Exhaust manifold with hollow sand core structure
By designing a hollow sand core structure, including an outer sand core wall and internal reinforcing ribs, the problems of heavy weight and casting defects of traditional sand cores are solved, achieving lightweight and efficient casting, reducing production costs and improving product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- FEILONG AUTO COMPONENTS CO LTD
- Filing Date
- 2025-04-30
- Publication Date
- 2026-05-01
AI Technical Summary
Traditional exhaust manifold sand core designs suffer from problems such as high weight, high material cost, and numerous casting defects, making it difficult to meet the demands for lightweight and efficient casting.
The hollow sand core structure is adopted, including an outer sand core wall and an internal support structure. The stability of the sand core is enhanced by reinforcing ribs, and a positioning structure is set at the connection point to ensure precise connection, thereby reducing material consumption and casting defects.
This achieves lightweight sand cores, reduces material costs, improves casting process efficiency and quality, prevents deformation and displacement during casting, and enhances product reliability and internal cavity dimensional accuracy.
Smart Images
Figure CN224182016U_ABST
Abstract
Description
A hollow sand core structure exhaust manifold Technical Field
[0001] This utility model belongs to the field of exhaust manifold casting technology, specifically relating to an exhaust manifold with a hollow sand core structure. Background Technology
[0002] In the field of exhaust manifold casting technology, the sand core, as a key component forming the inner cavity of the exhaust manifold, directly affects the performance, quality, and production cost of the exhaust manifold through its structural design and manufacturing process. Traditional sand core designs typically employ solid structures or simple weight-reduction designs. For exhaust pipes with relatively large inner cavities, solid sand cores have significant drawbacks: firstly, the sand core is heavy, leading to increased material consumption and higher material costs; secondly, solid sand cores generate a large amount of gas during casting, easily causing casting defects such as gas trapping and cold shuts during the molten metal filling process, affecting the internal quality and performance of the exhaust manifold. Furthermore, heavier sand cores are inconvenient to handle and assemble, placing a greater load on the mold and equipment, indirectly reducing the efficiency and stability of the casting process.
[0003] With the development of the automotive industry, higher demands have been placed on the lightweight, high reliability, and manufacturing cost control of exhaust manifolds. Traditional sand core designs can no longer meet the industry's needs for efficient and low-cost casting processes, necessitating structural innovation to optimize sand core performance. Current technologies often only involve partial slotting or simple hollowing, lacking a systematic hollow structure design. This fails to effectively guarantee the strength and deformation resistance of the sand core while reducing weight, and also fails to address casting defects caused by poor exhaust flow. These issues require improvement to achieve lightweight sand cores, reduce material consumption, and simultaneously improve the efficiency and quality of the casting process, thereby lowering production costs. Summary of the Invention
[0004] The technical problem to be solved by this utility model is how to achieve lightweight sand cores, reduce material consumption, improve the efficiency and quality of casting processes, and reduce production costs. In view of the shortcomings of the existing technology, this utility model provides an exhaust manifold with a hollow sand core structure.
[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:
[0006] This utility model provides an exhaust manifold with a hollow sand core structure, including a sand core head, an outer sand core wall, and an internal support structure; the internal support structure includes reinforcing ribs disposed on the inner side of the outer sand core wall, the hollow sand core includes an upper shell core and a lower shell core connected to the upper shell core, and a positioning structure is provided at the connection between the upper shell core and the lower shell core.
[0007] Optionally, the positioning structure includes a tenon and mortise structure on the core head of the sand core, the core head of the sand core is a detachable structure, and the upper shell core and the lower shell core are positioned and connected by the tenon and mortise structure.
[0008] Optionally, the positioning structure further includes a self-locking platform, which is disposed at the connection between the upper shell core and the lower shell core, and the reinforcing ribs are distributed in strips inside the hollow sand core.
[0009] Optionally, the dimensional accuracy of the tenon and mortise in the mortise and tenon structure is controlled within ±0.1mm.
[0010] Optionally, the outer sand core wall has a thickness of 8mm-10mm and is in direct contact with the molten metal.
[0011] Optionally, the outer diameter tolerance of the hollow sand core is controlled within ±0.3mm, and the inner diameter of the hollow part is 60%-80% of the outer diameter of the hollow sand core.
[0012] Optionally, the core head is an integral structure that cannot be separated. The core head is fixedly connected to the upper shell core. The upper shell core and the lower shell core are detachably connected by a self-locking platform. The reinforcing ribs are distributed in a cross shape inside the hollow core.
[0013] Optionally, the thickness of the reinforcing rib is 6mm-8mm.
[0014] Compared to existing technologies, the beneficial effects of this utility model include: the inner cavity of the exhaust manifold is formed by a hollow sand core, which includes an outer sand core wall and an internal support structure; by forming the hollow sand core with the outer sand core wall and the internal support structure, the weight is significantly reduced while ensuring the strength of the sand core, thus reducing the amount of sand core material used and lowering material costs. The internal support structure includes reinforcing ribs disposed on the inner side of the outer sand core wall, which enhance the stability of the sand core structure, prevent deformation of the sand core due to molten metal pressure or heat during casting, and ensure the dimensional accuracy of the inner cavity of the exhaust manifold. Furthermore, a positioning structure is provided at the connection between the upper shell core and the lower shell core; this achieves precise positioning and firm connection of the upper shell core and the lower shell core, avoids misalignment during assembly, prevents the sand core from shifting or falling off due to molten metal erosion during casting, and improves the reliability of the casting process. Attached Figure Description
[0015] The present invention will now be described in further detail with reference to the accompanying drawings.
[0016] Figure 1: A schematic diagram of the structure of an exhaust manifold with a hollow sand core structure in an embodiment of this utility model;
[0017] Figure 2: A schematic diagram of the structure of the upper shell core of an exhaust manifold with a hollow sand core structure in an embodiment of this utility model;
[0018] Figure 3: A schematic diagram of the structure of the lower shell core of an exhaust manifold with a hollow sand core structure in an embodiment of this utility model;
[0019] Figure 4: A schematic diagram of the structure of an exhaust manifold with a hollow sand core structure in another embodiment of the present invention;
[0020] Figure 5: A schematic diagram of the structure of the upper shell core of an exhaust manifold with a hollow sand core structure in another embodiment of the present invention;
[0021] Figure 6: Schematic diagram of the structure of the lower shell core of an exhaust manifold with a hollow sand core structure in another embodiment of the present invention.
[0022] The components include: 1. Upper shell core; 2. Lower shell core; 3. Reinforcing rib; 4. Tenon; 5. Mortise; 6. Self-locking platform; 7. Sand core head. Detailed Implementation
[0023] To better understand this utility model, the following embodiments further illustrate its content, but the scope of protection of this utility model is not limited to the embodiments described below. Numerous specific details are set forth in the following description to provide a more thorough understanding of this utility model. However, it will be apparent to those skilled in the art that this utility model can be practiced without one or more of these details.
[0024] It should be noted that the Z-axis in the attached figures represents the vertical direction, i.e., the up-down position, with the positive direction of the Z-axis representing upward and the negative direction representing downward; the Y-axis in the attached figures represents the horizontal direction and is designated as the front-back position, with the positive direction of the Y-axis representing the front and the negative direction representing the back; the X-axis in the attached figures represents the left-right position, with the positive direction of the X-axis representing the right and the negative direction representing the left. It should also be noted that the aforementioned representations of the Z, Y, and X axes are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.
[0025] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this utility model are only used to distinguish different devices, modules, or units, and are not used to limit the order of functions performed by these devices, modules, or units or their interdependencies.
[0026] It should be noted that the terms "one" and "multiple" used in this utility model are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".
[0027] In the field of exhaust manifold casting technology, traditional sand core designs are typically solid structures without weight reduction treatment, leading to several problems. Firstly, solid sand cores are heavy, resulting in higher material consumption and costs. Secondly, the large gas generation during casting can easily cause casting defects such as gas trapping and cold shuts, affecting the casting quality of the exhaust manifold. Furthermore, the heavier sand cores place higher demands on casting equipment parameters, indirectly increasing production costs.
[0028] To solve the above problems, one embodiment of the present invention provides an exhaust manifold with a hollow sand core structure, including a sand core head (7), an outer sand core wall and an internal support structure; the internal support structure includes a reinforcing rib (3) disposed on the inner side of the outer sand core wall, the hollow sand core includes an upper shell core (1) and a lower shell core (2) connected to the upper shell core (1), and a positioning structure is provided at the connection between the upper shell core (1) and the lower shell core (2).
[0029] In this embodiment, as shown in Figures 1 to 3, in order to achieve lightweight sand core, reduce material consumption, improve casting process efficiency and quality, and reduce production costs, the hollow sand core includes a sand core head (7), an outer sand core wall, and an internal support structure. By forming a hollow sand core with the outer sand core wall and the internal support structure, the weight is significantly reduced while ensuring the strength of the sand core, reducing the amount of sand core material used and lowering material costs. The internal support structure includes reinforcing ribs (3) set on the inner side of the outer sand core wall. The reinforcing ribs (3) enhance the stability of the sand core structure, prevent the sand core from deforming due to the pressure or heat of the molten metal during casting, and ensure the dimensional accuracy of the exhaust manifold cavity. In addition, a positioning structure is provided at the connection between the upper shell core (1) and the lower shell core (2). This achieves accurate positioning and firm connection between the upper shell core (1) and the lower shell core (2), avoids misalignment during assembly, prevents the sand core from shifting or falling off due to the scouring of the molten metal during casting, and improves the reliability of the casting process.
[0030] Optionally, the positioning structure includes a tenon structure set on the core head (7) of the sand core. The core head (7) of the sand core is a detachable structure, and the upper shell core (1) and the lower shell core (2) are positioned and connected by the tenon structure.
[0031] In this optional embodiment, as shown in Figures 1 to 3, in order to reduce the scrap rate caused by assembly errors, the positioning structure includes a tenon and mortise structure set on the sand core head (7). The sand core head (7) is a detachable structure. The upper shell core (1) and the lower shell core (2) are positioned and connected by the tenon and mortise structure. The tenon and mortise structure is accurately positioned, so that the exhaust manifold of the hollow sand core structure is tightly connected.
[0032] Optionally, the positioning structure also includes a self-locking platform (6), which is located at the connection between the upper shell core (1) and the lower shell core (2), and the reinforcing ribs (3) are distributed in strips inside the hollow sand core.
[0033] In this optional embodiment, as shown in Figures 1 to 3, in order to ensure the accurate positioning of the exhaust manifold of the hollow sand core structure, a self-locking platform (6) is set at the connection between the upper shell core (1) and the lower shell core (2), and the reinforcing ribs (3) are distributed in strips; the detachable sand core head (7) facilitates manufacturing and maintenance. The mortise and tenon structure is accurately positioned, and in conjunction with the self-locking platform (6), the connection reliability and error prevention capability are further improved; the strip reinforcing ribs (3) effectively enhance the overall strength of the sand core.
[0034] Optionally, the dimensional accuracy of the tenon (4) and mortise (5) in the mortise and tenon structure is controlled within ±0.1mm.
[0035] In this optional embodiment, as shown in Figures 1 to 6, in order to improve the tightness of the connection between the upper shell core (1) and the lower shell core (2), the dimensional accuracy of the tenon (4) and mortise (5) in the mortise and tenon structure is controlled within ±0.1mm. This high-precision control ensures accurate positioning during sand core assembly, ensures uniform mortise and tenon fit gap, tight connection, and improves the stability of sand core connection. During casting, it can prevent the molten metal from eroding and causing the sand core to shift or fall off, ensure the shape and dimensional accuracy of the exhaust manifold cavity, and improve product quality.
[0036] Optionally, the outer core wall has a thickness of 8mm-10mm and is in direct contact with the molten metal.
[0037] In this optional embodiment, as shown in Figures 1 to 6, to improve the casting quality of the exhaust manifold, the outer sand core wall thickness is set at 8mm-10mm. This thickness range is determined by considering the overall operating requirements of the exhaust manifold and the casting process. A thinner wall thickness can reduce the weight of the sand core, but may not be able to withstand the pressure and heat of the molten metal; a thicker wall increases material costs and is detrimental to the overall performance of the sand core. Under high temperature and high pressure casting conditions, a thickness of 8mm-10mm can ensure sufficient strength and dimensional accuracy, thus ensuring the casting quality of the exhaust manifold.
[0038] Optionally, the outer diameter tolerance of the hollow sand core is controlled within ±0.3mm, and the inner diameter of the hollow part is 60%-80% of the outer diameter of the hollow sand core.
[0039] In this optional embodiment, as shown in Figure 1, the outer diameter tolerance of the hollow sand core is controlled within ±0.3mm to ensure that the inner diameter accuracy of the exhaust manifold meets the design requirements. The inner diameter of the hollow part is 60%-80% of the outer diameter, which is determined through sand core strength calculations and casting process feasibility. For example, for a sand core with an outer diameter of 100mm, selecting an inner diameter of 60mm-80mm can reduce the weight of the sand core while ensuring its strength, facilitating the flow and forming of molten metal.
[0040] Optionally, the core head (7) is an integral structure that cannot be separated. The core head (7) is fixedly connected to the upper shell core (1). The upper shell core (1) and the lower shell core (2) are detachably connected by a self-locking platform (6). The reinforcing ribs (3) are distributed in a cross shape inside the hollow core.
[0041] In another optional embodiment, as shown in Figures 4 to 6, the sand core head (7) is an integral structure that cannot be separated. The sand core head is fixedly connected to the upper shell core (1), and the upper and lower shell cores (2) are detachably connected by a self-locking platform (6). The reinforcing ribs (3) are distributed in a cross shape. The non-separable sand core head (7) makes the upper shell core (1) structure more stable. The self-locking platform (6) is designed to assist in bonding and fixing, and at the same time, the structural features realize the misalignment function to ensure that the upper shell core (1) and the lower shell core (2) are correctly matched. The self-locking platform (6) realizes the detachable connection, which facilitates the assembly and adjustment of the sand core. The cross-shaped reinforcing ribs (3) enhance the strength of the sand core in all directions and effectively prevent the sand core from deforming.
[0042] Optionally, the thickness of the reinforcing rib (3) is 6mm-8mm.
[0043] In this optional embodiment, as shown in Figures 1 to 6, the thickness of the reinforcing rib (3) is 6-8mm: to provide suitable support strength for the sand core, reduce the weight of the sand core, prevent the sand core from deforming during manufacturing and use, and ensure the casting quality of the exhaust manifold.
[0044] In this optional embodiment, as shown in Figures 2 and 3, in order to ensure accurate positioning and tight connection of the hollow sand core assembly, the dimensional accuracy of the tenon (4) of the upper shell core (1) and the mortise (5) of the lower shell core (2) in the mortise and tenon structure is controlled within ±0.1mm.
[0045] This invention enables lightweight sand cores. The hollow sand core structure reduces the amount of sand core material used, lowering material costs. Optimized manufacturing processes and rigorous quality control reduce casting defects. The reduced weight of the sand core decreases gas generation, effectively preventing problems such as gas trapping and cold shuts. Product quality is improved, scrap rates are reduced, product reliability and lifespan are enhanced, material consumption is reduced, casting process efficiency and quality are improved, and production costs are lowered.
[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of this utility model, as long as they do not depart from the spirit and scope of the technical solution of this utility model, should be covered within the scope of the claims of this utility model.
[0047] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.
Claims
1. An exhaust manifold with a hollow sand core structure, characterized in that: It includes a core head, an outer core wall, and an internal support structure; the internal support structure includes reinforcing ribs disposed on the inner side of the outer core wall, and the hollow core includes an upper core and a lower core connected to the upper core, with a positioning structure provided at the connection between the upper core and the lower core.
2. The exhaust manifold with a hollow sand core structure as described in claim 1, characterized in that: The positioning structure includes a tenon and mortise structure set on the core head of the sand core. The core head of the sand core is a detachable structure. The upper shell core and the lower shell core are positioned and connected by the tenon and mortise structure.
3. The exhaust manifold with a hollow sand core structure as described in claim 2, characterized in that: The positioning structure also includes a self-locking platform, which is located at the connection between the upper shell core and the lower shell core, and the reinforcing ribs are distributed in strips inside the hollow sand core.
4. The exhaust manifold with a hollow sand core structure as described in claim 2, characterized in that: The dimensional accuracy of the tenon and mortise in the mortise and tenon structure is controlled within ±0.1mm.
5. The exhaust manifold with a hollow sand core structure as described in claim 1, characterized in that: The outer sand core wall has a thickness of 8mm-10mm and is in direct contact with the molten metal.
6. The exhaust manifold with a hollow sand core structure as described in claim 1, characterized in that: The outer diameter tolerance of the hollow sand core is controlled within ±0.3mm, and the inner diameter of the hollow part is 60%-80% of the outer diameter of the hollow sand core.
7. The exhaust manifold with a hollow sand core structure as described in claim 1, characterized in that: The core head is an integral, non-separable structure. The core head is fixedly connected to the upper shell core. The upper shell core and the lower shell core are detachably connected by a self-locking platform. The reinforcing ribs are distributed in a cross shape inside the hollow core.
8. The exhaust manifold with a hollow sand core structure as described in claim 1, characterized in that: The thickness of the reinforcing rib is 6mm-8mm.