Inserts and method and apparatus for embedding inserts in cast members

In combination, an insert and a reciprocatable pin assembly for receiving said insert for insertion into a casting material, said insert comprising:

• a hollow, substantially cylindrical-shaped, elongated housing having an open end and a closed end;
• one of said ends and having a flange lying in a plane diagonally aligned with a longitudinal axis of said housing;
• another one of said ends having a flange lying in a plane perpendicular to said longitudinal axis;
• said pin assembly having a first cylindrical-shaped portion of a first diameter;
• a second cylindrical-shaped portion of a second diameter less than said first diameter, one end of said second portion being integrally joined to one end of said first portion, forming an annular ledge at the juncture thereof;
• said ledge lying in a plane perpendicular to a longitudinal axis of said pin assembly;
• said pin assembly second portion being inserted into said insert through said open end with said open end resting on said ledge;
• said pin assembly having an integral projection arranged on said ledge and extending along said second portion toward a free end thereof;
• said insert having at least one slot extending inwardly from said open end for receiving said projection for aligning said insert on said pin assembly.

A method for producing in a mold assembly a cast member having openings for receiving the legs of a step and employing a pin assembly and insert comprising:

• (a) providing a pin assembly, said pin assembly having a first cylindrical-shaped portion of a first diameter;
• a second cylindrical-shaped portion of a second diameter less than said first diameter one end of said second portion being integrally joined to one end of said first portion, forming an annular ledge at the juncture thereof;
• said ledge lying in a plane perpendicular to individual axis of said pin assembly;
• said pin assembly having an integral projection arranged on said ledge and extending along said second portion toward a free end and thereof;
• (b) providing an insert having a hollow substantially cylindrical-shaped elongated housing having an open end and a closed end;
• one of said ends and having a flange lying in a plane diagonally aligned with a longitudinal axes of said housing
• another one of said ends having a flange lying in a plane perpendicular to said longitudinal axis;
• said insert having at least one slot extending inwardly from said open end for receiving said projection for aligning said insert on said pin assembly.
• (c) placing said insert on said pin assembly second portion by inserting said second portion through the open end of said insert;
• (d) sliding the insert onto said second portion until said open end engages said ledge;
• (e) orienting said insert on said pin assembly to align said insert so that said slot receives said projection;
• (f) projecting said pin assembly through an opening in said mold assembly and into casting material in said mold assembly;
• and
• (g) withdrawing said pin assembly from the casting material, whereby said insert remains properly positioned in said casting material.

An insert assembly adapted to be embedded in a cast member for force-fittingly receiving a leg portion of a step, said insert assembly being comprised of:

• first and second members adapted to be telescopingly mounted to one another;
• said first member comprising a hollow, substantially cylindrical-shaped elongated housing having first and second open ends and an integral annular flange intermediate said first and second ends, said flange being diagonally aligned to a longitudinal axis of said first member;
• said second member comprising a hollow, substantially cylindrical-shaped elongated housing having a first closed end and a second open end;
• said open end of said second member being telescopingly mounted upon one end of said first member, whereby the second member is force-fitted on said first member.

A method for embedding inserts in a cast member, said inserts being comprised of an assembly of first and second members adapted to be telescopingly mounted to one another;

• said first member being a hollow, substantially cylindrical-shaped elongated housing having first and second open ends and an integral annular flange intermediate said first and second ends, said flange being diagonally aligned to a longitudinal axis of said first member;
• said second member being a hollow, substantially cylindrical-shaped elongated housing having a first closed end and a second open end;
• said open end of said second member being capable of being telescopingly mounted upon one end of said first member, said method comprising the steps of:
• (a) providing a mold assembly including an annular-shaped core member having at least one opening and a tubular step tube joined to the core member and aligned with said opening and extending inwardly from a concave surface of said core member;
• (b) inserting one end of said first member into a convex surface side of said core member and into said step tube, whereby said first member is force-fitted in said step tube, said first member being pushed into said step tube by a distance sufficient to move said diagonally-aligned flange adjacent to a marginal portion of said core surrounding the opening in said core;
• and
• (c) telescopingly mounting said second member onto an end of said first member extending outwardly from the convex surface of said core, whereby said second member is force-fitted to said first member.

A method for embedding inserts in a cast member, said inserts being comprised of an assembly of first and second members adapted to be telescopingly mounted to one another;

• said first member being a hollow, substantially cylindrical-shaped elongated housing having first and second open ends and an integral annular flange intermediate said first and second ends, said flange being diagonally aligned to a longitudinal axis of said first member;
• said second member being a hollow, substantially cylindrical-shaped elongated housing having a first closed end and a second open end;
• said open end of said second member being adapted for being telescopingly mounted upon one end of said first member, said method comprising the steps of:
• (a) providing a mold assembly including an annular-shaped core member having a pair of openings and a pair of cylindrical step tubes joined to the core member and each being aligned with one of said openings and extending inwardly from a concave surface of said core members that the longitudinal axis of said step tubes are substantially parallel;
• (b) telescopingly mounting said second member onto one end of said first member, whereby said first and second members create a friction-fit therebetween;
• and
• (c) inserting another end of said first member into a convex surface side of said core member and into said step tube, whereby said step tube and said other end of said first member creates a friction-fit therebetween, said first member being pushed into said step tube by a distance sufficient to move said diagonally-aligned flange adjacent to a marginal portion of said core surrounding the opening in said core.

A method for embedding inserts in a cast member, comprising:

• providing first and second sets of holding pins, each set arranged along spaced intervals of an associated elongated support;
• mounting an insert on each of said holding pins;
• releasably securing said support along an exterior surface of a core member of a mold assembly with the support being aligned to position the holding pin sets in spaced, substantially parallel fashion;
• and
• placing cast material in the mold assembly so as to embed the inserts into the cast material.

An insert for receiving and supporting a leg of a step, comprising:

• a hollow body closed at one end and open at an opposite end for force-fittingly receiving and supporting said leg;
• an interior of said hollow body having a plurality of annular, spaced, inwardly directed projections for engaging and retaining the leg of the step therein;
• and
• said interior further having plurality of substantially linear, axially aligned spaced projections located near said closed end and adapted for receiving and engaging a positioning pin inserted into the hollow interior preparatory to a casting operation to form a force fit with the positioning pin.

In combination a plurality of inserts, insert positioning assemblies and an interior core of a mold assembly having at least one planar surface portion, comprising:

• said insert positioning assemblies comprising first and second elongated supports having a plurality of holding pins arranged at spaced intervals along each of said supports;
• said inserts each comprising a hollow shaped body having an open end for mounting on an associated one of said holding pins each inserted into one of said open ends;
• each elongated support having a magnet assembly arranged on a surface of each elongated support opposite the surface upon which said holding pins are mounted;
• said planar portion of said mold assembly inner-core having magnetically attractive means arranged therealong;
• said elongated supports being placed upon said planar region and being magnetically attracted thereto;
• and
• an alignment template provided with permanent magnet means along at least a portion of one surface thereof;
• and
• said template having at least one pair of opposite parallel sides and being positioned on said inner core so as to be magnetically attracted to said magnetically attractive means and between and abutting adjacent sides of said elongated supports to properly position said supports in parallel fashion and at a given spacing.

In combination a plurality of inserts, insert positioning assemblies and an interior core of a mold assembly having at least one planar surface, comprising:

• said mounting assemblies comprising first and second elongated supports having a plurality of holding pins arranged at spaced intervals along one surface each of said supports;
• said inserts each comprising a hollow shaped body having an open end for mounting on an associated one of said holding pins;
• each elongated support comprising a magnetically attractive material;
• said planar portion of said mold assembly inner-core having magnetic means arranged therealong;
• said elongated supports being placed upon said planar region and being magnetically attracted to said magnetic means;
• and
• an alignment template provided with magnetically attractive means along at least a portion of one surface thereof;
• and
• said template having at least one pair of opposite parallel sides and being positioned on said inner core so as to be magnetically attracted to said magnetic means and between and abutting adjacent sides of said elongated supports to properly position said supports in spaced parallel fashion.

A method for embedding inserts in a cast member, said inserts being comprised of a hollow, substantially cylindrical-shaped elongated support portion, a hollow, substantially cylindrical-shaped elongated insert portion having interior projections for gripping a leg of a step and a diagonally aligned flange between said holding portion and said insert portion;

• said method comprising the steps of:
• (a) providing a mold assembly including an annular-shaped core member having at least one opening and a tubular step tube joined to the core member and aligned with said opening and extending inwardly from a concave surface of said core member;
• and
• (b) inserting one end of said holding portion into a convex surface side of said core member and into said step tube, whereby said first member is force-fitted in said step tube, said holding portion being pushed into said step tube by a distance sufficient to move said diagonally-aligned flange adjacent to a marginal portion of said core surrounding the opening in said core.