Core release spray application method and apparatus

Abstract

A method for forming a core includes the step of providing a corebox defining in a closed configuration thereof a closed internal core-forming cavity and providing at least one external opening through the corebox into said cavity in the closed configuration ( 902 ). A core release substance is applied through the opening directly onto at least one surface of the closed core-forming cavity with the corebox in the closed configuration ( 904 ). A forming material is added to the cavity ( 906 ) followed by an addition of a core bonding agent ( 908 ). A core that has formed in said closed core-forming cavity is allowed to dry and removed from the cavity ( 910 ).

1 . An apparatus comprising: 
 a corebox for forming a core for a cast component having a closed configuration and defining a closed internal cavity having at least one opening operatively connecting the cavity with an exterior surface of the corebox;    a spray head for dispensing a core release substance disposed in operative engagement with said opening;    wherein the spray head is disposed to spray the core release substance onto at least one internal surface of the internal cavity with the corebox in the closed configuration.    
   
   
       2 . The apparatus of  claim 1 , wherein the corebox includes at least two mold pieces, and wherein each of the at least two mold pieces are connected to each other to form said closed configuration.  
   
   
       3 . The apparatus of  claim 1 , wherein the internal cavity has a second opening, and wherein the spray head enters the second opening to spray an additional quantity of the core release substance.  
   
   
       4 . The apparatus of  claim 1 , wherein the at least one opening is a passage through which a core forming material is added to the corebox.  
   
   
       5 . The apparatus of  claim 1 , wherein the spray head has at least one spray nozzle attached thereon, and wherein the at least one spray nozzle has an orifice through which the core release substance is sprayed.  
   
   
       6 . The apparatus of  claim 1 , wherein the spray head has freedom of axial motion and freedom of rotation along three axes.  
   
   
       7 . The apparatus of  claim 1 , further comprising an electronic controller, wherein at least one of a motion and a rotation of the spray head is controlled by the electronic controller.  
   
   
       8 . The apparatus of  claim 1 , wherein the spray head is controlled manually by an operator.  
   
   
       9 . The apparatus of  claim 1 , further comprising a shuttle that is connectable to the core box, wherein the spray head is disposed on the shuttle.  
   
   
       10 . The apparatus of  claim 1  wherein the spray head is disposed during operation within the cavity through the opening to spray the core release substance therewithin.  
   
   
       11 . A method for forming a core, comprising the steps of: 
 providing a multipiece corebox defining in a closed configuration thereof a closed internal core-forming cavity and providing an external opening through the corebox into said cavity;    applying a core release substance through the opening directly onto at least one surface of the closed core-forming cavity with the corebox in the closed configuration;    adding a core forming material into said closed core-forming cavity;    adding a core bonding agent to said closed core-forming cavity; and    allowing a core that has formed in said closed core-forming cavity to dry and removing the core from the corebox.    
   
   
       12 . The method of  claim 11 , wherein the application step is accomplished by spraying the core release substance from a spray head that is inserted into said cavity through the opening.  
   
   
       13 . The method of  claim 11 , wherein the application step is accomplished by spraying the core release substance from a spray head that is connected onto said corebox at the opening.  
   
   
       14 . The method of  claim 12 , further comprising the step of cleaning residual core forming material from the corebox after the previously formed core has been removed.  
   
   
       15 . The method of  claim 11 , wherein the step of application of the core release substance is accomplished by accelerating the core release substance through at least one spray nozzle, wherein the at least one spray nozzle is disposed on the spray head.  
   
   
       16 . The method of  claim 11 , wherein the core forming material is sand.  
   
   
       17 . A method for forming a core for use in a casting operation, comprising the steps of: 
 connecting a tooling mold having a closed configuration defining a closed internal cavity and an opening from the closed internal cavity through the tooling mold to a first shuttle;    filling the closed internal cavity with sand through the opening;    connecting said tooling mold to a second shuttle and injecting said sand in said closed internal cavity with a bonding agent;    allowing said sand in said closed internal cavity to cure and form a casting core;    opening said tooling mold, ejecting, and removing said casting core from said tooling mold;    closing said tooling mold;    connecting said tooling mold to a third shuttle at said opening;    spraying said closed internal cavity with a core release substance through a spray head extending through the opening that is connected on the third shuttle; and    allowing core release substance to dry.    
   
   
       18 . The method of  claim 17 , further comprising the step of removing loose sand away from said tooling mold when said tooling mold is open and after said casting core has been removed.  
   
   
       19 . The method of  claim 17 , further comprising the step of disconnecting said third shuttle from said tooling mold and reconnecting said third shuttle to said tooling mold at a second opening.  
   
   
       20 . The method of  claim 17 , wherein said tooling mold includes a plurality of cavities, each connected to at least one of a plurality of corresponding openings.