Laminated Sand Mold Curing via Aqueous Medium Spraying
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Solution Overview
Problem
Existing methods for forming sand molds through laminating processes face issues such as odor generation, internal stress, and nozzle clogging due to high energy requirements and the use of high-viscosity binders, which complicate the production process and maintenance.
Innovation Solution
A multilayer molding method using coated sand with a water-soluble binder, where an aqueous medium is sprayed and heated to cure the sand layers, reducing thermal energy needs and preventing nozzle clogging by using water as the medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shell sand is cured by heating with laser beam irradiation, then the sand layer can be cured and adhered to the base, but odor is generated by incineration of organic substance during heating
Solution Approach 1:
The invention changes the curing method from high-temperature laser heating to low-temperature aqueous medium treatment. The aqueous medium penetrates the sand layer and cures the binder at lower temperatures, preventing organic substance incineration and odor generation while achieving effective sand layer curing and adhesion.
2Reliability
If high power laser irradiation is used to heat and cure the sand layer, then the sand layer can be cured, but an expensive device is required and an extremely large amount of energy is consumed
Solution Approach 1:
The invention replaces the mechanical/thermal laser heating system with a chemical aqueous medium treatment system. The aqueous medium chemically cures the binder through penetration and reaction, eliminating the need for high-power laser equipment and dramatically reducing energy consumption while achieving reliable sand layer curing.
3Strength
If liquid binder with high viscosity is sprayed to bond sand grains, then the sand grains can be bonded, but the nozzle clogs after long period of use
Solution Approach 1:
The invention changes the binder delivery system from direct high-viscosity liquid binder spraying to aqueous medium spraying. The aqueous medium has low viscosity and prevents nozzle clogging, while still achieving effective sand grain bonding by penetrating the sand layer and enabling binder curing through the water-soluble binder mechanism.
4Reliability
If difference in temperature is generated between irradiated and non-irradiated parts of sand layers, then laser curing is achieved, but internal stress is generated requiring secondary firing
Solution Approach 1:
The invention changes the curing temperature parameters from high-temperature localized laser heating to low-temperature uniform aqueous medium treatment. The aqueous medium penetrates and cures the binder uniformly throughout the sand layer at low temperatures, preventing thermal gradients and internal stress generation while achieving reliable curing without secondary firing.
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 method effectively reduces odor generation, eliminates the need for secondary firing, and prevents nozzle clogging, enabling simpler and more efficient mass production of casting molds with improved energy efficiency.
Implementation Method 1
a water-soluble binder is used as a binding agent, wherein an aqueous medium is sprayed over parts of the successive sand layers corresponding to the plane shapes of the respective mold layers
Implementation Method 2
an aqueous medium is sprayed and heated to cure the sand layers, reducing thermal energy needs
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
A multilayer molding method for forming a casting mold, which makes it possible to produce the casting mold by using a relatively simple production device, while effectively preventing generation of an odor, without occurrence of clogging of a nozzle even after a long period of its use. A coated sand obtained by coating a refractory aggregate with a water-soluble binder is supplied onto a table disposed within a frame, and spread by a spreading member to form a thin sand layer having a predetermined thickness and a planar surface. The surface of the sand layer is covered by a mask, and an aqueous medium is sprayed from a sprayer over a part of the sand layer to be cured. By heating the part of the sand layer over which the aqueous medium has been sprayed, by using a heater, a mold layer having an intended shape is solidified or cured. By repeating the above-described steps for forming the mold layer a required number of times, the mold layers are successively formed and superposed on each other, whereby a laminar casting mold having an intended three-dimensional configuration is obtained as a one-piece body consisting of the mold layers.