Core assembly method for cylinder head castings

• US 6,435,259 B1
• Filed: 12/22/2000
• Issued: 08/20/2002
• Est. Priority Date: 12/22/2000
• Status: Expired due to Term

• Current Assignee: International Engine Intellectual Property Company, LLC (Volkswagen AG)
• Original Assignee: International Engine Intellectual Property Company, LLC (Volkswagen AG)
• Inventors: Werling, Joshua M., Baker, Stephen G.
• Primary Examiner(s): Elve, M. Alexandra
• Assistant Examiner(s): MCHENRY, KEVIN L
• Application Number:
  US09/748,792
• Publication Number:
  US 20020079079A1
• Time in Patent Office: 606 Days
• Field of Search: 164/137, 164/369, 164/228, 164/18, 164/24, 164/370, 164/232, 164/30
• US Class Current: 164/137
• CPC Class Codes: B22C 21/14 for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
• CPC Class Codes: B22C 9/10 Cores; Manufacture or installation of cores breaker cores B22C9/084
• CPC Class Codes: B22C 9/108 Installation of cores

Abstract

A method of fastening core elements together without the use of foreign agencies, such as adhesives, screws or other such fasteners, uses the same core sand and resin that form the core elements themselves. Core sand elements are retained in an assembly by bodies of cured core sand and resin in holes or cavities that span the interface between the core elements and fasten the core sand elements together. Core sand elements are provided with alignable holes, or cavities, into which a mixture of core sand and a curable resin, preferably the same resin used in forming the core sand elements, is added and the curable resin is cured to provide a body of cured core sand and resin, preferably adhering to the core sand elements, fastening the core sand elements together.

Claims

1. In a method of casting a cylinder head, the steps comprising

providing a frame core having at least one core supporting and positioning surface,

providing a one piece coolant jacket core having at least one core supporting and positioning surface,

positioning the one-piece coolant jacket core on the frame core by engaging the core supporting and positioning surface of said coolant jacket core with said frame core,

providing a one-piece exhaust core having a plurality of exhaust passage-forming portions extending transversely therefrom and at least one core supporting and positioning surface,

positioning the one-piece exhaust core on the assembled frame core and coolant jacket core by engaging its at least one core supporting and positioning surface with the assembled frame core and coolant jacket core,

providing an intake core having a plurality of intake passage-forming portions and at least one core supporting and positioning surface,

positioning the intake core on the assembled frame core, coolant jacket core, and exhaust core by engaging its at least one core supporting and positioning surface with the assembled frame core, coolant jacket core and exhaust core,

drilling a plurality of holes through the assembled cores,

adding a mixture of core sand and a curable resin therefor to the plurality of holes, and

curing said resin to retain the assembled cores in an integral assembly.

2. The method of claim 1, wherein the frame core, one-piece coolant core, one-piece exhaust core and intake core are formed with core sand and a cured resin and wherein the curable resin of the mixture added to the plurality of holes is the same resin as in the assembled cores.

3. In a method of assembly of at least two core sand elements for an internal combustion engine head casting assembly, the improvement comprising drilling a hole spanning an interface between the at least two core sand elements and retaining the at least two core sand elements in an assembly thereof by a body of cured core sand and resin spanning the interface between the at least two core sand elements.

4. In a method of assembly of an internal combustion engine head casting assembly comprising at least two core sand elements, the improvement comprising fastening the at least two core sand elements of the head casting assembly together by providing at least one cavity spanning the at least two core sand elements in the assembly by drilling into the at least two assembled core sand elements, inserting a mixture of core sand and a curable resin in the at least one cavity and curing the resin to provide at least one cured core sand/resin body fastening the at least two core sand elements together.

5. In a method of assembly of an internal combustion engine head casting assembly comprising at least two core sand elements, the improvement comprising fastening the at least two core sand elements of the head casting assembly together by providing at least one hole spanning the at least two core sand elements in the assembly by drilling hole portions through each of the at least two core sand elements with an expanded wall, the expanded walls of each of the at least two core sand elements expanding outwardly from the interface of the at least two core sand elements in the head core assembly, inserting a mixture of core sand and a curable rein in the at least one hole and curing the resin to provide at least one cured core sand/resin body fastening the at least two core sand elements together.

6. The method of claim 5 further comprising the step of placing a perforate holding plate over the at least one hole prior to inserting the mixture of core sand and a curable resin in the at least one cavity.

7. A method of assembling and retaining at least two core sand elements in an assembly for an internal combustion engine casting, comprising the steps of providing an alignable hole extending through each of the at least two core sand elements, aligning the holes in the at least two core sand elements, placing a perforate backing plate over the aligned holes of the at least two core sand elements, placing an uncured mixture of core sand and a curable resin in the aligned holes and curing the curable resin to retain at least two core sand elements in the assembly with the cured core sand and resin.