Bruno Christa Matz

45440131, Oct 1, 1985

Nov 7, 1983

6/549131

Dolores C. Kearney - Inkster MI
Peter Giza - Livonia MI
Bruno Matz - Milford MI

Ford Motor Company - Dearborn MI

B22C 902

164 5

The invention is a method of reclaiming sand used in a method of casting a metal having a liquidus temperature below 2000. degree. F. , the casting method using a vaporizable pattern set within a mold constituted of unbonded sand. The method comprises: (a) blowing, after a predetermined lapse of time after the pouring of the metal into the mold, a combustion supporting gas into and through substantially the entire volume of the mold to levitate at least a region of the sand adjacent to the casting and to combust volatilized byproducts of the pattern entering the mold, and (b) continuing the blowing of the combustion supporting gas to continue combustion and driving of the gas and byproducts of the combustion out of the mold.

48161993, Mar 28, 1989

Nov 4, 1986

6/926754

Bruno Matz - Milford MI
Dolores C. Kearney - Inkster MI

Ford Motor Company - Dearborn MI

C08J 922
B29C 6704

264 53

A method is disclosed of making dimensionally stable, expanded polystyrene foam patterns comprising: (a) expanding a supply of beads comprised of polystyrene and a thermally responsive expanding agent, the expansion being accomplished in one or more stages by use of a gaseous heating agent (steam) to define a fused pattern body of the expanded beads, and (b) subjecting the fused pattern body to subatmospheric pressure (in the range of 5-20" of Hg) for a period of about 0. 5-6 hours but no more than sufficient to accelerate and complete the migration of the trapped expanding agent out of the pattern body. The expanding agent can be selected from the group consisting of various forms of pentane or butane.

47285311, Mar 1, 1988

Nov 4, 1986

6/926758

Bruno Matz - Milford MI
Dolores C. Kearney - Inkster MI

Ford Motor Company - Dearborn MI

G05D 302

427 451

A method is disclosed of dehydrating a thin water based ceramic slurry coating on a foam pattern assembly having hidden internal surfaces. The method comprises sequentially subjecting the coated assembly to a first warm air flow at a sufficient temperature and time to dehydrate and remove 60-80% of the water of the coating, and secondly subjecting the dehydrated coating assembly to low level microwave energy to substantially remove the remainder of the water in all of the coating, the dehydrated coating being devoid of bubbles or cracking. The coating is made by use of a slurry comprising a thixotropic silica water suspension with the silica comprising only 40-50% of the slurry; the slurry also may include a small portion of clay and in some cases an acrylic or epoxy glue additive. The pattern assembly or cluster is comprised of a plurality of molding patterns integrally carried by a gating system and common sprue, the patterns being at least four in number and radiating from the common sprue. The patterns may be of a complex nature having tunnels or internal chambers not readily exposed, such as are present in an automotive manifold or head casting pattern.

41900936, Feb 26, 1980

Nov 2, 1978

5/957376

Dolores C. Kearney - Inkster MI
Bruno Matz - Milford MI

Ford Motor Company - Dearborn MI

B22C 904
B22C 702

164 34

A method of making a composite consumable pattern for use in the cavityless type of metal casting is disclosed. At least two mateable pattern parts are formed entirely of a low density expanded closed-cell polymeric material which is ignitable upon contact with molten metal. The parts are brought together with predetermined mateable surfaces in contact under a pressure of 5-10 psi; one of the parts is vibrated with a frequency of 120-240 cycles per second and an amplitude of 0. 03-0. 10", to promote a controlled friction at the interface. A predetermined depth of the parts is melted and merged to create a water-tight bond between the mating surfaces upon relief of the vibration.

47643285, Aug 16, 1988

Mar 23, 1987

7/028815

Bruno Matz - Milford MI
Dolores C. Kearney - Inkster MI

Ford Motor Company - Dearborn MI

B32B 3120
B29C 6500
B29C 4300
B29D 700

264248

A method for contact fusion bonding of compressible, low density thermoplastic parts is disclosed, which comprises essentially: (a) fluidizing only a surface film on opposed mateable margins of the thermoplastic parts by precompressing the margins against a transversely stationary heated platen located therebetween and, prior to fluidization, continuing such contact to promote such fluidization by thermal conductivity and make heat-settable a limited, predetermined, nonmelted subsurface layer of said mateable margins; and (b) within a time period during which said surface films remain fluid, withdraw said platen from between said opposed margins with minimal separation while bringing the mateable margins together with sufficient force to merge said fluid films and compress said subsurface layers a predetermined moulded dimension. The time period during which the fluid films must be merged after removal of the heated platen is typically less than one second for most low density thermoplastics (low density here being used to mean less than or equal to 2. 5 lbs/ft. sup. 3).

53913370, Feb 21, 1995

Jun 24, 1991

7/720147

Dolores C. Kearney - West Bloomfield MI
Bruno Matz - West Bloomfield MI

Ford Motor Company - Dearborn MI

B29C 6722

264 51

A method for making expandable foam patterns for use in an evaporative casting process includes assembling a plurality of mold parts of a molding tool having mold walls defining a mold cavity, each mold part having a housing wall separated from the mold wall to form a heat exchange cavity adjacent the mold wall, inserting at least one heat pipe adjacent a mold wall portion, filling the mold cavity formed by the mold parts with expandable foam beads, heating the tool by introducing a fluid heat exchange medium to the heat exchange cavity to heat the cavity for a predetermined time, cooling the tool and separating the mold parts to release the expanded foam pattern.