Ford Global Technolgoies, LLC

Ford Motor Company Limited

Elaine Cecilia Beckwith

James Stewart Rankin, Ii

Warren Benjamin Copple

Thomas J Korniski

James S Rankin

Scott Raymond Zimdars

A method of making sand cores to obtain optimum mechanical properties and particularly to obtain accurate adjustment of the gas curing cycle for making optimum resin-coated sand cores. The method comprises blowing, into a core box cavity, mixture of core making particulated sand and gas curable liquid resin having a first level of pH, such mixture containing a uniform distribution of a pH indicating dye additive that changes color in response to a change in pH level, in contact therewith, such blowing being continued to fill the cavity to a desired density and form an uncured sand core shape with a predetermined porosity, (b) introducing a catalyst gas having a second level of pH, through the pores of the core shape to cure the resin and contact the dye additive, (c) concurrently, or subsequent to step (b), sensing the degree of color change of any part of the core shape that is or has taken place as a result of exposure to the flow front of the catalyst gas, and (d) responding to such color sensing to modify the parameters of catalyst gas introduction (i.e. exposure time, gas pressure, gas concentration or gas inlet/out location) to ensure the desired degree of catalyst reaction in the desired time period.

Method of making gas curable resin-coated sand cores

A resin coated sand is blown into a core box to form an uncured core with a desired packing density. The core box has one or more inlets to permit ingress of gases and one or more outlets to permit egress of only gases. A non-catalyzing gas is passed through the defined sand core in the core box to create a first effluent and the hydrocarbon content in such first effluent that was exposed to the uncured resin of the sand core is measured. A catalyst carrying gas (nitrogen) is injected into the inlets to pass through the defined sand core within the core box for polymerizing the resin and thence exit from the outlets as a second effluent. The hydrocarbon content of the second effluent is continuously measured (i.e. non-dispersive infrared spectroscopy system). When the hydrocarbon content decreases to approximately the hydrocarbon content of the first effluent, the core box is opened to remove the sand core in a consistently cured condition.

Method of making catalyst cured resin-coated sand cores

A closed core box is provided with one or more inlets for receiving and passing gas fluidized resin-coated sand to fill the interior of such core box, and with one or more screened outlets for allowing egress of such gas. A closed cylindrical or angular sand-fluidizing chamber is provided for each of the inlets, the chamber having one end connectable to a pressurized gas supply and an opposite end communicating with an inlet. At least part of each chamber is filled with resin-coated sand and a non-porous piston is placed on the sand within each chamber, each piston providing an annular gap (i.e. about 1/16 of an inch) with the interior of such chamber to direct the gas supply along the periphery of the chamber interior. The pressurized gas supply (40-80 psi) is connected to the chamber above the pistons whereby gas will move past each of the pistons to fluidize the sand therebelow in the chamber in a manner that continuously and toroidally recirculates the sand away from the periphery of the chamber while communicating with an inlet to the core box to promote smooth fluidized flow through such inlet, the piston moving down with the top level of the sand in the chamber as sand moves through the inlets.

Method of making sand cores

A molded workpiece is formed using a mold having an inner cavity, an injection port which communicates with the inner cavity for permitting molding material to be injected into the inner cavity, and at least one disposable vent line. The vent line has sidewalls which are substantially transparent to light and provides for venting gases from the inner cavity as molding material is injected into the cavity. A material injector is coupled to the injection port for injecting molding material into the inner cavity through the injection port. A removably sensor receives the disposable vent line for detecting when molding material has substantially filled the vent line and for generating a first signal indicating that the vent line is substantially filled. The sensor includes an infrared light emitting diode positioned adjacent to the vent line for radiating light toward the vent line, and a phototransistor for detecting light radiated through the transparent sidewalls of the vent line and for generating the first signal when no light is detected.

Growing community of inventors

Northville, MI, United States of America

Elaine Cecilia Beckwith