Feeder Assembly Spill Guard Pool Design
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Solution Overview
Problem
In metal casting processes, excess liquid metal can escape through ventilation openings in feeder inserts when not embedded in a sand mold, leading to undesirable contact with mold components.
Innovation Solution
A pool or recess is designed on the outer surface of the feeder body's cover area to collect excess liquid metal, which can be monitored and contained, and a holding element can be used to form this pool without altering the feeder body's shape, optionally with a cover to prevent flame formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ventilation opening is formed in the cover area of the feeder body to allow air to escape during casting, then air can be vented from the feeder volume, but liquid metal may escape through the same opening and contact mold parts causing damage
Solution Approach 1:
A holding element is introduced as an intermediary component between the feeder body and the mold. This holding element features a cover with a through-opening that aligns with the ventilation opening, allowing air to escape while the cover itself acts as a barrier to prevent liquid metal from escaping and damaging the mold.
Solution Approach 2:
The system is segmented into distinct functional components: the feeder body for metal storage, the holding element for controlled dispensing, and the cover for protection. The cover is further segmented with a specific through-opening positioned to align with the ventilation opening, creating separate pathways for air and metal.
2Adaptability or versatility
If the feeder insert is used outside of a sand mold for greater versatility, then it can be applied to more casting configurations, but excess liquid metal will run off the outside and contact mold parts
Solution Approach 1:
The holding element serves as a protective intermediary that enables the feeder insert to be used in versatile configurations (including outside sand molds) while preventing the harmful effect of metal runoff. The cover of the holding element creates a controlled environment that contains the metal until it is ready to flow into the mold cavity.
Solution Approach 2:
The cover of the holding element performs a preliminary protective action by containing the liquid metal before it exits the feeder system. This preliminary containment prevents damage to the mold while still allowing the feeder to be positioned in various locations for versatile application.
3Device complexity
If the organic binder in the feeder body burns when hot metal enters to form a flame, then the binder decomposes during the casting process, but this flame formation is undesirable and needs to be prevented
Solution Approach 1:
The cover of the holding element acts as an intermediary barrier that prevents direct contact between the hot metal and the organic binder in the feeder body. This intermediate protection eliminates the condition necessary for flame formation while allowing the binder to still serve its binding function in the feeder structure.
Solution Approach 2:
The design accepts that the organic binder will burn under certain conditions, but converts this potentially harmful flame formation into a controlled or prevented event. By positioning the cover and through-opening strategically, the system allows the binder to decompose without creating harmful flames that could damage the mold or surrounding area.
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
Prevents excess liquid metal from escaping and causing damage by containing it within the feeder insert, allowing for controlled metal feed and preventing flame formation during hot metal entry.
Implementation Method 1
a feeder insert with a feeder body (10) forming a feeder volume (14) made of an exothermic and/or insulating material
Implementation Method 2
a feeder insert with a feeder body (10) forming a feeder volume (14) made of an exothermic and/or insulating material
Implementation Method 3
A ventilation opening (16) is formed in the cover area (12) of the feeder body (10) so that the air displaced during the casting process by the inflow of liquid metal into the feeder volume (14) of the feeder insert (10, 30, 40) can escape
Implementation Method 4
a pond connected to the ventilation opening (16) is arranged on the outer surface of the cover area (12) of the feeder body (10) for receiving liquid metal escaping from the feeder volume (14) via the ventilation opening (16)
Implementation Method 5
If an organic binder with generally different proportions is used in the manufacture of the feeder body and the holding element, the organic binder may burn when the hot metal enters the feeder volume, forming a flame
Data Source
Figure 1~2
Figure 3
AI summary
The feeder arrangement for use in a casting mold used during casting the metals, comprises a feeder insert formed from an exothermic and/or insulating material and having a feeder body (10) forming a feeder volume (14). The feeder body containing the feeder volume for receiving the liquid metals flowing from a mold cavity to the casting mold has side walls (11), a covering area (12) and a base area (13) with a feeder opening (15) formed in it as connection for the mold cavity to the casting mold and an aeration opening is formed in the covering area for the feeder volume. The feeder arrangement for use in a casting mold used during casting the metals, comprises a feeder insert formed from an exothermic and/or insulating material and having a feeder body (10) forming a feeder volume (14). The feeder body containing the feeder volume for receiving the liquid metals flowing from a mold cavity to the casting mold has side walls (11), a covering area (12) and a base area (13) with a feeder opening (15) formed in it as connection for the mold cavity to the casting mold and an aeration opening is formed in the covering area for the feeder volume. A pool connected to the aeration opening is arranged on the outer surface of the covering area of the feeder body for receiving the liquid metal emerging from the feeder volume over the aeration opening. The pool consists of a recess on the outer side of the covering area, where the recess is formed in the covering area of the feeder body. An edge surface of the covering area surrounding the recess has an inclined progression corresponding to the formation of a funnel aligned to the aeration opening. The recess of the covering area of the feeder body is formed during the production of the feeder insert. A holding element to be assigned to the casting mold and externally overlapping the feeder body is provided in the feeder arrangement and completely overlaps the covering area of the feeder body with a cover and with a rotating retaining lug only over a partial area, so that the edge surface of the retaining lug forms and surrounds the pool on the upper side of the covering area of the feeder body. The pool is arranged on the outer surface of the cover of the holding element and the cover of the holding element has a passage opening aligned to the aeration opening of the feeder body. The recess is formed in the cover at the outer side of the cover of the holding element.