape, or other suitable equivalent, (not shown) is used to seal the vent holes until pourable investment has thoroughly set.

Securing one end of tie wires 108, or suitable equivalent, to various locations around the sprue former ring 20 and allowing long ends of said wires to dangle loosely down into the space separating the flask from the pattern provides sufficient bonding of the sprue former ring to the pourable investment (not shown) once said investment is thoroughly set. Investing and burn out of said flask type mold is done according to conventional foundry practices.

The manner of using the present invention to cast metal is identical to investment casting methods in present use whether or not vacuum pressure is employed. Namely, one first prepares a disposable foundry pattern (see Figs. 2,3, 4, and 7), sprueing and investing said pattern in a refractory mold, eliminating and burning out said pattern from said mold, introducing molten metal into the mold, and finally, retrieving the cast article by breaking away the mold is standard foundry practice.

Using vacuum pressure to evacuate air from a mold cavity reduces cold shuts, which generally result from trapped air blocking passage of molten metal in an improperly vented and gated mold. The vacuum casting apparatus disclosed in the present invention more effectively removes air from a mold cavity due to subjecting the entire mold to maximum vacuum pressure equally and uniformly. The present invention reduces the need for vents and greatly reduces the amount of gating normally associated with investment casting.

SEQUENCE LISTING 10 Gas permeable mold 12 Sprue-forming device 14 Disposable foundry pattern 16 Long sprue pipe 18 Drain holes 20 Sprue former ring 22 Sprue former flask 24 Sealing surface 26 Mounting device 28 Base plate 30 Drain port 32 Handle mount 34 Drain plug 36 Alignment plug 38 Base plate anchor bar 40 Handle 42 Connecting rod 44 Tie wire 46 Vacuum casting unit 48 Top closure 50 Center hole 52 Spill guard 54 Compressible seal 56 Adjustable hanger device 58 Lifting device 60 Latching device 62 Sealing surface 64 Vacuum tank 66 Vacuum chamber 68 Vacuum gauge 70 Vacuum pump connecting port 72 Vacuum release valve 74 Compressible seal 76 Wax sprue pattern 78 Molten metal 80 Mold cavity 82 Trapped air 84 Mold wall 86 Mold sprue 88 Pourable investment 90 Short sprue pipe 92 Tie wire 94 Ceramic shell investment 96 Wax 98 Disposable foundry pattern 100 Flask 102 Flat plate 104 Vent hole 106 Disposable foundry pattern 108 Tie wire