Patent ID: 8517083
Filing Date: 2013-08-27
Classification: B22D,Y10T

Abstract:
1. A method of manufacturing metal ingots comprising: a) providing a mold comprising a main body having a floor and sidewalk that form a cavity; b) providing a plurality of sideboards comprising a first layer of a rigid refractory material and a second layer of a flexible refractory material, the first layer and the second layer integrally formed as a monolithic structure from, the same refractory material via a casting process, the first layer having a density that is greater than the second layer, wherein the rigid refractory material is a fiber ceramic board and the flexible refractory material is a fiber ceramic blanket; c) securing the sideboards to the sidewalk so as to form a perimeter about the cavity in a spaced relation from the floor, the sideboards secured to the sidewalls so that the second layer is compressed between the first layer and the sidewall; d) pouring molten metal into the cavity until a surface level of the molten metal is above a bottom edge of the sideboards and below a top edge of the sideboard; e) covering the surface level of the molten metal with an insulating powder; and f) allowing the molten metal to cool.