# US 5,702,628 A · Method of fabricating article by using non-sand core and article produced thereby, and core structure

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- Number: US 5,702,628 A
- Document ID: US5702628A
- Status: Granted
- Kind: A
- Application number: 08/102,974
- Filed: 1993-07-28
- Granted: 1997-12-30
- Earliest claimed: 1992-07-30
- Inventors: Masaru Nemoto
- Web page: https://patentgrep.com/patent/US5702628A

## CPC

- B22C 9/10: Cores; Manufacture or installation of cores {(breaker cores B22C9/084)}
- B22C 1/00: Compositions of refractory mould or core materials; Grain structures thereof (refractory materials in general C04B35/00); Chemical or physical features in the formation or manufacture of moulds
- B22C 1/16: characterised by the use of binding agents; Mixtures of binding agents
- B22C 3/00: Selection of compositions for coating the surfaces of moulds, cores, or patterns
- B28B 7/32: inflatable {(connection of valves to inflatable elastic bodies B60C29/00)}
- B28B 7/34: Moulds, cores, or mandrels of special material, e.g. destructible materials (for slip casting B28B1/26)
- B28B 7/342: {which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not}
- B29C 33/40: Plastics, e.g. foam or rubber
- B29C 33/52: soluble or fusible {(in particular used in injection moulding B29C45/4457)}
- B29C 33/76: Cores (B29C33/02 - B29C33/70, {B29C41/40, B29C53/74, B29C53/82} take precedence)
- Y10S 249/02: Paper core
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS

## Abstract

A casting is produced using a non-sand plastic core. The plastic core is made of a thermoplastic resin and set in a casting mold so as to form a cavity in the casting mold. A molten metal such as aluminum is poured under pressure into the cavity to form the casting (product). The plastic core maintains its initial shape during casting. The remaining heat of the casting or the solidifying metal causes the plastic core to melt after the casting so that the molten plastic core is easily removed.

## Claims

### Claim 1

A core assembly in a fabrication mold for fabrication of an article from a flowable material which is flowable at a high temperature, the article having at least one of a hollow section and an undercut section, said core assembly comprising a core formed of a non-sand material and configured to define at least part of the at least one of the hollow section and the undercut section of the article, means defining a fluid flow passage formed in said core, and a continuously flowing fluid contained in said fluid flow passage for cooling said core during fabrication of the article, wherein said non-sand material is fibrous material and said fibrous material is selected from the group consisting of paper, synthetic paper, non-woven fabric, and fibers.

### Claim 2

A core assembly in a fabrication mold for fabrication of an article from a flowable material which is flowable at a high temperature, the article having at least one of a hollow section and an undercut section, said core assembly comprising a core formed of a non-sand material and configurated to define at least part of the at least one of the hollow section and the undercut section of the article, means defining a fluid flow passage formed in said core, and a continuously flowing fluid contained in said fluid flow passage for cooling said core during fabrication of the article, wherein said non-sand material is low melting point metal, and said low melting point metal is one selected from the group consisting of tin, lead and antimony.

### Claim 3

A core assembly in a fabrication mold for fabrication of an article from a flowable material which is flowable at a high temperature, the article having at least one of a hollow section and an undercut section, said core assembly comprising a core formed of a non-sand material and configurated to define at least part of the at least one of the hollow section and the undercut section of the article, means defining a fluid flow passage formed in said core, and a continuously flowing fluid contained in said fluid flow passage for cooling said core during fabrication of the article, wherein said non-sand material is composite material, and said composite material is one selected from the group consisting of a fiber reinforced rubber, a fiber reinforced plastic, a carbon fiber reinforced plastic, and a glass fiber reinforced plastic.