Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

TITLE OF THE INVENTION
A METALLIC BREAKER CORE ASSEMBLY FOR A SLEEVE USED IN FOUNDRY

APPLICANT

Name Nationality Address
GRIND CHEM INDIA GAT NO. 1224/1B, PUNE NAGAR ROAD, SANASWADI, PUNE, MAHARASHTRA, INDIA 412208

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
[001] The present invention relates to a metallic breaker core assembly for a sleeve used in foundry, and more specifically, to a two-parts assembly of a metallic breaker core for a high-density sleeve used in a high-pressure molding line of an iron and steel foundry.
BACKGROUND ART
[002] A metallic breaker core used in foundry, particularly on feeder sleeve, showcases a combination of advanced materials, innovative design, and enhanced functionality addressing key challenges in casting process, helping prevent issues related to graphite degeneration, and minimizing the risk of contact between exothermic material and the casting surface. These metallic breaker cores play a crucial role in optimizing the casting process for improved efficiency, precision, and quality. The metallic breaker core functions to permit the flow of molten metal as needed to compensate for metal shrinkage into a mold cavity. The metallic breaker core is typically constructed from high-quality alloys or steel with specific metallurgical properties to withstand the harsh conditions of the casting process. This ensures durability, thermal stability, and resistance to the corrosive effects of molten metal. The metallic breaker core also features an innovative design that includes either stepped structures or simple elevated or curved design at its center providing an optimized neck configuration. This design allows for precise spot feeding in even the smallest casting contact areas, promoting a well-defined knock-off edge on the casting surface.
[003] High density sleeve with metallic breaker cores is used in the foundry in high pressure molding line to provide excellent spot feeding, higher yield efficiency, excellent surface finish and lower fettling costs. The high-density sleeve has very high compressive strength to withstand the high pressure in the molding lines and are placed on heavy casting sections with special pins which hold the high-density sleeve inside the mold.
[004] When the high-density sleeve is subjected to very high compressive force applied inside the mold for sand compactions during sand molding process, a sudden force causes high impact pressure on the neck area of the high-density sleeve below the metallic breaker core. If the metallic breaker core doesn’t absorb the sudden force significantly, then the high impact pressure gets transferred to the neck area of the high-density sleeve and causes breakage of the high-density sleeve inside the mold. This leads to problems like sand fusion, sand inclusion, and poor casting finish, increasing the chances of foundry rejections. Therefore, there is a need to address the aforementioned problems that exist, and design metallic breaker cores that can withstand the high impact pressure during sand molding in the molding lines of the foundry.
SUMMARY OF THE INVENTION
[005] Before the present system(s) are described, it is to be understood that this application is not limited to the particular system(s) described, as there can be multiple possible embodiments, which are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular implementations or versions or embodiments only and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to a metallic breaker core assembly for a high-density sleeve used in foundry. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[006] In order to solve the problems described above and to achieve the object, we introduce a two-parts assembly of the metallic breaker core to be used with the high-density sleeve so that the high-density sleeve can withstand high impact pressure during sand molding in high pressure molding lines of the foundry, in particular iron and steel foundry. The metallic breaker core of the present invention absorbs completely sudden high impact pressure and gives good cushioning effect to the high-density sleeve thereby, preventing any breaking or tear of the high-density sleeve.
[007] The two-parts assembly of the metallic breaker core comprises a metallic cap placed on top of the high-density sleeve and a frustum-shaped hollow metallic bushing pipe snugly fit into the metallic cap and further insertable when acted upon an external force.
[008] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
[009] These elements, together with the other aspects of the present disclosure and various features are pointed out with particularity in the claims annexed hereto and form a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[010] To describe the technical solutions in the embodiments of the present disclosure or in the prior art more clearly, the following briefly describes the accompanying drawings required for describing the embodiments or the prior art. Apparently, the accompanying drawings in the following description merely show some embodiments of the present disclosure, and a person of ordinary skill in the art can derive other implementations from these accompanying drawings without creative efforts. All of the embodiments or the implementations shall fall within the protection scope of the present disclosure.
[011] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustration of the present subject matter, an example of construction of the present subject matter is provided as figures; however, the invention is not limited to the specific assembly disclosed in the document and the figures.
[012] It is therefore to be noted that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered for limiting its scope, for the invention may admit to other equally effective embodiments.
[013] The advantages and features of the present disclosure will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawing, in which:
[014] FIG. 1 illustrates a sectional view of a two-parts assembly of a metallic breaker core for a high-density sleeve used in foundry; and
[015] FIG. 2 illustrates a front view of an assembled metallic breaker core placed on a high-density sleeve.
[016] Like reference, numerals refer to like parts throughout the description of several views of the drawing.
[017] The metallic breaker core assembly for a sleeve used in foundry is illustrated in the accompanying drawings, which like reference letters indicate corresponding parts in the various figures. It should be noted that the accompanying figure is intended to present illustrations of exemplary embodiments of the present disclosure. This figure is not intended to limit the scope of the present disclosure. It should also be noted that the accompanying figure is not necessarily drawn to scale.
DETAILED DESCRIPTION
[018] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.
[019] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. It may be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without some of these specific details.
[020] Various terms as used herein are shown below. To the extent a term is used, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[021] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items. It must also be noted that as used herein, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any system similar to or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary system is now described. The disclosed embodiments are merely examples of the disclosure, which may be embodied in various forms. The disclosed embodiments can be used standalone or in combination. Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, a person having ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments described but is to be accorded the widest scope consistent with the principles and features described herein.
[022] Before the present system(s) are described, it is to be understood that this application is not limited to the particular assembly described, as there can be multiple possible embodiments, which are not expressly illustrated in the present disclosures.
[023] Referring to figure 1 and figure 2, a two-parts assembly of a metallic breaker core (10) for a high-density sleeve (12) comprises a metallic cap (14) and a frustum-shaped hollow metallic bushing pipe (16). The metallic cap (14) has a base (18) with an aperture (20) located centrally therein, and an annular lip region (22) with either an inwardly inclined or orthogonal surface projecting upwards from the periphery of the aperture (20). The metallic cap (14) further comprises a hollow pipe (24) projecting upwards from the annular lip region (22). The frustum-shaped hollow metallic bushing pipe (16) has a top annular region (26) and a bottom annular region (28). The frustum-shaped hollow metallic bushing pipe (16) is inserted into the hollow cylindrical pipe from the side of the top annular region (26). The top annular region (26) of the frustum-shaped hollow metallic bushing pipe (16) has an outer diameter (dtop) marginally less than an inner diameter (dinner) of the hollow pipe (24) ranging from 0.1 mm to 0.5 mm, so that the top annular region (26) snugly fits into the frustum-shaped hollow metallic bushing pipe (16). The bottom annular region (28) of the frustum-shaped hollow metallic bushing pipe (16) has an outer diameter (dbottom) greater than the inner diameter (dinner) of the hollow pipe (24) maintaining a taper ranging from 0.4 mm to 0.8 mm, so that the frustum-shaped hollow metallic bushing pipe (16) cannot be fully inserted into the hollow pipe (24). The taper allows the frustum-shaped hollow metallic bushing pipe (16) to fit into the hollow pipe (24), absorbing the high impact pressure and thereby, providing cushioning effect to the high-density sleeve (14) so that it doesn’t break at its neck area.
[024] When a user applies a sudden force from the side of the bottom annular region (28), a high impact pressure develops on the wall of the frustum-shaped hollow metallic bushing pipe (16) which gets transferred to the wall of the hollow cylindrical pipe (24). Owing to the tapering surface of the frustum-shaped hollow metallic bushing pipe (16), the frustum-shaped hollow metallic bushing pipe (16) faces a gradually increasing resistance and is insertable into the hollow pipe up to 100% of its height. Due to this, the hollow pipe (24) is able to absorb the high impact pressure thereby ensuring the high impact pressure does not get transferred to the high-density sleeve (16) for a longer duration.
[025] According to various embodiments of the present invention, the shape of the base (18) of the metallic cap (14) and the shape of the aperture (20) of the metallic cap (14) may either be circular, oval, square, or rectangular.
[026] According to various embodiments of the present invention, the base (18) of the metallic cap (14) may have either a flat surface or an arcuate surface in order to conform to top surface of the high-density sleeve (12).
[027] According to various embodiments of the present invention, the shape of the periphery of the hollow pipe (24), and the shape of the periphery of the frustum-shaped hollow metallic bushing pipe (16) may either be circular, oval, square, or rectangular.
[028] The thickness and the taper of the frustum-shaped hollow metallic bushing pipe (16) vary according to different sizes of the high-density sleeve (14) and the pressure in molding lines. Depending on the thickness and the taper of the frustum-shaped hollow metallic bushing pipe (16), the resistance to the frustum-shaped hollow metallic bushing pipe (16) begins to develop and gradually increase with the high impact pressure.
[029] According to an embodiment of the present invention, the thickness of the frustum-shaped hollow metallic bushing pipe (16) ranges between 1 mm to 1.5 mm to provide the desired strength and compression flexibility due to the high impact pressure caused by the sudden force on the frustum-shaped hollow metallic bushing pipe (16). For HDS134 sleeve, the thickness is 1.2 mm and the taper is 0.8 mm (refer Table 1).
[030] According to an embodiment of the present invention, the taper of the frustum-shaped hollow metallic bushing pipe (16) ranges from 0.5 mm to 1 mm to provide the desired resistance and tightness to the high impact pressure in the molding lines.
[031] The diameter of the metallic breaker core for the metallic cap and the frustum-shaped hollow metallic bushing pipe (24) will change based on the different sizes of the high-density sleeve, particularly the top diameter of the high-density sleeve.
[032] According to the present invention, the metallic breaker core (10) can be used for a wide range of high-density sleeve (12) ranging from a high-density sleeve of 8 cc volume (HDS8) to a high-density sleeve of 720 cc volume (HDS720).
Table 1. Technical specification details of the metallic breaker core (10) for HDS134 sleeve
Description Dimensions Remarks

Metallic Cap (14) Diameter of the base (18) = 80 mm
Diameter of the base (18) ideally is 2 mm to 5 mm less than diameter of high-density sleeve
Diameter of the aperture (20) / inner diameter (dinner) of the hollow pipe (24) = 26.2 mm

Diameter of the aperture (20) / inner diameter (dinner) of the hollow pipe (24) ideally is 50% to 60% of the diameter of the base (18) to provide better molten metal flow efficiency and breaker core formation
Thickness of the hollow pipe (25) = 1.5 mm
Height = 14 mm Height of the hollow pipe (24) depends on the gap required between casting and sleeve

Frustum-shaped hollow metallic bushing pipe (16) Outer diameter of the top annular region (26) = 26 mm Outer diameter of top annular region (26) ideally is 0.1 to 0.5 mm less than the inner diameter (dinner) of the hollow pipe (24) for better insertion at entry
Thickness = 1.2 mm
Outer diameter of the bottom annular region (28) = 26.8 mm Outer diameter of the bottom annular region (28) ideally is to maintain a taper of 0.8 mm of the frustum-shaped hollow metallic bushing pipe (16)
Thickness = 1.2 mm
Height = 14 mm

[033] As the two-parts assembly of the metallic breaker core (10) ensures no breakage and wear or tear of the neck area of the high-density sleeve (14), no sand fusion is observed resulting in reduced foundry rejections. Further, there are no possibilities of bending or changes in the shape of the metallic breaker core (10) due to the high impact pressure, and the hollow pipe (24) and the frustum-shaped hollow metallic bushing pipe (16) do not bend and remain intact as before. This leads to better and uniform sand compaction, reduced sand fusion and better neck formation of the metallic breaker core (10).
[034] For instance, while the various designs have been described with respect to structure and constructional features of the preferred embodiments of the invention, novel aspects of the embodiments described may be incorporated in other designs. Also, the description is made with respect to exemplary embodiments only and it should be understood that the configuration of the components may be changed without departing from the scope of an appended claim. Also, it should be understood that in alternate embodiments claimed in the claims, many of the components described with respect to the exemplary embodiments may be withheld or may be replaced by equivalent structures. Numerous modifications and adaptations of the system of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the true spirit and scope of this invention.
[035] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described to best explain the principles of the present disclosure and its practical application, and to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the present disclosure. , Claims:WE CLAIM:
1. A two-parts assembly of a metallic breaker core (10) for a high-density sleeve (12) comprising:
a metallic cap (14) having a base (18) with an aperture (20) located centrally therein, an annular lip region (22) with an orthogonal surface projecting up from the periphery of the aperture (20), and a hollow pipe (24) projecting upwards from the annular lip region (22); and
a frustum-shaped hollow metallic bushing pipe (16) having a top annular region (26) which has an outer diameter (dtop) marginally less than an inner diameter (dinner) of the hollow pipe (24) and a bottom annular region (28) which has an outer diameter (dbottom) greater than the inner diameter (dinner) of the hollow pipe (24), wherein the frustum-shaped hollow metallic bushing pipe (16) when inserted from the side of the top annular region (26) snugly fits into the hollow pipe (24).
2. The two-parts assembly of a metallic breaker core (10) as claimed in claim 1, wherein the base (18) and the aperture (20) is circular.
3. The two-parts assembly of a metallic breaker core (10) as claimed in claim 1, wherein the base (18) and the aperture (20) is square.
4. The two-parts assembly of a metallic breaker core (10) as claimed in claim 1, wherein the base (18) and the aperture (20) is rectangular.
5. The two-parts assembly of a metallic breaker core (10) as claimed in claim 1, wherein the base (18) and the aperture (20) is oval.
6. The two-parts assembly of a metallic breaker core (10) as claimed in claim 2, wherein taper of the frustum-shaped hollow metallic bushing pipe (16) is 0.8 mm.
7. The two-parts assembly of a metallic breaker core (10) as claimed in claim 3, wherein taper of the frustum-shaped hollow metallic bushing pipe (16) is 0.8 mm.
8. The two-parts assembly of a metallic breaker core (10) as claimed in claim 4, wherein taper of the frustum-shaped hollow metallic bushing pipe (16) is 0.8 mm.
9. The two-parts assembly of a metallic breaker core (10) as claimed in claim 5, wherein taper of the frustum-shaped hollow metallic bushing pipe (16) is 0.8 mm.
10. The two-parts assembly of a metallic breaker core (10) as claimed in claim 1, wherein the frustum-shaped hollow metallic bushing pipe (16) can be inserted into the hollow pipe (24) from the side of the top annular region (26) up to an extent of 100% of its height.