Pattern alignment means for use with lost foam molding process

Claim 1

Pattern apparatus for use in making multiple castings from a single pouring through a common sprue in a body of sand, the apparatus comprising: a. a plurality of consumable foam type patterns which are combustible substantially without residue on subjection to a molten casting charge, each of said patterns having at least one ear effective to serve as a stabilizer, b. a rigid stabilizing frame supported against movement, said frame having at least one extending finger for each of said patterns, each finger providing a support upon which said ear of one of said patterns may be journalled, c. independent sprue means for conducting a molten metallic charge to said combustible patterns for consummation, and d. means to prevent consummation of said frame during introduction of said molten charge.

Claim 9

A method for fabricating a plurality of castings from a single pouring through a common sprue in a body of sand, the method comprising: a. preparing a skeleton stabilizing frame effective to be easily inserted into a fluidized sand medium, said frame having a plurality of fingers extending inwardly thereof in a number of common planes generally equally spaced apart, b. preparing a plurality of consumable foam patterns of the type which is combustible substantially without residue on subjection to a molten casting charge, each said pattern being provided with a plurality of foam ears extending generally away from said pattern to lay in one of said horizontal planes defined by the fingers of said frame, said patterns being joined together by a consumable sprue effective to be combusted without residue by said molten charge for defining a channel to feed said patterns, c. filling said flask with a body of dry, loose unbonded sand, said sand being iNtroduced to said flask by means effective to fluidly locate said sand progressively from the bottom upwardly through said flask, d. pouring molten metal into said consumable sprue and pattern for combusting said foam material to occupy the void left by said foam, e. stripping said patterns from said frame and fingers and from said sand, and then breaking off said cast ears from said casting, and f. re-installing said frame in a stripped flask and repeating steps b through e.

Claim 10

A method for fabricating a plurality of castings from a single pouring through a common sprue in a body of sand, the method comprising: a. preparing a skeleton stabilizing frame effective to be easily inserted into a fluidized sand medium, said frame having a plurality of fingers extending inwardly thereof in a number of common planes generally equally spaced apart, b. preparing a plurality of consumable foam patterns of the type which is combustible substantially without residue on subjection to a molten casting charge, each said pattern being provided with a plurality of foam ears extending generally away from said pattern to lay in one of said horizontal planes defined by the fingers of said frame, said patterns being joined together by a consumable sprue effective to be combusted without residue by said molten charge for defining a channel to feed said patterns, c. filling said flask with a body of dry, loose unbonded sand, said sand being iNtroduced to said flask by means effective to fluidly locate said sand progressively from the bottom upwardly through said flask, d. pouring molten metal into said consumable sprue and pattern for combusting said foam material to occupy the void left by said foam, e. stripping said patterns from said frame and fingers and from said sand, and then breaking off said cast ears from said casting, and f. re-installing said frame in a stripped flask and repeating steps b through e.