Composite Casting Core for Sanitary Fittings
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Solution Overview
Problem
Current casting core technologies for sanitary fittings face challenges in producing complex designs cost-effectively, with issues in core removal, positioning, sealing, and material contamination, leading to surface defects and difficulties in series production of non-ferrous metal fittings.
Innovation Solution
A composite casting core comprising an outer shell part made of water-soluble material and an inner shell part made of non-water-soluble material, allowing for precise handling and insertion into a casting tool, enabling the production of sanitary fittings with thin walls and facilitating series production of non-ferrous metal bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a permanent core made of plastic material with lower melting point is used, then the core remains in the cast component to provide water supply, but the process control becomes very complex to match internal pressure and melt pressure
Solution Approach 1:
The casting core is divided into two distinct parts: an outer shell made of water-soluble material that can be easily removed, and an inner shell made of non-water-soluble material that remains in the casting. This segmentation allows the outer shell to be discarded after serving its molding purpose, while the inner shell provides the permanent water supply function without requiring complex pressure matching during casting.
Solution Approach 2:
The water-soluble outer shell is extracted as a temporary, disposable component that serves only during the casting process. After casting, this outer shell can be removed by water dissolution, leaving only the essential non-water-soluble inner shell that provides the permanent water supply function, thereby simplifying the overall system.
2Ease of manufacture
If lost casting core made of molding sand is used, then the core is detached after casting by thermal, catalytic or dissolving methods, but material detaching from the core contaminates the casting tool and causes surface defects
Solution Approach 1:
The outer shell is designed as a disposable component made of water-soluble material that serves its purpose during casting and then dissolves away in water without contaminating the casting tool. This eliminates the need for complex removal processes and prevents surface defects caused by material detachment, as the outer shell simply dissolves cleanly.
Solution Approach 2:
The mechanical or thermal removal processes are replaced with a chemical dissolution process. Instead of using heat or catalysts to remove the core material, water is used to dissolve the water-soluble outer shell material, providing a cleaner and simpler removal mechanism that does not contaminate the casting tool.
3Adaptability or versatility
If multi-part casting cores are used to form complicated waterways, then the water supply can be provided, but sealing between parts becomes complex and time-consuming
Solution Approach 1:
The casting core is segmented into an outer shell and an inner shell that can be manufactured separately and then assembled. The outer shell provides the overall structure and water-tight sealing, while the inner shell forms the complicated waterways. This segmentation allows each part to be optimized independently and simplifies the assembly process.
Solution Approach 2:
The casting core uses a composite structure combining water-soluble outer shell material and non-water-soluble inner shell material. This composite design allows the outer shell to provide structural integrity and sealing, while the inner shell provides the permanent functional elements, simplifying the overall assembly process.
4Manufacturing precision
If high injection pressure is used during casting, then the casting quality is improved, but the partially hollow casting cores are damaged or destroyed
Solution Approach 1:
The core is segmented into an outer shell and an inner shell, where the outer shell provides structural strength to withstand high injection pressures during casting, while the inner shell contains the waterways. This segmentation allows the outer shell to be designed for strength while the inner shell can be more delicate.
Solution Approach 2:
The composite structure of water-soluble outer shell and non-water-soluble inner shell creates a hierarchical system where the outer shell bears the mechanical loads during casting, protecting the inner shell from damage while still allowing high injection pressures for quality casting.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables the cost-effective production of sanitary fittings with precise internal structures, reduces surface defects, and allows for series production of non-ferrous metal bodies, improving the reliability and efficiency of the manufacturing process.
Implementation Method 1
The at least one outer shell part is formed with a water-soluble material
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a casting core (1) for a sanitary fitting (2), comprising a composite (15) of at least one outer jacket part (3) formed with a water-soluble material (4) and at least one inner jacket part (5) formed with a non-water-soluble material (6). Furthermore, various manufacturing processes for a sanitary fitting and sanitary fittings are proposed in which such a casting core (1) is used.