Superimposed modular construction of vaporizable patterns

Claim 1

A method of constructing multi-part vaporizable patterns, consisting of the steps of carving from vaporizable partially elastic pattern material a first and a second pattern module with mating surfaces adapted to abut each other, cutting in the mating surfaces of each module a lengthwise under-cut groove spaced to align with a corresponding groove in the mating surface of the other module, press fitting, into the groove of one module, one half of an oversize bi-symmetrical spline of the same material and having such form as will engage within the undercut of said groove, press fitting the groove of the other pattern module over the other half of tHe dovetail spline projecting from said mating surface, whereby the partial elasticity of the material will hold the mating surfaces in abutment in a sealed bend-resistant joint.

Claim 2

A method of constructing multi-part vaporizable patterns, consisting of the steps of carving from vaporizable partially elastic pattern material a first and a second pattern module with mating surfaces adapted to abut each other, cutting in the mating surfaces of each module a lengthwise under-cut groove spaced to align with a corresponding groove in the mating surface of the other module, press fitting, into the groove of one module, one half of an oversize bi-symmetrical spline of the same material and having such form as will engage within the undercut of said groove, press fitting the groove of the other pattern module over the other half of tHe dovetail spline projecting from said mating surface, whereby the partial elasticity of the material will hold the mating surfaces in abutment in a sealed bend-resistant joint.

Claim 3

A method of constructing hollow patterns for castings, consisting of the steps of carving out the interior portion of a solid slab of vaporizable pattern material to leave an outer wall terminating in a square cut mating surface, thereby to provide a first pattern module, carving from the same material a second pattern module including an aligned wall terminating in a square cut mating surface adapted to abut the mating surface of the first module, cutting in the mating surfaces of each module an undercut groove spaced to align with a corresponding groove in the mating surface of the other module, and press fitting, into the groove of one module, one dovetail side of an oversize bi-symmetrical spline of the same material, whereby the partial elasticity of the material will hold the mating surfaces in a sealed bend-resistant joint.

Claim 4

A method of constructing hollow patterns for castings, consisting of the steps of carving out the interior portion of a solid slab of vaporizable pattern material to leave an outer wall terminating in a square cut mating surface, thereby to provide a first pattern module, carving from the same material a second pattern module including an aligned wall terminating in a square cut mating surface adapted to abut the mating surface of the first module, cutting in the mating surfaces of each module an undercut groove spaced to align with a corresponding groove in the mating surface of the other module, and press fitting, into the groove of one module, one dovetail side of an oversize bi-symmetrical spline of the same material, whereby the partial elasticity of the material will hold the mating surfaces in a sealed bend-resistant joint.

Claim 5

A method of machine carving and assembling vaporizable patterns whose depth exceeds the available working length of rotating cutters of a machine tool, comprising the steps of establishing a standard depth to which modules of such pattern may be carved, which depth is no greater than such working length of the rotating cutters, dividing the overall form of the pattern into a plurality of modules whose depth equals or is no greater than said standard depth, carving square cut slabs of expanded, partially elastic, vaporizable pattern material of such standard depth to form such pattern modules by rotating such cutters on axes aligned in the direction of said depth, and providing square cut mating surfaces on adjacent modules, machining undercut grooves in said mating surfaces in alignment with the corresponding grooves in the mating surfaces of adjacent modules, press fitting, into the grooves in one module, one dovetail side of an oversize bi-symmetrical spline of the same partially elastic material, and press fitting the groove of a second module elastically over said other dovetail side of the spline, whereby the partial elasticity of the material will hold the mating surfaces in a sealed bend-resistant joint.

Claim 6

A method of machine carving and assembling vaporizable patterns whose depth exceeds the available working length of rotating cutters of a machine tool, comprising the steps of establishing a standard depth to which modules of such pattern may be carved, which depth is no greater than such working length of the rotating cutters, dividing the overall form of the pattern into a plurality of modules whose depth equals or is no greater than said standard depth, carving square cut slabs of expanded, partially elastic, vaporizable pattern material of such standard depth to form such pattern modules by rotating such cutters on axes aligned in the direction of said depth, and providing square cut mating surfaces on adjacent modules, machining undercut grooves in said mating surfaces in alignment with the corresponding grooves in the mating surfaces of adjacent modules, press fitting, into the grooves in one module, one dovetail side of an oversize bi-symmetrical spline of the same partially elastic material, and press fitting the groove of a second module elastically over said other dovetail side of the spline, whereby the partial elasticity of the material will hold the mating surfaces in a sealed bend-resistant joint.

Claim 8

A method of machine carving and assembling vaporizable patterns whose depth exceeds the available working length of rotating cutters of a machine tool, comprising the steps of establishing a standard depth to which modules of such pattern may be carved, which depth is no greater than such working length of the rotating cutters, dividing the overall form of the pattern into a plurality of modules whose depth equals or is no greater than said standard depth, carving square cut slabs of expanded, partially elastic, vaporizable polystyrene pattern material of such standard depth to form such pattern modules by rotating such cutters on axes aligned in the direction of said depth, and providing square cut mating surfaces on the modules to be mated to each other, machining grooves in said mating surfaces in alignment with the corresponding grooves in the mating surfaces of the adjacent modules, masking said grooved mating surfaces, applying a pattern coating onto the pattern modules about the surface portions so masked, removing the masking, press fitting, into the grooves in one module, one half of an oversize bi-symmetrical spline of the same partially elastic material, and press fitting the groove of a second module elastically onto said other half of the spline until the mating surfaces abut each other, whereby the Uncoated mating surfaces will be held sealed in a bend-resistant joint.

Claim 9

A method of machine carving and assembling vaporizable patterns whose depth exceeds the available working length of rotating cutters of a machine tool, comprising the steps of establishing a standard depth to which modules of such pattern may be carved, which depth is no greater than such working length of the rotating cutters, dividing the overall form of the pattern into a plurality of modules whose depth equals or is no greater than said standard depth, carving square cut slabs of expanded, partially elastic, vaporizable polystyrene pattern material of such standard depth to form such pattern modules by rotating such cutters on axes aligned in the direction of said depth, and providing square cut mating surfaces on the modules to be mated to each other, machining grooves in said mating surfaces in alignment with the corresponding grooves in the mating surfaces of the adjacent modules, masking said grooved mating surfaces, applying a pattern coating onto the pattern modules about the surface portions so masked, removing the masking, press fitting, into the grooves in one module, one half of an oversize bi-symmetrical spline of the same partially elastic material, and press fitting the groove of a second module elastically onto said other half of the spline until the mating surfaces abut each other, whereby the Uncoated mating surfaces will be held sealed in a bend-resistant joint.

Claim 10

A method of machine carving and assembling vaporizable patterns comprising the steps of dividing the overall form of the pattern into a plurality of modules, carving expanded, partially elastic, vaporizable polystyrene pattern material to form such pattern modules, and providing square cut mating surfaces on the modules, to be mated to each other, machining grooves in said mating surfaces in alignment with the corresponding grooves in the mating surfaces of the adjacent modules, masking said grooved mating surfaces, applying a pattern coating onto the pattern modules about the surface portions so masked, removing the masking, press fitting, into the grooves in one module, one portion of an oversize spline of the same partially elastic material, and press fitting the groove of a second module elastically onto said other half of the spline until the mating surfaces abut each other, whereby the uncoated mating surfaces will be held sealed in a bend-resistant joint.

Claim 11

A method of machine carving and assembling vaporizable patterns comprising the steps of dividing the overall form of the pattern into a plurality of modules, carving expanded, partially elastic, vaporizable polystyrene pattern material to form such pattern modules, and providing square cut mating surfaces on the modules, to be mated to each other, machining grooves in said mating surfaces in alignment with the corresponding grooves in the mating surfaces of the adjacent modules, masking said grooved mating surfaces, applying a pattern coating onto the pattern modules about the surface portions so masked, removing the masking, press fitting, into the grooves in one module, one portion of an oversize spline of the same partially elastic material, and press fitting the groove of a second module elastically onto said other half of the spline until the mating surfaces abut each other, whereby the uncoated mating surfaces will be held sealed in a bend-resistant joint.