IP Library Granted Patent US 9,315,663
Granted Patent B2
US 9,315,663 · App. 13/121,086 · Granted Apr 19, 2016

Systems, devices, and/or methods for manufacturing castings

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Quick Facts
Patent No.
US 9,315,663
App. No.
13/121,086
Granted
Apr 19, 2016
Kind
B2
Abstract

Certain exemplary embodiments can provide a composition, system, machine, device, manufacture, circuit, and/or user interface adapted for, and/or a method and/or machine-readable medium comprising machine-implementable instructions for, activities that can comprise, after removing a cast device from a stack-lamination-derived mold, said cast device formed from a molding composition, applying a desired shape to said cast device to form a shaped cast device, said molding composition comprising: a ceramic composition comprising silica; an cycloaliphatic epoxy binder composition, said cycloaliphatic epoxy binder composition present in said molding composition in an amount up to 30% by weight of said molding composition; a silicone composition comprising a siloxane resin, said silicone composition present in said molding composition in an amount up to 30% by weight of said molding composition; and a solvent composition adapted to dissolve said cycloaliphatic epoxy binder composition and said silicone composition.

Claims (39)

1. A method comprising:

after removing a cast device from a stack-lamination-derived mold, said cast device formed from a molding composition, applying a desired shape to said cast device to form a shaped cast device, said molding composition comprising:

a ceramic composition comprising a plurality of crystalline forms of silica, a first crystalline form of silica from the plurality of crystalline forms of silica being cristobalite in an amount greater than 2.5% and less than 10% by weight of the molding composition;

an cycloaliphatic epoxy binder composition, said cycloaliphatic epoxy binder composition present in said molding composition in an amount up to 30% by weight of said molding composition;

a silicone composition comprising a siloxane resin, said silicone composition present in said molding composition in an amount up to 30% by weight of said molding composition; and

a solvent composition adapted to dissolve said cycloaliphatic epoxy binder composition and said silicone composition

wherein:

said molding composition, responsive to being cross-linked at a predetermined cross-link temperature, is configured to allow said shaped cast device to be substantially re-shaped upon exposing said shaped cast device to a temperature above said predetermined cross-link temperature; and

said shaped cast device is configured to be substantially carbon-free after sintering; and

said shaped cast device having a post-sintering measured apparent porosity of 15 to 35 percent and a predetermined surface characteristic.

2. A method comprising:

after removing a cast device from a stack-lamination-derived mold, said cast device comprising a reduced solvent version of a molding composition, applying a desired shape to said cast device to form a shaped cast device, said molding composition comprising:

a ceramic composition comprising a plurality of crystalline forms of silica, a first crystalline form of silica from the plurality of crystalline forms of silica being cristobalite in an amount greater than 2.5% and less than 10% by weight of the molding composition;

an cycloaliphatic epoxy binder composition, said cycloaliphatic epoxy binder composition present in said molding composition in an amount up to 30% by weight of said molding composition;

a silicone composition comprising a siloxane resin, said silicone composition present in said molding composition in an amount up to 30% by weight of said molding composition; and

a solvent composition configured to dissolve said cycloaliphatic epoxy binder composition and said silicone composition;

wherein:

said shaped cast device is configured to be substantially carbon-free after sintering; and

said shaped cast device having a post-sintering measured apparent porosity of 15 to 35 percent and a predetermined surface characteristic.

3. The method of claim 2 , further comprising:

firing said shaped cast device.

4. The method of claim 2 , further comprising:

sintering particles of said ceramic composition in said shaped cast device.

5. The method of claim 2 , further comprising:

coupling said cast device to a part.

6. The method of claim 2 , further comprising:

coupling said shaped cast device to a part.

7. The method of claim 2 , further comprising:

casting investment material around said shaped cast device.

8. The method of claim 2 , wherein:

said cast device defines a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate an ancestor mold surface defined by a plurality of layers of a metallic foil stack lamination ancestor mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said plurality of wall surfaces defining a periphery of a layer-less volume.

9. The method of claim 2 , wherein:

said shaped cast device defines a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate an ancestor mold surface defined by a plurality of layers of a metallic foil stack lamination ancestor mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said plurality of wall surfaces defining a periphery of a layer-less volume.

10. The method of claim 2 , further comprising:

casting investment material around said shaped cast device to form an investment cast part.

11. The method of claim 2 , further comprising:

after casting investment material around said shaped cast device to form an investment cast part, removing said shaped cast device from said investment cast part.

12. The method of claim 2 , further comprising:

casting investment material around said shaped cast device to form an investment cast part, said investment cast part defining a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate an ancestor mold surface defined by a plurality of layers of a metallic foil stack lamination ancestor mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said plurality of wall surfaces defining a periphery of a layer-less volume.

Assignments (4)
CHANGE OF NAME Recorded Jul 27, 2023
From: RAYTHEON TECHNOLOGIES CORPORATION
To: RTX CORPORATION
Reel/Frame 064714/0001 →
CORRECTIVE ASSIGNMENT TO CORRECT THE AND REMOVE PATENT APPLICATION NUMBER 11886281 AND ADD PATENT APPLICATION NUMBER 14846874. TO CORRECT THE RECEIVING PARTY ADDRESS PREVIOUSLY RECORDED AT REEL: 054062 FRAME: 0001. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF ADDRESS. Recorded Mar 4, 2021
From: UNITED TECHNOLOGIES CORPORATION
To: RAYTHEON TECHNOLOGIES CORPORATION
Reel/Frame 055659/0001 →
CHANGE OF NAME Recorded Sep 4, 2020
From: UNITED TECHNOLOGIES CORPORATION
To: RAYTHEON TECHNOLOGIES CORPORATION
Reel/Frame 054062/0001 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 28, 2018
From: MIKRO SYSTEMS, INC.
To: UNITED TECHNOLOGIES CORPORATION
Reel/Frame 046232/0716 →