Nested Plunger Injection Sleeve for Molten Metal Retention
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Solution Overview
Problem
The existing hot metal supply injection method faces challenges in handling low-viscosity molten metal, as it tends to spill out when the injection sleeve is oriented horizontally, making it difficult to utilize semi-molten metal with a high liquid-phase ratio effectively.
Innovation Solution
A method utilizing a cylindrical container with an annular outer plunger tip and an inner plunger tip, combined with a negative pressure generation device, which sucks molten metal from a retention furnace, retains it inside the container by closing the opening, and injects it into a mold cavity through a gate, preventing spilling regardless of the container's orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the injection sleeve is put down horizontally to facilitate handling, then the operation becomes easier, but the molten metal spills out from the end portion of the injection sleeve
Solution Approach 1:
The invention employs a nested structure where the inner plunger tip is positioned inside the outer plunger tip, and both are located within the injection sleeve. This nested arrangement allows the inner plunger tip to seal the opening of the injection sleeve when moved to the tip side, preventing metal spillage while maintaining the horizontal orientation for ease of operation.
Solution Approach 2:
The inner plunger tip acts as an intermediary element that seals the opening of the injection sleeve. By moving this intermediary component to close the opening, the system prevents spillage without requiring changes to the injection sleeve's orientation, thus resolving the contradiction between ease of operation and prevention of loss.
2Productivity
If the inner plunger tip moves to the rear end side to release negative pressure, then the molten metal can be injected, but the molten metal may spill out during the movement
Solution Approach 1:
The invention applies preliminary action by having the inner plunger tip move to the tip side of the injection sleeve before the outer plunger tip begins its injection movement. This preliminary sealing action ensures that the opening is closed prior to any movement that could cause spillage, allowing the outer plunger tip to move freely for high-speed injection without risking metal loss.
Solution Approach 2:
The system employs dynamic control where the inner plunger tip can change position independently to seal or open the injection sleeve opening. This dynamic adjustment allows the system to prevent spillage during the injection process while maintaining high productivity, as the sealing action is coordinated with the injection timing.
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 configuration ensures that molten metal is retained within the container and injected into the mold cavity without spilling, allowing for efficient filling and maintaining high metal quality, even with low casting pressure, thus improving the quality of cast products and reducing the need for additional components in the casting machine.
Implementation Method 1
a negative pressure generation device that generates a negative pressure in the cylindrical container
Implementation Method 2
generating a negative pressure in the cylindrical container by the negative pressure generation device, and causing the molten metal to be sucked into the cylindrical container
Data Source
AI summary
A hot metal supply injection method includes generating a negative pressure in a cylindrical container by a negative pressure generation device, and causing molten metal to be sucked into the cylindrical container from a retention furnace, while keeping an opening portion of the cylindrical container immersed in the molten metal, arranging the opening portion of the cylindrical container in a gate of a cavity while holding the negative pressure by closing up the opening portion of the cylindrical container after moving an inner plunger tip to a tip side of the cylindrical container, and moving the inner plunger tip to a rear end side of the cylindrical container, then moving an outer plunger tip, together with the inner plunger tip, to the tip side of the cylindrical container, and filling the interior of the cavity with the molten metal through injection via the gate.