Abstract:
An ingot mold top comprising a base having a pair of side walls, each side wall having a first end and a second end, each of the first ends terminating in an angled portion and the second ends connected by a first end wall, a wedge having an end wall and a pair of side walls, the pair of side walls extending generally perpendicularly away from the end wall, and wherein the wedge pair of side walls each terminate in an angled portion and the base and wedge completely encompass an interior periphery of a mold.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Technical Field 
         [0002]    The invention relates generally to mold top insulating assemblies and exothermic assemblies. More particularly, the invention relates to a safer and easily installed mold top. Specifically, the invention relates to a multiple piece mold top assembly which can be safely installed with an alignment device and provide an increased usable ingot yield. 
         [0003]    2. Background Information 
         [0004]    The use of a mold top in casting metal has been common place for numerous years. Traditionally, a mold top is used to insulate the molten metal and maintain a more constant temperature during the solidification process. The constant temperature provides a more consistent material with fewer contaminants. 
         [0005]    Mold tops, or “hot tops”, have varying heights and dimensions. Initially, the mold top is sized and shaped to fit the mold and extends from the top of the mold only the distance necessary to provide consistent cooling for the molten metal. Originally, mold tops were a two-piece assembly with the base installed first and the top located on the base after the molten was poured. 
         [0006]      FIGS. 1 and 2  illustrate a pair of three and four piece, respectively, mold tops with wedging side walls. The prior art mold top in  FIG. 1  uses a pair of angled side walls to ensure that the mold top base is securely held in place and located at the extreme interior periphery of the mold. The  FIG. 1  mold top suffers from numerous shortcomings, including the fact that two side walls must be installed. Since the two side walls will each move the mold top in opposing directions, the side walls must be installed simultaneously, requiring two people working together, or the installer must fight to install the second side wall as the first attempts to move out of place. Yet another shortcoming of the  FIG. 1  mold top is that it requires the operator to stand over the mold in order to install both side walls. Although one side wall may be located close to the working edge of the ledge, the second end will be on the opposite side. Thus, the installer is required to stand over the mold which is very dangerous and not practical. 
         [0007]    The mold top of  FIG. 2  is used for installation of round molds. Although the round mold has advantages over the two-piece base of  FIG. 1 , the round mold top still suffers from shortcomings. In particular, the round mold top is difficult to place perfectly centered along the extreme interior periphery. While having only one angled side wall prevents the installer from having to step over the mold, it is much more difficult for the installer to provide a force tangential to the mold top so that the side wall opposite the angled side wall is located proximate the interior periphery. 
         [0008]    Thus there is a long-felt need in the art for a mold top which can easily and safely be installed in a mold by a single installer and provides a higher usable yield of material. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention broadly comprises an ingot mold top comprising a base having a pair of side walls, each side wall having a first end and a second end, each of the first ends terminating in an angled portion and the second ends connected by a first end wall, a wedge having an end wall and a pair of side walls, the pair of side walls extending generally perpendicularly away from the end wall, and wherein the wedge pair of side walls each terminate in an angled portion and the base and wedge completely encompass an interior periphery of a mold. 
         [0010]    The present invention further broadly comprises a method of installing an ingot mold top comprising the steps of inserting a mold top base having a pair of side walls with angled terminating portions within a mold, locating a mold top wedge at least partially between the base and the mold, and forcing the wedge downwards to provide axial movement in a direction along the angled terminating portions. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The preferred embodiment of the invention, illustrative of the best modes in which Applicant has contemplated applying the principles of the invention, are set forth in the following description and are shown in the drawings. 
           [0012]      FIG. 1  is a perspective view of a prior art mold top with two opposing angled side walls; 
           [0013]      FIG. 2  is a perspective view of a prior art mold top for a round mold with a single angled side wall; 
           [0014]      FIG. 3  is a perspective view of three molds and a preferred embodiment mold top; 
           [0015]      FIG. 4  is an exploded perspective view of a preferred embodiment mold top of the present invention; 
           [0016]      FIG. 5  is a top plan view of a preferred embodiment mold top wedge of the present invention; 
           [0017]      FIG. 6  is a top plan view of a preferred embodiment mold top base of the present invention; 
           [0018]      FIG. 7  is a right plan view of a preferred embodiment mold top lid of the present invention; 
           [0019]      FIG. 8  is a right plan view of a preferred embodiment mold top wedge of the present invention; 
           [0020]      FIG. 9  is a right plan view of a preferred embodiment mold top base of the present invention; 
           [0021]      FIG. 10  is a perspective view of a preferred embodiment alignment device of the present invention; 
           [0022]      FIG. 11  is a perspective view of a person installing a preferred embodiment mold top base within the mold; 
           [0023]      FIG. 12  is a perspective view of a preferred embodiment mold top base located within the mold; 
           [0024]      FIG. 13  is a perspective view of a person installing a preferred embodiment mold top wedge; 
           [0025]      FIG. 14  is a cross-sectional view of a preferred embodiment mold top wedge being installed; 
           [0026]      FIG. 15  is a perspective view of a person installing a preferred embodiment mold top wedge with a preferred embodiment alignment device; 
           [0027]      FIG. 16  is a cross-sectional view of a preferred embodiment mold wedge being installed with a preferred embodiment alignment device; 
           [0028]      FIG. 17  is a front plan view of a preferred embodiment mold top wedge being installed with a preferred embodiment alignment device; 
           [0029]      FIG. 18  is a perspective view of a person installing a preferred embodiment mold top wedge with a preferred embodiment alignment device by providing a downward force on the alignment device; 
           [0030]      FIG. 19  is a cross-sectional view of a preferred embodiment mold top installed within the mold; 
           [0031]      FIG. 20  is a perspective view of a person removing a preferred embodiment alignment device after installing a preferred embodiment mold top wedge; 
           [0032]      FIG. 21  is a perspective view of molten metal being poured into a mold with a preferred embodiment mold top installed. 
           [0033]      FIG. 22  is a cross-sectional view of molten metal in a mold with a preferred embodiment mold top installed; 
           [0034]      FIG. 23  is perspective view of a person installing a preferred embodiment mold top lid; 
           [0035]      FIG. 24  is a perspective view of a preferred embodiment mold top lid partially installed; 
           [0036]      FIG. 25  is cross-sectional view of a preferred embodiment mold top lid partially installed; 
           [0037]      FIG. 26  is a perspective view of a person pushing a preferred embodiment mold top lid towards the far end of the mold top; 
           [0038]      FIG. 27  is a perspective view of a preferred embodiment mold top with the lid completely installed; and, 
           [0039]      FIG. 28  is a cross-sectional view of a preferred embodiment mold top with the lid completely installed. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0040]    At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred embodiment, it is to be understood that the invention as claimed is not limited to the disclosed aspects. 
         [0041]    Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described. 
         [0042]    The mold top assembly of the present invention is indicated generally at  30 , as is particularly shown in  FIGS. 1 through 28  sitting on a platform  32 , shown with the components separated. 
         [0043]    As seen in  FIG. 3 , mold top assembly  30  generally includes a base  34 , a wedge  36 , and a lid  38 . Platform  32  is preferably located close to molds  40  so that the operator can easily locate the mold top assembly within the mold. Each mold preferably has a distal end  41  and a proximate end  43 . In particular, mold top assembly  30  is placed on sidewalls  42  and within an opening  44  formed by the sidewalls. Thus, the mold top assembly is shaped complimentary to the opening of the molds, which is generally rectangular in a preferred embodiment. 
         [0044]      FIGS. 4 through 9  illustrate various views of mold top assembly  30 . Base  34  includes a first side wall  46 , a second side wall  48 , and a first end wall  50 . First side wall  46  and second side wall  48  are preferably parallel to each other and spaced apart by first end wall  50 . An end  52  of first side wall  46  opposite first end wall  50  terminates in an angled portion, while an end  54  of second side wall  48  opposite first end wall  50  terminates in an angled portion. The angled portions extend along the end parallel to first end wall  50  and the distance from the first end wall to the ends ( 52  and  54 ) increases from top to bottom, or in other words, the end walls are angled. Although the ends may have any suitable angle, a preferred embodiment angle is in the range of approximately 5 to 45 degrees. 
         [0045]    Base  34  also includes a shoulder  56  attached to the exterior periphery, which may be formed integral to the base in a preferred embodiment. Shoulder  56  forms the top surface of the base, as well as extends outward of the first side wall, the second side wall, and the first end wall. Since the shoulder extends outwards of the remainder of the base, the bottom side of shoulder  56  rests on the top of mold sidewall  42 . 
         [0046]    Further, base  34  includes a ledge  58  attached to the interior periphery, which may be formed integral to the base in a preferred embodiment. Ledge  58  extends outward from the upper portion of the first side wall, the second side wall, and the first end wall. Ledge  58  may be formed by locating shoulder  56  partially outward of the side walls and end wall of base  34 . Advantageously, ledge  58  provides a locating and holding area for lid  38 , as will be described in greater detail below. 
         [0047]    As seen in  FIGS. 4 and 5 , wedge  36  includes an end wall  60 , a first side wall  62 , and a second side wall  64 . First side wall  62  and second side wall  64  are preferably arranged generally parallel to one another and separated by end wall  60 . Further, first side wall  62  terminates in an angled portion  66 , while second side wall  64  terminates in an angled portion  68 . 
         [0048]    In accordance with one of the main features of the present invention, first side wall  62  and second side wall  64  extend away from end wall  60  a sufficient distance to allow an angled portion that is complimentary to ends  52  and  54  respectively. In particular, the angled portions of first side wall  62  and second side wall  64  are preferably in the same range as ends  52  and  54 , namely 5 to 45 degrees. However, it should be immediately apparent to one of ordinary skill in that art that almost any angle would be sufficient. 
         [0049]      FIG. 8  illustrates a side profile view of a preferred embodiment of wedge  36 , while  FIG. 9  illustrates a side profile view of a preferred embodiment of base  34 . As can be seen, wedge  36  is preferably the same height as base  34 . In addition, base ends ( 52  and  54 ) and angled portions ( 66  and  68 ) are complimentary shaped to each other to provide a vertical sliding engagement that yields a horizontal movement in base  34 . 
         [0050]      FIGS. 4 and 7  illustrate lid  38 , which is sized and shaped to fit within the assembled combination of base  34  and wedge  36 . Specifically, lid  38  preferably has a thickness T approximately equal to the distance between ledge  58  and the top of shoulder  56 . Advantageously, this allows the lid to fit securely along ledge  58  without the possibility of lid  38  easily failing off. Further, when wedge  36  is fully seated, a top side  70  of the wedge is located on approximately the same plane as shoulder  56  and lid  38  fits between base  34  and wedge  36 . 
         [0051]    Base  34 , wedge  36 , and lid  38  are all preferably composed of a heat resilient material such as a ceramic composite or ceramic fiber, however any suitable material which can reduce impurities in the ingot head and still be located within the mold opening as detailed below may be used and is within the spirit and scope of the invention as claimed. 
         [0052]    Having described the structure of a preferred embodiment of the mold top assembly, a preferred mold top installation device  72  will now be described in detail and should be viewed in light of  FIG. 10 .  FIGS. 15 through 20  illustrate an installation process with the device and will be described with the full installation procedure of the mold top assembly. 
         [0053]    Installation device  72  includes tube  74  with an inner rod  76  movable axially within tube  74 . Tube  74  terminates in first end  78  and inner rod  76  terminates in second end  80 . A guide  82  is attached at each end ( 78  and  80 ), each guide includes a central member  84  arranged generally perpendicular to tube  74  and generally parallel to side walls  46  and  48  of base  34  during operation. Further, an angled member  86  extends from both the top and bottom of central member  84 . Each angled member is preferably directed back towards tube  74 . Advantageously, the angled members help to locate and center the installation device, as well as spread base  34  apart in order to facilitate installation of wedge  36 . In particular, the gradual increase in distance between the angled members allows the installation device to more easily slide between side walls  46  and  48  of base  34  since there is less contact at the guides. 
         [0054]    The installation device also includes an arm  88  and a driving bar  90 . The driving bar is spaced apart from tube  74  by the generally L-shaped arm  88  in a preferred embodiment. In particular, the driving bar remains parallel to tube  74 , but the driving bar is offset from tube  74  both vertically and horizontally. Driving bar  90  is preferably rectangular in shape, with the widest end directed upwards so that the installer can strike the face to urge the installation device and wedge  36  downwards. 
         [0055]    Having described the structure of the a preferred embodiment of the mold top assembly and installation device, a preferred method of installing a mold top assembly will now be described in detail and should be viewed in light of  FIGS. 11 through 28 . 
         [0056]      FIGS. 11 and 12  illustrate an installer locating base  34  within mold opening  44 . The installer preferably picks up and handles base  34  by the open end and leads with first end wall  50 . Base  34  is then inserted within opening  44  such that end wall  50  is adjacent distal end  41  of the mold and first wall end  52  and second wall end  54  are located near proximate end  43  of the mold. As described above, shoulder  56  rests on side walls  42  of the mold. 
         [0057]    As seen in  FIGS. 13 and 14 , the installer then locates wedge  36  within a gap  92  formed by proximate end  43  of the mold and base  34 . A lower end of wedge  36  is inserted within gap  92  first in order to properly align angled portions  66  and  68  of wedge  36  with ends  52  and  54  of base  34 . As particularly seen in  FIG. 14 , after partially installing wedge  36 , the installer pushes on top side  70  in the direction associated with arrow  94  until the wedge is at least partially installed within the mold. 
         [0058]      FIGS. 15 ,  16 , and  17  illustrate the use of installation device  72  to seat wedge  36  within the mold. Next, the installer locates top side  70  of wedge  36  proximate the bottom side of driving bar  90 . Since wedge  36  is partially located within gap  92 , guides  82  are arranged proximate the interior periphery of base first side wall  46  and base second side wall  48 . 
         [0059]      FIG. 17  is an endwise view of the installation device being used to locate wedge  36  and illustrates how guides  82  and specifically central members  84  maintain the distance between the first and second side walls of base  34 . Further, it should be noted that angled members  86  also operate to ensure proper alignment of the installation device, as the angled members tend to urge the guides into alignment with one another due to the consistent angled wall at each guide. 
         [0060]    Averting to  FIGS. 18 and 19 , the installer then uses a mallet or other solid object to provide a force in the direction associated with arrow  96  on driving bar  90  until the wedge is fully seated between base  34  and proximate end  43  of mold  40 . The force in the direction associated with arrow  96  directs wedge  36  downwards and the interaction between wedge  36  and base  34  at angled portions  66  and  68  translates a portion of the force into an axial force in the direction associated with arrow  98 . In particular, the complimentary shaped angled ends of base  34  and wedge  36  moves base  34  in the direction associated with arrow  98  and forces first end wall  50  to a position adjacent distal end  41 . 
         [0061]    The next step is seen in  FIG. 20 , where the installer removes the installation device by pulling upwards in the direction associated with arrow  100 . Advantageously, angled members  86  help to ease removal of the installation device from the mold top assembly in the same manner as angled members  86  assisted in the installation. 
         [0062]    Next, as seen in  FIGS. 21 and 22 , molten metal  102  is poured into the mold until the top of the molten metal is still below shoulder  56 . In a preferred embodiment, top pouring is utilized, however it should be immediately apparent to one of ordinary skill in the art that bottom pouring may be incorporated without departing from the spirit and scope of the present invention as claimed. 
         [0063]    Averting to  FIGS. 23-28 , the final step is installing lid  38 . The installer locates one end of lid  38  on ledge  58 , as seen in  FIGS. 24 and 25 . Next, lid  38  is moved in the direction associated with arrow  104  and the end of lid  38  slides along ledge  58  until the end is located proximate distal end  41 . Further, the installer may use a pushing rod  106  or other similarly situated tool to help move the lid into place. Rod  106  is helpful due to the gap between mold  40  and platform  32 . As specifically seen in  FIGS. 27 and 28 , in the full installed position, lid  38  rests on ledge  58  and abuts wedge  36 . Further, the combination of base  34 , wedge  36 , and lid  38  provide a sealed mold top assembly that can easily and efficiently be installed within a mold by a single person while minimizing potential danger. 
         [0064]    Accordingly, the mold top assembly is an effective, safe, inexpensive, and efficient device that achieves all the enumerated objectives of the invention, provides for eliminating difficulties encountered with prior art devices, systems, and methods, and solves problems and obtains new results in the art. 
         [0065]    In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. 
         [0066]    Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described. 
         [0067]    Having now described the features, discoveries, and principles of the invention, the manner in which the mold top assembly is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangement, parts, combinations, and methods are set forth in the appended claims.