Method of casting fusible materials

Claim 1

THE METHOD OF CASTING IN A MOLD DEFINING A SOLID SUPPORTING MATRIX SURFACE AND HAVING AN EFFECTIVE LENGTH SUBSTANTIALLY GREATER THAN ITS EFFECTIVE DEPTH, COMPRISING COLLECTING IN A RESERVOIR RIGID WITH THE MOLD TO FORM A UNIT THEREWITH, A BODY OF FUSED MATERIAL TO BE CAST WITH A LAYER OF FUSIBLE MOLD MATERIAL FLOATING ON THE TOP SURFACE THEREOF AND HAVING (1) A SOLIDIFICATION TEMPERATURE LOWER THAN THAT OF THE MATERIAL TO BE CAST, (2) A THERMAL CONDUCTIVITY LESS THAN THAT OF THE WALL OF THE MOLD ADJACENT ITS SUPPORTING MATRIX SURFACE, (3) IMMISCIBILITY WITH THE FUSED MATERIAL TO BE CAST WHEN SAID MOLD MATERIAL IS IN FUSED STATE, (4) LOW VOLATILITY AT THE MAXIMUM TEMPERATURE TO WHICH THE MOLD MATERIAL WILL BE SUBJECTED DURING CAST, (5) CHEMICAL NON-REACTIVITY WITH THE MATERIAL BEING CAST AND WITH WALL MATERIAL OF THE MOLD ADJACENT TO ITS SUPPORTING SURFACE, AND (6) A SPECIFIC GRAVITY WHEN FUSED LESS THAN THAT OF THE FUSED MATERIAL TO BE CAST, AND TILTING THE UNIT TO CAUSE THE BODY OF FUSED MATERIAL TO BE CAST TO BE TRANSFERRED TO THE MOLD WITH THE FLOATING LAYER OF MOLD MATERIAL FLOWING IN ADVANCE OF THE MATERIAL TO BE CAST TO LINE THE INNER SURFACES OF SAID MOLD BEFORE THE MATERIAL TO BE CAST REACHES SAID MOLD SURFACES, WHEREBY THERE IS FORMED BETWEEN SAID MOLD SURFACES AND THE BODY OF FUSED MATERIAL TO BE CAST A LAYER OF MOLD MATERIAL SOLIDIFIED IN THE REGION IN CONTACT WITH SAID SUPPORTING MATRIX SURFACE AND FUSED IN THE REGION IN CONTACT WITH THE MATERIAL BEING CAST, SAID UNIT BEING TILTED UNTIL THE MOLD IS IN MOLD-LINED STATE AND IN POSITION WITH THE TOP HORIZONTAL SURFACE OF THE BODY OF FUSED MATERIAL EXTENDING ALONG THE LENGTH OF THE MOLD AND THE DEPTH OF THE MOLD BEING VERTICALLY DOWNWARD FROM SAID HORIZONTAL SURFACE, AND ALLOWING THE MATERIAL TO BE CAST TO SOLDIFY IN SAID MOLD WHILE IN SAID MOLD-LINED STATE.

Claim 2

THE METHOD OF CASTING IN A MOLD DEFINING A SOLID SUPPORTING MATRIX SURFACE AND HAVING AN EFFECTIVE LENGTH SUBSTANTIALLY GREATER THAN ITS EFFECTIVE DEPTH, COMPRISING COLLECTING IN A RESERVOIR RIGID WITH THE MOLD TO FORM A UNIT THEREWITH, A BODY OF FUSED MATERIAL TO BE CAST WITH A LAYER OF FUSIBLE MOLD MATERIAL FLOATING ON THE TOP SURFACE THEREOF AND HAVING (1) A SOLIDIFICATION TEMPERATURE LOWER THAN THAT OF THE MATERIAL TO BE CAST, (2) A THERMAL CONDUCTIVITY LESS THAN THAT OF THE WALL OF THE MOLD ADJACENT ITS SUPPORTING MATRIX SURFACE, (3) IMMISCIBILITY WITH THE FUSED MATERIAL TO BE CAST WHEN SAID MOLD MATERIAL IS IN FUSED STATE, (4) LOW VOLATILITY AT THE MAXIMUM TEMPERATURE TO WHICH THE MOLD MATERIAL WILL BE SUBJECTED DURING CAST, (5) CHEMICAL NON-REACTIVITY WITH THE MATERIAL BEING CAST AND WITH WALL MATERIAL OF THE MOLD ADJACENT TO ITS SUPPORTING SURFACE, AND (6) A SPECIFIC GRAVITY WHEN FUSED LESS THAN THAT OF THE FUSED MATERIAL TO BE CAST, AND TILTING THE UNIT TO CAUSE THE BODY OF FUSED MATERIAL TO BE CAST TO BE TRANSFERRED TO THE MOLD WITH THE FLOATING LAYER OF MOLD MATERIAL FLOWING IN ADVANCE OF THE MATERIAL TO BE CAST TO LINE THE INNER SURFACES OF SAID MOLD BEFORE THE MATERIAL TO BE CAST REACHES SAID MOLD SURFACES, WHEREBY THERE IS FORMED BETWEEN SAID MOLD SURFACES AND THE BODY OF FUSED MATERIAL TO BE CAST A LAYER OF MOLD MATERIAL SOLIDIFIED IN THE REGION IN CONTACT WITH SAID SUPPORTING MATRIX SURFACE AND FUSED IN THE REGION IN CONTACT WITH THE MATERIAL BEING CAST, SAID UNIT BEING TILTED UNTIL THE MOLD IS IN MOLD-LINED STATE AND IN POSITION WITH THE TOP HORIZONTAL SURFACE OF THE BODY OF FUSED MATERIAL EXTENDING ALONG THE LENGTH OF THE MOLD AND THE DEPTH OF THE MOLD BEING VERTICALLY DOWNWARD FROM SAID HORIZONTAL SURFACE, AND ALLOWING THE MATERIAL TO BE CAST TO SOLDIFY IN SAID MOLD WHILE IN SAID MOLD-LINED STATE.