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1. 发明申请

US20110132562A1 WAXLESS PRECISION CASTING PROCESS 审中-公开
标题翻译：无水精密铸造工艺
公开(公告)号：US20110132562A1
公开(公告)日：2011-06-09
申请号：US12961621
申请日：2010-12-07
申请人： Gary B. Merrill , Michael P. Appleby , Iain A. Fraser , Jill Klinger , John R. Paulus
发明人： Gary B. Merrill , Michael P. Appleby , Iain A. Fraser , Jill Klinger , John R. Paulus
IPC分类号： B22C9/12 , B22D19/00 , B22C9/10
摘要： Alloy products are produced with a waxless casting process. A model of a ceramic casting vessel (34) defining a desired product shape is digitally divided into sections (10, 40, 42). Each section is translated into a soft alloy mater tool (14) including precision inserts (20) where needed for fine detail. A flexible mold (24) is cast from each master tool, and a section of the ceramic casting vessel is cast from the respective flexible mold. The vessel sections are assembled by aligning cooperating precision features (58, 60) cast directly into each section and the alloy part is cast therein. No wax or wax pattern tooling is needed to produce the cast alloy product. Engineered surface features (54) may be included on both the interior and exterior surfaces of the shell sections.
摘要翻译：合金产品采用无蜡铸造工艺生产。限定期望产品形状的陶瓷铸造容器（34）的模型被数字地分成部分（10,40,42）。每个部分被翻译成软合金工具（14），其包括精确插入件（20），其中需要精细的细节。从每个主工具铸造柔性模具（24），并且从相应的柔性模具铸造一部分陶瓷铸造容器。通过对准协调的精确特征（58,60）直接铸造到每个部分中并且合金部件被浇铸在其中来组装容器部分。不需要蜡或蜡图案模具来生产铸造合金产品。工程表面特征（54）可以包括在壳部分的内表面和外表面上。

2. 发明授权

US09272324B2 Investment casting process for hollow components 有权
标题翻译：中空部件投资铸造工艺
公开(公告)号：US09272324B2
公开(公告)日：2016-03-01
申请号：US12961720
申请日：2010-12-07
申请人： Gary B. Merrill , Andrew J. Burns , Michael P. Appleby , Iain A. Fraser , John R. Paulus
发明人： Gary B. Merrill , Andrew J. Burns , Michael P. Appleby , Iain A. Fraser , John R. Paulus
IPC分类号： B22C9/10 , B22C7/06 , B22C7/02 , B22C9/04 , B22C9/24
CPC分类号： B22C9/101 , B22C7/02 , B22C7/06 , B22C9/04 , B22C9/10 , B22C9/103 , B22C9/24
摘要： An investment casting process for a hollow component such as a gas turbine blade utilizing a ceramic core (10) that is cast in a flexible mold (24) using a low pressure, vibration assisted casting process. The flexible mold is cast from a master tool (14) machined from soft metal using a relatively low precision machining process, with relatively higher precision surfaces being defined by a precision formed insert (22) incorporated into the master tool. A plurality of identical flexible molds may be formed from a single master tool in order to permit the production of ceramic cores at a desired rate with a desired degree of part-to-part precision.
摘要翻译：一种用于中空部件的熔模铸造方法，所述中空部件例如是使用利用低压振动辅助铸造工艺铸造在柔性模具（24）中的陶瓷芯（10）的燃气轮机叶片。柔性模具使用相对低精度的加工工艺从由软金属机加工的主工具（14）铸造，相对较高精度的表面由结合到主工具中的精密成型刀片（22）限定。可以由单个主工具形成多个相同的柔性模具，以便允许以期望的速率以期望的部件到部件的精度制造陶瓷芯。

3. 发明申请

US20110132563A1 INVESTMENT CASTING PROCESS FOR HOLLOW COMPONENTS 有权
标题翻译：投资铸造工艺为中空部件
公开(公告)号：US20110132563A1
公开(公告)日：2011-06-09
申请号：US12961720
申请日：2010-12-07
申请人： Gary B. Merrill , Andrew J. Burns , Michael P. Appleby , Iain A. Fraser , John R. Paulus
发明人： Gary B. Merrill , Andrew J. Burns , Michael P. Appleby , Iain A. Fraser , John R. Paulus
IPC分类号： B22C9/00
CPC分类号： B22C9/101 , B22C7/02 , B22C7/06 , B22C9/04 , B22C9/10 , B22C9/103 , B22C9/24
摘要： An investment casting process for a hollow component such as a gas turbine blade utilizing a ceramic core (10) that is cast in a flexible mold (24) using a low pressure, vibration assisted casting process. The flexible mold is cast from a master tool (14) machined from soft metal using a relatively low precision machining process, with relatively higher precision surfaces being defined by a precision formed insert (22) incorporated into the master tool. A plurality of identical flexible molds may be formed from a single master tool in order to permit the production of ceramic cores at a desired rate with a desired degree of part-to-part precision.
摘要翻译：一种用于中空部件的熔模铸造方法，所述中空部件例如是使用利用低压振动辅助铸造工艺铸造在柔性模具（24）中的陶瓷芯（10）的燃气轮机叶片。柔性模具使用相对低精度的加工工艺从由软金属机加工的主工具（14）铸造，相对较高精度的表面由结合到主工具中的精密成型刀片（22）限定。可以由单个主工具形成多个相同的柔性模具，以便允许以期望的速率以期望的部件到部件的精度制造陶瓷芯。

4. 发明申请

US20110204205A1 CASTING CORE FOR TURBINE ENGINE COMPONENTS AND METHOD OF MAKING THE SAME 审中-公开
标题翻译：涡轮发动机组件的铸造芯及其制造方法
公开(公告)号：US20110204205A1
公开(公告)日：2011-08-25
申请号：US12712632
申请日：2010-02-25
申请人： Ahmed Kamel , Dhafer Jouini , Gary B. Merrill , John R. Paulus , Michael P. Appleby , Iain Alasdair Fraser , Jill Klinger , Gabriel Victor Orsinger , Daniel Ellgass
发明人： Ahmed Kamel , Dhafer Jouini , Gary B. Merrill , John R. Paulus , Michael P. Appleby , Iain Alasdair Fraser , Jill Klinger , Gabriel Victor Orsinger , Daniel Ellgass
IPC分类号： B22C9/10
CPC分类号： B22C9/103
摘要： A turbine engine component, such as a turbine blade or vane, with complex internal features can be cast using a core having a first region with normal resolution features and a second region with high resolution features. The core can be formed from a single structure. Alternatively, the first region can be defined by a first ceramic core piece, which can be formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomo lithographic molding. The first core piece and the second core piece can be joined by interlocking engagement, such as by male and female dovetails. The high resolution features can be effective to produce high efficiency internal cooling features in the cast component.
摘要翻译：可以使用具有具有正常分辨率特征的第一区域的芯体和具有高分辨率特征的第二区域来铸造具有复杂内部特征的涡轮发动机部件，例如涡轮叶片或叶片。芯可以由单一结构形成。或者，第一区域可以由可以通过任何常规工艺形成的第一陶瓷芯片来定义，例如通过注塑或传递模塑。第二区域可以由通过有效产生高分辨率特征的方法分开形成的第二陶瓷芯片来定义，例如层压平版印刷。第一芯片和第二芯片可以通过互锁接合来连接，例如由公母头和雌尾燕尾。高分辨率功能可以有效地在铸件中产生高效率的内部冷却功能。

5. 发明授权

US08678771B2 Process for manufacturing a component 有权
标题翻译：制造零件的工艺
公开(公告)号：US08678771B2
公开(公告)日：2014-03-25
申请号：US12637030
申请日：2009-12-14
申请人： Gary B. Merrill , Andrew J. Burns , Michael P. Appleby , Iain Alasdair Fraser , John R. Paulus
发明人： Gary B. Merrill , Andrew J. Burns , Michael P. Appleby , Iain Alasdair Fraser , John R. Paulus
IPC分类号： F01D5/14 , G06F19/26
CPC分类号： B23K20/021 , B23P15/04 , B23P15/246 , B23P2700/12 , B33Y80/00 , F01D5/147 , F05D2230/30 , Y10T156/10 , Y10T156/1052 , Y10T428/1241 , Y10T428/12493
摘要： A method of manufacturing a component, including providing a three-dimensional computer model of the component to be produced; deconstructing the three-dimensional computer model by defining a plurality of model slices; forming a plurality of metallic foils, where each foil corresponds to a specific model slice; assembling the plurality of formed foils in a tool to form a three-dimensional component stack; and bonding the three-dimensional component stack to form the component. Characteristics of the foils may differ in various portions of the stack, such as being a different material, having a different thickness, or having a different grain orientation. The control of dimensional tolerances of internal structures, such as cooling passages, in three dimensions is devolved into two separate steps of 1) selecting a thickness of each slice/foil, and 2) controlling in two dimensions a material removal process applied to the respective foil.
摘要翻译：一种制造部件的方法，包括提供要生产的部件的三维计算机模型; 通过定义多个模型切片来解构三维计算机模型; 形成多个金属箔，其中每个箔对应于特定的模型切片; 将多个形成的箔组装在工具中以形成三维组件堆叠; 并结合三维组件堆叠以形成组件。箔的特征可能在堆叠的各个部分不同，例如具有不同厚度的不同材料，或具有不同的晶粒取向。三维内部结构（如冷却通道）的尺寸公差的控制被分解为两个单独的步骤：1）选择每个切片/箔的厚度，以及2）在二维中控制施加到相应的材料的材料去除过程挫败。

6. 发明授权

US08196640B1 Self supporting core-in-a-core for casting 失效
标题翻译：自支撑核心铸造
公开(公告)号：US08196640B1
公开(公告)日：2012-06-12
申请号：US13382325
申请日：2011-07-01
申请人： John R. Paulus , Michael P. Appleby
发明人： John R. Paulus , Michael P. Appleby
IPC分类号： B22C9/04 , B22C9/10
CPC分类号： B22C9/10
摘要： A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).
摘要翻译：一种核心铸造方法和用于该方法的混合型芯（40）。由设置在粘合剂材料中的由过程惰性颗粒形成的内芯（42）用作铸造由在随后的烧制步骤期间将烧结的颗粒形成的外芯（（44））的模具，内芯为所述内核在所述烧制步骤期间，并且其中所述内芯下降到压实但未结合的颗粒中，其可以在所述烧制步骤之后方便地从所述外芯移除以暴露所述被烧制的中空外芯（44）。

7. 发明申请

US20120138252A1 Self Supporting Core-In-A-Core for Casting 失效
标题翻译：自主支持核心的铸造
公开(公告)号：US20120138252A1
公开(公告)日：2012-06-07
申请号：US13382325
申请日：2011-07-01
申请人： John R. Paulus , Michael P. Appleby
发明人： John R. Paulus , Michael P. Appleby
IPC分类号： B22C9/10
CPC分类号： B22C9/10
摘要： A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).
摘要翻译：一种核心铸造方法和用于该方法的混合型芯（40）。由设置在粘合剂材料中的由过程惰性颗粒形成的内芯（42）用作铸造由在随后的烧制步骤期间将烧结的颗粒形成的外芯（（44））的模具，内芯为所述内核在所述烧制步骤期间，并且其中所述内芯下降到压实但未结合的颗粒中，其可以在所述烧制步骤之后方便地从所述外芯移除以暴露所述被烧制的中空外芯（44）。

8. 发明授权

US09208916B2 Methods for manufacturing three-dimensional devices and devices created thereby 有权
公开(公告)号：US09208916B2
公开(公告)日：2015-12-08
申请号：US12141455
申请日：2008-06-18
申请人： Michael P. Appleby , Iain Fraser , James E. Atkinson
发明人： Michael P. Appleby , Iain Fraser , James E. Atkinson
IPC分类号： B29C33/44 , G21K1/02 , B29C33/00 , B23P15/24 , B29C33/30 , B29C33/38 , B29C39/02 , B29C39/34 , B29C69/00 , G03F7/00 , A61B6/00 , G01T7/00 , B29C33/42 , B29C47/00 , B29C67/00 , B29K83/00 , B29L31/00
CPC分类号： B29C33/44 , A61B6/4258 , A61B6/502 , B22D19/00 , B22D29/00 , B23P15/246 , B28B7/20 , B28B7/24 , B29C33/0088 , B29C33/12 , B29C33/302 , B29C33/3842 , B29C33/42 , B29C33/424 , B29C39/021 , B29C39/34 , B29C39/36 , B29C47/003 , B29C64/00 , B29C69/001 , B29K2083/00 , B29L2031/756 , G01T1/20 , G01T7/00 , G03F7/0017 , G21K1/02 , Y10T428/31
摘要： In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.

9. 发明授权

US07893413B1 Systems, devices, and methods for large area micro mechanical systems 有权
公开(公告)号：US07893413B1
公开(公告)日：2011-02-22
申请号：US12541610
申请日：2009-08-14
申请人： Michael P. Appleby , Iain Fraser , James E. Atkinson
发明人： Michael P. Appleby , Iain Fraser , James E. Atkinson
IPC分类号： G21K1/02 , B29C33/40
CPC分类号： B29C33/302 , B29C33/3842 , B29C33/42 , B29C39/34 , B29K2083/00 , G21K1/02 , G21K1/025
摘要： Certain exemplary embodiments can provide a first isogrid defining a first plurality of zones, each zone from said first plurality of zones comprising a plurality of ligaments, each zone from said first plurality of zones defining a plurality of spaces, each space bounded by a first sub-plurality of ligaments from said plurality of ligaments, each of said ligaments comprising a plurality of ligament surfaces.

10. 发明授权

US06185278B2 Focused radiation collimator 有权
标题翻译：聚焦辐射准直仪
公开(公告)号：US06185278B2
公开(公告)日：2001-02-06
申请号：US09339365
申请日：1999-06-24
申请人： Michael P. Appleby , Joseph A. Buturlia , Iain Fraser , Robert F. Lynch
发明人： Michael P. Appleby , Joseph A. Buturlia , Iain Fraser , Robert F. Lynch
IPC分类号： G21K104
CPC分类号： G21K1/025
摘要： A focused radiation collimator for collimating radiation emitted from a radiation point source located at a substantially known focal distance from the collimator is disclosed. In one embodiment of the disclosed collimator, the collimator is formed by at least two collimator layer groups, aligned, stacked and bonded together immediately adjacent to one another. Each of the collimator layer groups have a plurality of layer group passages arranged there through in a predetermined pattern which is unique to the layer group but which, with the passages of the other collimator layer group in the aligned stack, additively form a plurality of collimator through channels which are substantially aimed at the radiation point source. Each collimating layer group is formed by at least two substantially identical radiation absorbing layers, aligned, stacked and bonded together immediately adjacent to one another. Each of the substantially identical radiation absorbing layers have a plurality of openings arranged there through in substantially the same predetermined pattern which, with the plurality of openings of the other radiation absorbing layer in the aligned stack, additively form the layer group passages. High aspect ratio collimators having very small diameter through channels can be efficiently made in accordance with the teachings of the disclosure.
摘要翻译：公开了一种用于准直来自位于与准直器基本上已知的焦距的辐射点源发射的辐射的聚焦辐射准直器。在所公开的准直仪的一个实施例中，准直器由至少两个准直器层组形成，它们彼此对准，堆叠并结合在一起。每个准直器层组具有多个层组通道，其中以预定图案布置在层上，该预定图案对于层组是唯一的，但是在对准的叠层中的另一个准直器层组的通道相加地形成多个准直器通过基本上瞄准辐射点源的通道。每个准直层组由至少两个基本上相同的辐射吸收层形成，其彼此对齐，堆叠并结合在一起。基本上相同的辐射吸收层中的每一个具有多个通过基本上相同的预定图案布置在其上的开口，其中对准的叠层中的另一个辐射吸收层的多个开口相加地形成层组通道。根据本公开的教导，可以有效地制造具有通过通道的非常小直径的高纵横比准直器。

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