Patent ID: 8591787
Filing Date: 2013-11-26
Classification: B22C,B29C,B33Y

Abstract:
1. A method of creating a fugitive foam pattern used to make a shell mold for an investment casting operation, the method comprising: mixing a polyol component and an isocyanate component to form a liquid mixture; adding at least one additive to the mixture of the polyol component and the isocyanate component; placing a temporary core having a shape corresponding to a desired feature of a resulting foam pattern in a cavity of a mold; inserting the mixture into the cavity of the mold such that the mixture flows into the cavity and surrounds a portion of the temporary core; waiting for a predetermined time sufficient for a reaction from the mixture to form a thermoset rigid foam pattern structure within the mold corresponding to the shape of the cavity, wherein the foam pattern structure encloses around a portion of the temporary core-such that: removing the foam pattern structure from the mold; and removing the temporary core from the foam pattern structure independent of chemical leaching such that the resulting foam pattern structure has the desired feature.