Sprue Sleeve Protuberances for Shrinkage Cavity Containment
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Solution Overview
Problem
Current sprue sleeves in metal foundry processes result in energy wastage due to the need for the sprue to be melted and discarded, while also requiring minimum dimensions to prevent shrinkage cavities from entering the non-sacrificial mould portion.
Innovation Solution
A sleeve for sprue with a smaller volume than conventional designs, featuring retaining walls made of refractory material and an inner volume that allows the entire shrinkage cavity to be contained within the non-sacrificial mould portion, thereby minimizing energy wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the sprue volume is reduced to minimize energy wastage, then energy efficiency improves, but the shrinkage cavity may enter the non-sacrificial mould portion
Solution Approach 1:
The invention introduces a vertical dimension to the sprue design by adding a raised portion that extends upward from the horizontal sprue. This vertical extension provides additional volume for shrinkage cavity formation without increasing the horizontal footprint, thereby containing the cavity within the sacrificial portion while maintaining compact overall dimensions and reducing energy wastage.
Solution Approach 2:
The sprue is segmented into two distinct portions: a horizontal portion that connects to the mould cavity and a raised vertical portion that serves as the primary shrinkage cavity receptacle. This segmentation allows the shrinkage cavity to form preferentially in the raised portion due to its elevated position and geometry, preventing cavity intrusion into the non-sacrificial mould portion while minimizing the total sprue volume.
2Loss of energy
If the sprue volume is minimized, then energy wastage decreases, but the sprue may not provide sufficient volume to accommodate the shrinkage cavity
Solution Approach 1:
The raised vertical portion adds volumetric capacity in the vertical dimension without proportionally increasing the horizontal dimensions. This allows the sprue to accommodate the required shrinkage cavity volume while maintaining a compact overall size, thereby reducing the quantity of metal required in the sprue and minimizing energy wastage associated with melting and discarding excess metal.
3Reliability
If the sprue has larger dimensions to contain the shrinkage cavity, then reliability improves, but energy wastage increases
Solution Approach 1:
By utilizing the vertical dimension through the raised portion, the invention provides adequate volume for shrinkage cavity containment without proportionally increasing the overall sprue dimensions. The vertical extension offers an efficient space utilization strategy that contains the cavity reliably while minimizing the total metal volume that requires melting and subsequent disposal, thereby reducing energy wastage.
Solution Approach 2:
The raised portion is configured with a curved upper surface that transitions smoothly from the horizontal sprue. This curved geometry efficiently distributes and contains the shrinkage cavity within the raised portion, providing reliable cavity containment with optimized volume utilization, thereby avoiding the need for larger dimensional sprues that would increase energy wastage.
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
The proposed sleeve design maintains the liquid metal at a higher temperature for a longer period, reducing energy wastage and allowing the entire shrinkage cavity to be contained within the non-sacrificial mould portion, thus improving the efficiency of the metal casting process.
Implementation Method 1
retaining walls (2), preferably made of refractory material
Implementation Method 2
when metal solidifies from a liquid state
Implementation Method 3
it includes shrinkage volumes or cavities that do not allow the metal to maintain the same shape
Data Source
Figure 1~2
Figure 3~4
AI summary
It is provided a sleeve for sprue (1) comprising: retaining walls (2), an internal volume (3) defined by the retaining walls (2), the retaining walls (2) defining a connection portion (20) with a main mould (100) and a main portion (21), the main portion (21) defining a portion of internal volume (3) having a substantially tubular shape defining a central axis (21a), the retaining walls (2) in the main portion (21): define an outer wall (22) defining a first mean diameter d, comprise protuberances (23) protruding from said outer wall (22) towards the interior of the internal volume (3), the protuberances (2b) protrude by a value between 0.1 d and 0.5 d and extend predominantly in the axial direction (21a).