# US 9,038,706 B2 · Casting of internal features within a product > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,038,706 B2 - Document ID: US9038706B2 - Status: Granted - Kind: B2 - Application number: 12/953,963 - Filed: 2010-11-24 - Published: 2011-06-16 - Granted: 2015-05-26 - Earliest claimed: 2009-12-15 - Assignees: ROLLS-ROYCE plc - Applicants: Steven M. Hillier - Inventors: Steven M. Hillier - Web page: https://patentgrep.com/patent/US9038706B2 ## CPC - B22C 9/103: {Multipart cores} - Y10T 428/24331: including nonapertured component - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of forming a cast product (30) by providing a core (52) having a plurality of sections (54) and one or more gaps (55) there-between. The core further includes an insert member (60) spanning the gap (55) between adjacent sections (54). The core (52) is located within a mold (68) and a liquid phase material is introduced into gap (55) between the core sections. The liquid phase material is solidified in the gap so as to form a cast feature of a resulting solid product and the core sections (54) are removed from the solid product (30) such that the insert member (60) remains securely held within the feature (74). ## Claims ### Claim 1 A method of forming a cast product comprising: providing a core having a plurality of sections and one or more gaps there-between, the core including a first insert member spanning the gap between adjacent sections of the core, both ends of the first insert member extending partially into adjacent sections of the core, and the first insert member being directly connected between the adjacent sections of the core so as to hold the adjacent sections in a fixed relative position, the plurality of sections being formed of a ceramic material; locating the core within a mould; introducing a liquid phase metal material into the gap between the core sections; solidifying the liquid phase metal material in the gap so as to form a cast feature of a resulting solid product; and removing the core sections from the solid product to form cavities therein such that the first insert member remains securely held within the feature located between said cavities. ### Claim 2 (depends on 1) The method according to claim 1, wherein the first insert member is formed substantially of a first material and the core sections are formed substantially of a second material, wherein the first and second materials are different. ### Claim 3 (depends on 1) The method according to claim 1, wherein the first insert member is formed of a metal. ### Claim 4 (depends on 1) The method according to claim 1, wherein the cast feature is an internal wall within the resulting product. ### Claim 5 (depends on 1) The method according to claim 1, wherein the core sections define opposing internal cavities within the resulting product such that the cast feature is formed between the opposing internal cavities. ### Claim 6 (depends on 1) The method according to claim 1, wherein the plurality of sections comprise a plurality of first sections and the core comprises a plurality of further sections depending from said first sections. ### Claim 7 (depends on 1) The method according to claim 1, wherein the core defines a network of internal cooling cavities in the resulting product. ### Claim 8 (depends on 1) The method according to claim 1, wherein the first insert member comprises opposing retaining features, shaped to retain the first insert member in the feature of the solid product once cast. ### Claim 9 (depends on 8) The method according to claim 8, wherein the first insert member comprises outwardly dual tapered portions on either side of a neck portion. ### Claim 10 (depends on 1) The method according to claim 1, wherein the core comprises one or more arm members depending outwardly therefrom and the arm members are received within corresponding locating formations in the mould. ### Claim 11 (depends on 1) The method according to claim 1, wherein the resulting product is a gas turbine engine component. ### Claim 12 (depends on 1) The method according to claim 1, wherein in the solid product, the first insert member extends into but not fully across adjacent cavities. ### Claim 13 (depends on 1) The method according to claim 1, wherein the first insert member includes tapered portions on either side of a neck portion that form a polygonal hourglass shape. ### Claim 14 (depends on 1) The method according to claim 1, wherein the core includes additional insert members. ### Claim 15 (depends on 1) The method according to claim 1, wherein the first insert member is formed of a first ceramic material and the plurality of sections are formed of a second ceramic material, the first ceramic material being different from the second ceramic material. ### Claim 16 A method of forming a cast product comprising: providing a core having a plurality of sections and one or more gaps there-between, the core including a first insert member spanning the gap between adjacent sections of the core and directly connected between the adjacent sections of the core so as to hold the adjacent sections in a fixed relative position, the plurality of sections being formed of a ceramic material; locating the core within a mould; introducing a liquid phase metal material into the gap between the core sections; solidifying the liquid phase metal material in the gap so as to form a cast feature of a resulting solid product; and removing the core sections from the solid product to form cavities therein such that the first insert member remains securely held within the feature located between said cavities, wherein the first insert member includes outwardly dual tapered portions on either side of a neck portion. ### Claim 17 (depends on 16) The method according to claim 16, wherein the tapered portions on either side of the neck portion form a polygonal hourglass shape. ### Claim 18 (depends on 16) The method according to claim 16, wherein in the solid product, the first insert member extends into but not fully across adjacent cavities. ### Claim 19 (depends on 16) The method according to claim 16, wherein both ends of the first insert member extend partially into adjacent sections of the core. ### Claim 20 (depends on 16) The method according to claim 16, wherein the core includes additional insert members. ### Claim 21 (depends on 16) The method according to claim 16, wherein the first insert member is formed of a first ceramic material and the plurality of sections are formed of a second ceramic material, the first ceramic material being different from the second ceramic material.