US1744974A - Metal pattern and method of making same - Google Patents

Description

2 Sheets-Sheet 1 gwuemtop jr/ Uri ima e A. K. LAUKEL Fild Dec. 13, 1926 iii A METAL PATTERN AND METHOD OF MAKING SAME Jan. 28, 1930.

Jan. 28, 1930. A. K. LAUKEL mam. PATTERN AND mswuov OF rumme sms Filed Dec. 13. 1926- 2 Sheets-Sheet 2 Patented Jan. 28, 1930 I UNITED STATES OFFICE a ARTHUR KL LAUREL, OFDETROIT, MICHIGAN V i i METAL IPATTE-Rhl AND METHOD OF MIAKING "SAME application filed December 13, 1926. SeriaI'No'. 154,530

fillet to become loose or separate from its support.

V This invention relates to the manufacture of mounted metal patterns :such as cope and drag plates, wherein such patterns are utilized for providing the required impressions in the cope and drag of a mold, castings made in a parted mold in this manner being usually characterized by the fact that they show the parting and it is often required that the mark ol the part be removed from the casting and that this be done in a neat, accurate manner without cutting into the body of the casting itself. In order tolacilitate the grinding or machining of the parting impression from the casting, it is 'c'ommonipr-actice to accentuate the parting by providing'fillets on the pattern which Will cause a decided ridge of metal to 'be formed on the casting at the parting of the mold, which ridge is afterwards removed a suit-able manner as is well known in this art, and does not require further description hereinafter. I

The'use of such fillets is however attended with certain disadvantages because ordinarily the pattern is not integral withthe plate on which it is mounted, mainly due to the fact that it must necessarily be separate from the plate during machining and finishing to give it the proper surface and contour and the plate ifintegral therewith would-interfere aowith such operations and rendert-hem very expensive it they were to be conducted by hand or by such processes as the limiting effect-of the attached plate would necessitate.

Therefore, it h'as been common practice to first completely machine or finish the pattern and then secureit to the cope'or drag plate "as the case may loe, alter which a filletsuch' usually necessary to giveitithe proper con tour and bind the edges of it smoothly into the surface of t-heipattern and the plate, and

also is often difficult to secure a proper adhesion of the solder throughout the length of the fillet to both the pattern and the plate 56 th emst mes ther sisat n sney a t By my present invention I propose toovercome all these disadvantages and provide a pattern plate and fillet of an integral nature and secure this structure by electr'o deposition' in a cheap, simple and highly elleetive manner. I

I have described a somewhat'similar process to that disclosed herein, in my co-pen'din we application, Serial No.- 101,069, filed Apri 10, 1 926,wherein the making of core boxes is described, the dilierence in this case being found in the provision of a filleted split pattern especially devised to overcome the par '5 ticular disadvantages attending the ordinary methods hitherto employed 'inthe making of filleted sp-l-it patterns.

In carrying my invention into efiect I may adopt novel methods hereinafter described and "ascertained hereinafter by way of example, havingreterence to the accompanying drawings, 'wherei n I Figure 1 is a plan of a mold adapted to the making of a filleted split pattern by electrodeposition in accordance with this invention;

Figure 2 is a section of the same on thelin'e Q -Q Figure 1; I

Figure 3 is a similar view to Figure 1, illustrating metal inserts applied to the mold 9 for giving strength and rigidity to the plate 7 of the pattern to be formed;

Figure 4 is a sectional view taken'on the line P- l", Figure 3; I

Figure 5 is'xa' similar viewto Figure 3,=il "s5 lustra ting the appearance of the mold after metal has been electrolytically deposited therein; I

Figure =6 is :a section-on the line 6 Fi-gure5; I WQYO Figure .7 is a broken perspective view of :a working master pattern used making the mold, Figure 1; Q; F gure "-7 is a similarview of :a completed electr0=deposited isplit pattern removed from '95 the mold;-and I r 1 Figure 8 is a perspective view of a 'casting made by means of the pattern illustrated in Figure 7. o 7 Similar, charactersxof reference indicate similar parts in the several figures of the drawings.

The mold for making the electro-deposited pattern may be of any suitable material which will lend itself to the carrying out of the operations herein described, and I have used in a quite satisfactory manner for this purpose, plaster of Paris, suitably treated as with wax to render it acid resistant to an extent enabling it to withstand the action of acid in the electrolyte in which the electro-deposition of the pattern is effected.

In Figure 7 is shown a master pattern which may be of wood, metal or other material having a plate 1 upon which is mounted the pattern body 2, these parts usually being separately made for convenience in machining and finishing and afterwards secured together, after which a fillet 3 is provided about the edges of the pattern to eliminate the sharp angles or corners which would otherwise exist at such points, and which are to he usually avoided for reasons well known in the metal molding art. Some of these reasons have already been referred to, and still further, it might be mentioned that the existence of sharp edges in a mold at the parting is also objectionable as tending to offer an obstruction to the flow of metal over such edges, this sometimes resulting in the breaking down of the said edges and consequent formation of the undesirable deformities in the casting.

The fillets 3 of the master pattern in the case of a wood pattern may be of wax or leather, and in the case of a metal pattern, of solder or any other suitable material, and are in many cases diflicult to provide in a neat and efiicient form or to insure their remaining in place and intact throughout long use.

In making my improved pattern by the improved method, I take a master pattern such as that referred to and make a plastic cast about such pattern so that the plastic cast will have formed therein the impression of both the plate and the pattern proper as well as the fillet, Figure 1 illustrating such a plastic cast 4, wherein 5 is the impression of the plate 1, 6 the impression of the pattern body 2, and 7 the impression of the fillet. Of course, the master pattern used for the making of the plastic cast may be simply a pattern which has already been constructed by the processes described herein and may be of an electrodeposited nature with the plate, fillet and pattern proper in one piece, and are not necessarily always made from a specially constructed master pattern as will be readily understood. In other words, a pattern having been made by the herein described process, it may be reproduced in any number without having recourse to the original master pattern.

The mold of plastic composition, Figure 1, having been made, the surface of the mold on which the plating is to be deposited, that is,

the surface of the cavities 6 and surrounding parts of the mold upon which metal is to be electrolytically deposited, is suitably coated or provided with a film or surface of conducting material, such for example as silver sulphide which is indicated in Figure 2 by the heavy line 8. The margins of such coating are indicated by the lines 8 in Figure 1, although such coating may extend throughout the entire surface of the plate impression 5 if so desired, but in the present case that is not necessary due to the fact that brass or similar inserts 9 are indicated, see Figures 3 and 4, as being utilized in connection with the formation of the plate of the pattern to be produced. These inserts are not absolutely essential, and are simply used for the purposes of reducing the area to be plates, of giving rigidity to the plate of the pattern to be formed which, would not be secured to an equal extent were the entire plate of electrolytically deposited metal, and to provide substantial anchoring means whereby the plate may be secured to any suitable support or backing.

Where the pattern is to be utilized in a jolt molding machine, and subjected to the vibration and strains occurring in connection with such machine molding, strength in the plate of the pattern, is more particularly desirable, and it is for that reason that the use of such inserts of strong metal such as brass is suggested.

These inserts 9 terminate at some little distance from the margins of the mold cavities 6, and the edges of the inserts presented towards the mold cavities are preferably beveled as at 10 so that a substantially obtuse angle is formed between the surface of the plastic mold and the margins of the metallic inserts, thus avoiding sharp angles in which it is diflicult to secure adequate metal deposit.

The metallic inserts overlap the margins 8 of the conductive surface of the plastic mold, and they may be secured in position by screws 11. The mold is then plated in a suitable plating bath such as a copper sulphate electrolyte, cathode connection being made to the conducting surface of the mold as through the medium of one of the screws 11, and the method employed in effecting the plating may be similar to that described in my co-pending application, Serial No. 101,070, filed April 10, 1926, and does not call for detailed explanation herein, except to say that the deposition is effected over the surface of the cavities and of the plate impression of the mold to the inserts, where such are provided, so that the said inserts become an integral part of the deposited pattern and more particularly a 1 5 part of the plate of the pattern. Paper or other insulation 9 may be applied over the inserts 9 to prevent unnecessary deposition of metal on the faces thereof.

Figures 5 and 6 clearly indicate the result inserts left vacant by the removal of screws 11 being suitably filled with metal if so desired, the said metallic device then having the appearance shown in Figure 7 a of the drawing, in which 12 is the pattern body, and 13 the plate of the pattern integral therewith and with the fillet 14 which forms an integral merging of the said pattern body into the plate of the pattern, as will be readily understood.

In making castings by means of the pattern shown in Figure 7 the pattern body is impressed in both the cope and drag portions of themold in a manner well known in the art, the mold being suitably cored and the resulting casting has the appearance shown in Figure 8, wherein the parting line is characterized by a ridge 16 resulting from the presence of the fillet 14 of the pattern, this ridge being so accentuated that it may be easily removed without the danger of mutilating the body of the casting which is present when provision for such ridges in the casting is not properly made.

It will be understood that the cope and drag patterns are not always similar as in the illustrated case and the margins of the cope and drag cavities are therefore not always coincident. Sometimes for instance the cope or drag portion of the pattern is plain without any impression, and in this case the fillet of the pattern serves to provide a rib or flange about the margins of the casting which may be easily removed and overcomes the tendency of molten metal to avoid completely fi ling the corner or. angle between the margins of the moldcavity and the opposed surface of the other half of the mold, or to shrink away from such corners or angles.

'The'pattern, Figure 7 in actual use is similar to that shown in Figure 7, but its capacity to withstandihard usage, its simplicity of manufacture "and reproduction, and

its unbroken contourbetween plate and pattern body present advantages "over a builtup pattern; as in Figure 7, provided with applied fillets, which, advantages have not hithertobeen available in the mounted patterns made according to prior art methods and overcome the ditficulties set forth in the. general statement of the nature of the in vention. I v

This invention may be developed within the scope of the following claims without departing from the essential features of the said invention, and it is desired that the specification and drawing be read as merely pattern body on a plate, applying a fillet to said pattern, formlng in a mold the impression of the plate, pattern body and fillet, and effecting the electro-deposition of metal on the surface of said impression to provide an electro-deposited reproduction of the plate, pattern body and fillet as an integral body.

2. The methodof making mounted metal patterns which comprises mounting a split. pattern body on a plate, applying a fillet to said pattern, forming in a mold the impression of the plate, pattern body and fillet, effecting the electro-deposition of metal on the surface of said impression to provide an electro-deposited reproduction of the plate, pattern body and fillet as an integral body, and subsequently backing said reproduction with a suitable material to give strength thereto.

3. As a new article of manufacture, a

mounted metal pattern comprising a face plate and an electrolytically deposited pattern integral with said face plate, the junction of the margins of said pattern with said face plate being in the form of an electrolytically deposited integral fillet.

4. A method of making mounted metal patterns which consists in forming the impression of the plate, pattern body and fillets of a mounted pattern in a mold, laying metallic plate material in the plate impression and at a distance outwardly from the pattern body and fillet impressions, and effect. ing the electro deposition of metal on said latter impressions, whereby said deposited metal adheres to said plate material.

In testimony whereof I aflix my signature.

ARTHUR K. LAUKEL.

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