Multicore with Water-Soluble Inner Segment for Hollow Casting

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Solution Overview

Problem

Conventional methods for molding hollow products using cores, such as sand or salt cores, face challenges in completely removing the core material, which can lead to residual particles obstructing the hollow and causing system failures.

Innovation Solution

A multicore system comprising a water-insoluble first core with hollows and openings, and a water-soluble second core inside, surrounded by a coating layer, allowing for easy removal by fluid flow through connected spaces in the first core, enabling sequential dissolution and extraction of both cores.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single-material core (sand or salt) is used for molding hollow products, then the core can be easily broken by impact, but the broken pieces cannot be completely removed from the hollow, causing particle residue and system failure

Engineering Contradiction:

Improvecore breakingVSAvoidcore removal completeness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The core is divided into multiple segments with different material properties: an outer core made of water-insoluble material and an inner core made of water-soluble material. This segmentation allows the inner core to be selectively removed through dissolution while the outer core provides structural support during molding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Water acts as an intermediary substance that selectively dissolves the water-soluble inner core material without affecting the water-insoluble outer core material. This enables complete removal of the inner core through fluid injection without leaving particle residue.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If conventional impact breaking method is used to remove the core, then the core can be fragmented, but some areas of the core (especially bent or spiral portions) remain unbroken and block the hollow

Engineering Contradiction:

Improvecore removal efficiencyVSAvoidhollow clearance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The mechanical impact breaking method is replaced with a chemical dissolution process. Water is injected through the fluid injection hole to dissolve the water-soluble inner core material, eliminating the need for mechanical breaking and ensuring complete removal even from complex geometries.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Hydraulic injection is used to deliver water through the fluid injection hole located on the outer core. The pressurized water flows through the hollow and dissolves the inner core material, enabling efficient and complete core removal without mechanical impact.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Strength

If sand core is used for molding, then the core provides good structural support, but sand particles stick to the casting surface and cannot be completely removed

Engineering Contradiction:

Improvecore structural supportVSAvoidparticle residue on surface

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

Different regions of the core have different material properties: the outer core is made of water-insoluble material for structural support, while the inner core is made of water-soluble material for complete removal. This local differentiation eliminates particle residue on the casting surface.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The material property parameter (solubility in water) is changed for the inner core material, making it water-soluble. This parameter change enables the inner core to be completely dissolved and removed, preventing particle residue on the casting surface.

Inventive Principle:

Principle #35Parameter changes

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

Facilitates the easy removal of the core from the molded hollow product, preventing particle residue on the inner surface and ensuring complete core extraction, thus enhancing the quality of the molded product.

Implementation Method 1

a second core, being made of a water-soluble material and disposed inside the hollow

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

a coating layer, being configured to surround the first core to prevent at least a portion of the first core and the second core from being exposed to an outside

Methodology Applied

Scientific EffectPhysical barrier protection: Physical Containment

Implementation Method 3

the first core includes a plurality of spaces to allow a fluid supplied to an interior of the first core to flow toward the second core

Methodology Applied

Scientific EffectFluid flow through porous structure: Porosity

Data Source

PatentUS11607722B2Multicore and method of manufacturing hollow product using multicore

Publication Date: 2023.03.21 MH TECH INC

AI summary

Provided is a multicore. The multicore includes a first core, being made of a water-insoluble material, having a hollow formed in the first core and, having an opening formed at both ends of the first core and connected to the hollow, a second core, being made of a water-soluble material and disposed inside the hollow, and a coating layer, being configured to surround the first core to prevent at least a portion of the first core and the second core from being exposed to an outside. Further, the first core includes a plurality of spaces to allow a fluid supplied to an interior of the first core to flow toward the second core.