DESC:FIELD
The present disclosure relates to the field of foundries. More specifically, the present disclosure relates to the field of core manufacturing processes.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
A core is a device used in casting and molding processes to produce internal cavities and reentrant angles. The core is manufactured by various processes of which shell coring manufacturing process and cold box process are widely employed.
In the shell core box process, a core box equipment is mounted in an open chamber for heating the core box to a temperature ranging from 280 to 330 Degrees Celsius. Pre-coated silica sand, having resin proportion of 3%, is blown into heated the core box at a pressure ranging from 3.5 bar to 5 bar. After a predetermined time period, the manufactured core is ejected out of the core box and finished for producing castings. However, high amount of heat produced by using at least high consumption of natural resources (around 65 tons of piped natural gas) does not make this process an eco-friendly option. Additionally, the curing time is 270 seconds which is considerably high. Further, the shell core box process is immensely tiring for the associates working thereon.
On the other hand, the cold box process eliminates the use of heat by using a catalyst. The core box is mounted on a machine. Pre-mixed sand, having a resin proportion of 1%, is blown into the core box at a pressure varying from 3.5 bar to 5 bar. The catalyst is passed through the core box to activate the resin at room temperature, and enable the curing of the core. After a predetermined time period, the manufactured core is ejected out of the core box. The core is finished for producing castings. However, the cold box process is not an economical option for small scale and medium scale foundries. Further, the foundries employed in cold box making process do not have any kind of arrangement either for regeneration or neutralization of the catalyst.
There is therefore required an apparatus and method for core manufacturing that alleviates the aforementioned drawbacks.
OBJECT
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide an apparatus for core manufacturing.
Another object of the present disclosure is to provide an apparatus that improves productivity.
Yet another object of the present disclosure is to provide an apparatus that is cost-effective.
Still another object of the present disclosure is to provide an apparatus that facilitates ease in operation
One object of the present disclosure is to provide an apparatus that is simple in construction and assembly.
Another object of the present disclosure is to provide an apparatus that has less number of parts.
Yet another object of the present disclosure is to provide an apparatus that is durable, strong and reliable.
Still another object of the present disclosure is to provide an apparatus that facilitates ease in serviceability.
Another object of the present disclosure is to provide an apparatus that is environment friendly.
SUMMARY
The present disclosure envisages an apparatus for manufacturing foundry cores. The apparatus comprises a sealable chamber and a perforated core box removably disposable in the chamber, for retaining a homogenous core forming mixture there within. At least one inlet port is configured on the chamber. The inlet port(s) is configured to introduce a catalyst gas at a controlled pressure and flow rate into the chamber to permeate through the core box for curing the core forming mixture. At least one outlet port is configured on the chamber. The outlet port(s) is configured to purge the gas out of the chamber after the gas resides in the core box for a predetermined time.
In an embodiment, the apparatus includes a catalyst gas generator in communication with the inlet port(s). The gas generator is configured to supply gas to the chamber at a predetermined pressure and flow rate.
In another embodiment, the catalyst gas generator includes a pressure regulator configured to control the pressure of the catalyst gas before supplying the catalyst gas to the inlet port(s).
In yet another embodiment, the apparatus includes a purging unit in communication with the outlet ports(s) for extracting the gas from the chamber.
In still another embodiment, the apparatus includes a controller configured to control the pressure, flow rate and residence time of the gas supplied to the chamber.
In one embodiment, the apparatus includes an inlet manifold provided for the inlet port(s). The inlet port(s) are connected to the gas generator via the inlet manifold.
In another embodiment, the apparatus includes an outlet manifold provided for the outlet port(s). The outlet port(s) are connected to the purging unit via the outlet manifold.
In yet another embodiment, the core box is a sealable core box.
In still another embodiment, the homogenous core forming mixture comprises thermosetting resin and sand in predefined ratios.
In an embodiment, the purging unit includes a gas scrubber configured to facilitate removal of particulates from the extracted gas.
In another embodiment, outlet of the purging unit is in communication with the inlet manifold.
In yet another embodiment, the catalyst is amine.
In still another embodiment, the core box and the chamber is sealed with the help of silicon nitride for preventing leakage of amine gas from the chamber.
In another embodiment, the shape of the core box conforms to the shape of the core that is required to be manufactured.
The apparatus (100) of the present disclosure ensures improved productivity by reducing time, number of operations, failure rate and efforts. Since the entire process is done at room temperature without the involvement of heat for curing of the core, the operation is relaxed and the operator fatigue is reduced. Further, the consumption of natural resources for heating is reduced by the apparatus 100. Additionally, the proportion of the thermosetting resin required to bind the sand in the desired shape is less as compared to conventional ways of core manufacturing. Additionally, the curing time is reduced to at least 120 seconds. The construction and assembly of the parts of the apparatus (100) is simple and requires few components which can be easily modified for the incorporation of the additional features. The apparatus (100) can be modified as a shell core manufacturing apparatus. The apparatus (100) is strong, durable and reliable. Further, the overall manpower and the working time required for manufacturing the core box (110) is reduced by the apparatus (100).
The present disclosure also envisages a method for manufacturing foundry cores. The method comprises the following steps of:
• introducing a homogenous core forming mixture in a core box;
• sealing the core box;
• placing the core box in a chamber;
• sealing the chamber;
• generating a catalyst gas;
• supplying the gas to the core box at a predetermined pressure and flow rate to at least one inlet port configured on the chamber;
• allowing the gas to permeate in the core box to intimately contact the mixture to facilitate curing of the mixture;
• allowing the gas to reside in the chamber for a predetermined time;
• purging the gas out of the chamber through at least one outlet port configured on the chamber;
• unsealing the chamber;
• removing the core box;
• unsealing the core box; and
• removing the core from the core box.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
An apparatus, of the present disclosure, for core manufacturing will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a schematic view of the apparatus of the present disclosure;
Figure 2 illustrates a schematic view of a core box of the apparatus of Figure 1; and
Figure 3 illustrates the method for core manufacturing.
LIST OF REFERENCE NUMERALS
100 – Apparatus
105 – Chamber
110 – Core box
115 – catalyst gas generator
118 – catalyst reservoir
120 – purging unit
128 – inlet manifold
130 – outlet manifold
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Terms such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
An apparatus (100), of the present disclosure, for manufacturing foundry cores will now be explained in detail with reference to Figure 1 through Figure 3.
The apparatus (100) comprises a sealable chamber (105) in which a perforated core box (110) (as seen in Figure 2) is removably disposed. The core box (110) is configured to retain a homogenous core forming mixture there within. At least one inlet port (not specifically shown in figures) is configured on the chamber (105). The inlet port(s)is configured to introduce a catalyst gas at a controlled pressure and flow rate into the chamber (105). The catalyst gas permeates through the core box (110) to facilitate curing of the core forming mixture at ambient temperatures. At least one outlet port (not specifically shown in figures) is configured on the chamber (105). The outlet port(s)is configured to purge the gas out of the chamber (105) after the gas resides in the core box (110) for a predetermined time.
The apparatus (100) includes a catalyst gas generator (115) configured to be in communication with the inlet port(s). The gas generator (115) is configured to supply gas to the chamber (105) at a predetermined pressure and flow rate. In an embodiment, the gas generator (115) is connected to a catalyst reservoir (118), wherein the catalyst is stored in its liquid form. In another embodiment, the gas generator (115) includes a heating unit (not specifically shown in figures), which is configured to convert the liquid catalyst into its gaseous form, by heating the liquid catalyst.
The catalyst gas generator (115) includes a pressure regulator (not specifically shown in figures) configured to control the pressure of the catalyst gas such that the predetermined pressure of the catalyst gas is maintained before being supplied to the inlet port(s).
The apparatus (100) further includes a purging unit (120) which is in communication with the outlet ports(s) for extracting the gas from the chamber (105).
In an embodiment, the apparatus (100) includes a controller (not specifically shown in figures). The controller is configured to control the pressure, flow rate and residence time of the gas supplied to the chamber (105). The controller is configured to be in communication with the pressure regulator.
In one embodiment, the apparatus (100) includes an inlet manifold (128) provided for the inlet port(s). The inlet port(s) are connected to the gas generator (115) via the inlet manifold (128).
In another embodiment, the apparatus (100) includes an outlet manifold (130) provided for the outlet port(s). The outlet port(s) are connected to the purging unit (120) via the outlet manifold (130).
The core box (110) is a sealable core box (110).
The homogenous core forming mixture comprises thermosetting resin and sand in predefined ratios. The thermosetting resin and the sand are mixed to form a semi-liquid mixture.
In a working embodiment, the core box (110) is sealed after being filled with the homogenous core forming mixture. The core box (110) is kept inside the chamber (105) which is then sealed. The inlet port(s) of the chamber (105) is connected to the catalyst gas regulator, and the outlet port(s) of the chamber (105) is connected to the purging unit (120). The pressure, flow rate and the time for residence of the gas inside the core box (110) is determined and controlled and set by the controller. Accordingly, the gas is supplied to the core box (110) through the inlet port(s)for curing the core forming mixture to manufacture the core. After the predetermined time period, the gas is extracted by the purging unit (120) through the outlet port(s). The chamber (105) is unsealed to remove the core box (110) which is then unsealed to remove the core manufactured.
When the gas is extracted and passed through the purging unit (120), it is necessary that the gas must be cleaned for recirculation purposes. The purging unit (120) hence, includes a gas scrubber (not specifically shown in figures) configured to facilitate removal of particulates from the extracted gas.
In an embodiment, the outlet of the purging unit (120) is in communication with the inlet manifold (128).
In one embodiment, the catalyst is amine. In another embodiment, the core box (110) and the chamber (105) is sealed with the help of silicon nitride for preventing leakage of amine gas from the chamber (105).
In another embodiment, the shape of the core box (110) conforms to the shape of the core that is required to be manufactured.
The present disclosure also envisages a method (200) (as seen in Figure 3) for manufacturing foundry cores. The method comprises the following steps of:
Step 202: introducing a homogenous core forming mixture in a core box (110);
Step 204: sealing the core box (110);
Step 206: placing the core box (110) in a chamber (105);
Step 208: sealing the chamber (105);
Step 210: generating a catalyst gas;
Step 212: supplying the gas to the core box (110) at a predetermined pressure and flow rate to at least one inlet port configured on the chamber (105);
Step 214: allowing the gas to permeate in the core box (110) to intimately contact the mixture to facilitate curing of the mixture;
Step 216: allowing the gas to reside in the chamber (105) for a predetermined time;
Step 218: purging the gas out of the chamber (105) through at least one outlet port configured on the chamber (105);
Step 220: unsealing the chamber (105);
Step 222: removing the core box (110);
Step 224: unsealing the core box (110); and
Step 226: removing the core from the core box (110).
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of an apparatus and method for core manufacturing, that:
• reduced use of natural resources for heating, since heating of the core box is eliminated;
• improves productivity;
• is cost-effective;
• facilitates ease in operation;
• is simple in construction and assembly;
• has less number of parts;
• is durable, strong and reliable;
• is adaptable into an apparatus for shell core manufacturing;
• facilitates ease in serviceability; and
• is environment friendly.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:
1. An apparatus (100) for manufacturing foundry cores, said apparatus (100) comprising:
• a sealable chamber (105);
• a perforated core box (110) removably disposable in said chamber (105), for retaining a homogenous core forming mixture there within;
• at least one inlet port configured on said chamber (105), said inlet port(s) configured to introduce a catalyst gas at a controlled pressure and flow rate into said chamber (105) to permeate through said core box (110) for curing said core forming mixture; and
• at least one outlet port configured on said chamber (105), said outlet port(s)configured to purge said gas out of said chamber (105) after said gas resides in said core box (110) for a predetermined time.
2. The apparatus (100) as claimed in claim 1, which includes a catalyst gas generator (115) in communication with said inlet port(s) for supplying gas to said chamber (105) at a predetermined pressure and flow rate.
3. The apparatus (100) as claimed in claim 2, wherein said catalyst gas generator (115) includes a pressure regulator configured to control the pressure of said catalyst gas before supplying said catalyst gas to said inlet port(s).
4. The apparatus (100) as claimed in claim 1, which includes a purging unit (120) in communication with said outlet ports(s) for extracting said gas from said chamber (105).
5. The apparatus (100) as claimed in claimed in claim 1, which includes a controller configured to control the pressure, flow rate and residence time of said gas supplied to said chamber (105).
6. The apparatus (100) as claimed in claim 2, which includes an inlet manifold (128) provided for said inlet port(s), wherein said inlet port(s) are connected to said gas generator (115) via said inlet manifold (128).
7. The apparatus (100) as claimed in claim 4, which includes an outlet manifold (130) provided for said outlet port(s), wherein said outlet port(s) are connected to said purging unit (120) via said outlet manifold (130).
8. The apparatus (100) as claimed in claim 1, wherein said core box (110) is a sealable core box (110).
9. The apparatus (100) as claimed in claim 1, wherein said homogenous core forming mixture comprises thermosetting resin and sand in predefined ratios.
10. The apparatus (100) as claimed in claim 4, wherein said purging unit (120) includes a gas scrubber configured to facilitate removal of particulates from the extracted gas.
11. The apparatus (100) as claimed in claim 6, wherein outlet of said purging unit (120) is in communication with said inlet manifold (128).
12. The apparatus (100) as claimed in claim 1, wherein said catalyst is amine.
13. The apparatus (100) as claimed in claim 12, wherein said core box (110) and said chamber (105) is sealed with the help of silicon nitride for preventing leakage of amine gas from said chamber (105).
14. The apparatus (100) as claimed in claim 1, wherein the shape of said core box (110) conforms to the shape of the core that is required to be manufactured.
15. A method for manufacturing foundry cores, said method comprising the following steps of:
• introducing a homogenous core forming mixture in a core box (110);
• sealing said core box (110);
• placing said core box (110) in a chamber (105);
• sealing said chamber (105);
• generating a catalyst gas;
• supplying said gas to said core box (110) at a predetermined pressure and flow rate to at least one inlet port configured on said chamber (105);
• allowing said gas to permeate in said core box (110) to intimately contact said mixture to facilitate curing of said mixture;
• allowing said gas to reside in said chamber (105) for a predetermined time;
• purging said gas out of said chamber (105) through at least one outlet port configured on said chamber (105);
• unsealing said chamber (105);
• removing said core box (110);
• unsealing said core box (110); and
• removing the core from said core box (110).