System and method for making tilted cast supports for fuel cells

Abstract

A system and method for making an aluminum fuel cell support is provided. The method includes providing a negative foundry mold having a cavity to form the support, and includes providing a feed mechanism disposed about the mold and in fluid communication with the cavity thereof. The feed mechanism includes a plurality of main risers connected to and in fluid communication with the cavity. The method further includes melting a first metallic material to define a molten metallic material, and includes moving the mold about an axis of rotation to a vertical casting orientation while feeding the molten metallic material through the runners to the cavity. The method further includes cooling the molten metallic material to define a solidified metallic material. A second solidification time in the risers is greater than a first solidification time in the mold, such that a shrinkage of the solidified metallic material occurs away from the mold in the risers.

Description

Technical Field

[0001] This disclosure relates to cast aluminum tilted casting fuel cell supports, and more specifically, to a system and method for fabricating tilted casting fuel cell supports that compensate for shrinkage during the casting process. Background Technology

[0002] Fuel cell mounts are used to hold the fuel cell in place when it is installed in a vehicle. Many fuel cell mounts are cast and molded from a metallic material, such as metal or metal alloy. During the curing process of the metallic material, the mold may experience undesirable shrinkage. Summary of the Invention

[0003] Therefore, although current systems and methods for fabricating fuel cell supports have achieved their intended purpose, there is still a need for a new and improved system and method for fabricating cast aluminum tilted casting fuel cell supports for vehicle fuel cells.

[0004] According to one aspect of this disclosure, a method for fabricating a cast aluminum tilted fuel cell support for a fuel cell is disclosed. The method includes providing a cavity-based negative casting mold to form the support. The support includes a plurality of support legs interconnected to define a frame having a first side and a second side for supporting the fuel cell. In this aspect, the frame has horizontal and vertical casting orientations for casting the support. Each support leg has a peripheral edge surrounding it. Furthermore, each support leg has a first outer ridge and a second outer ridge formed on the peripheral edge with a vertical casting orientation relative to the second side of the frame. Additionally, each of the outer ridges extends along the second side therefrom. Furthermore, at least one support leg has an inner ridge formed away from the peripheral edge and extends transversely across it on the second side.

[0005] In this respect, the support also includes a plurality of peripheral bosses formed on the second side of the frame for structural attachment. Each peripheral boss has a boss diameter. Moreover, each peripheral boss is formed on one of the support legs and abuts one of the first outer ridge and inner ridge.

[0006] The support also includes multiple main ribs arranged on the second side of the frame to achieve structural integrity. Each main rib is arranged adjacent to a peripheral boss and extends vertically upward relative to the vertical casting orientation defining the riser contact area to the first outer ridge. Moreover, the width of each main rib is at least 70% of the boss diameter, and each main rib extends from the peripheral boss with a draft angle of at least 3° relative to the peripheral boss.

[0007] The method further includes providing a feeding mechanism arranged around and in fluid communication with the cavity of the mold. The feeding mechanism includes a runner arranged around and in fluid communication with the mold. The feeding mechanism also includes a plurality of ingates in fluid communication with the runner and the cavity of the mold. Furthermore, each ingate has a first side connected to the runner and extends to a second side connected to the mold.

[0008] The feeding mechanism also includes multiple main risers connected to and in fluid communication with the cavity of the casting mold. Each main riser is connected to the first outer edge of a support leg at one point in the riser contact area and is adjacent to a peripheral boss. Moreover, each main riser is vertically positioned above a peripheral boss relative to the vertical casting orientation of the frame.

[0009] The method further includes: melting a first metallic material at a predetermined temperature to confine the molten metallic material. The method also includes: moving the casting mold and feeding mechanism from a horizontal casting orientation to a vertical casting orientation about a rotation axis, while simultaneously feeding the molten metallic material into the cavity of the casting mold through a runner.

[0010] The method further includes: cooling molten metal material in a casting mold during a first curing time, and cooling molten metal material in multiple risers during a second curing time to define risers having the dimensions of a cast aluminum fuel cell support and the cured metal material in the casting mold. The second curing time is longer than the first curing time, thereby causing the cured metal material in the risers farther from the casting mold to shrink. The method further includes: separating the cured metal material from the anodized casting mold to define the cast aluminum tilted casting fuel cell support.

[0011] In one example of this aspect, each main riser has a height at least twice the diameter of the boss. In another example, each main riser has a width greater than the diameter of the boss. In yet another example, at least one second boss is arranged adjacent to a peripheral boss on the second side of the frame and is positioned downwards from the peripheral boss relative to the vertical casting orientation. Each second boss has a boss diameter.

[0012] In one example, the bracket further includes a second rib disposed on a second side of the frame. In this example, the second rib is disposed adjacent to the second boss and extends vertically upward relative to the vertical casting orientation to the peripheral boss. In another example, the second rib has a width of at least 70% of the boss diameter and extends from the second boss with a draft angle of at least 3° relative to the second boss.

[0013] In one example, at least one support leg is positioned vertically relative to the vertical casting orientation defining the second leg. Furthermore, the feeding mechanism includes a side riser disposed to the second leg of the casting mold and in fluid communication with the second leg of the casting mold at a corresponding riser contact area. In this example, the side riser is configured to have a connector through which molten metal material flows. The connector has a neck in fluid communication with at least one molding cavity. The connector has an open end configured to extend to at least one molding cavity at the riser contact area, the riser contact area defining a riser connection angle of at least 45° relative to the horizontal plane.

[0014] In one example, the first metallic material comprises: 7.0 wt% silicon (Si), 0.4 wt% magnesium (Mg), 0.14 wt% iron (Fe), and the balance being aluminum (Al).

[0015] According to another aspect of this disclosure, a system is provided for fabricating a cast aluminum tilted-cast fuel cell support for a fuel cell. The system includes a molding unit configured to form a negative casting mold for the cast aluminum tilted-cast fuel cell support. The mold includes at least one molding cavity having a pattern with the dimensions of the cast aluminum support.

[0016] The support includes multiple support legs interconnected to define a frame for supporting a fuel cell, having a first side and a second side. The frame has horizontal and vertical casting orientations for casting the support. Each support leg has a peripheral edge surrounding it. Furthermore, each support leg has a first and a second outer ridge formed on the peripheral edge relative to the vertical casting orientation on the second side of the frame. In this respect, each of the outer ridges extends along the second side. Additionally, at least one support leg has an inner ridge formed away from the peripheral edge and extends across it on the second side.

[0017] The support also includes multiple peripheral bosses formed on the second side of the frame for structural attachment. Each peripheral boss has a boss diameter. Furthermore, each peripheral boss is formed on one of the support legs and abuts one of the first outer ridge and inner ridge.

[0018] The support also includes multiple main ribs arranged on the second side of the frame to achieve structural integrity. Each main rib is arranged adjacent to a peripheral boss and extends vertically upward relative to the vertical casting orientation defining the riser contact area to a first outer ridge. In this respect, the width of each main rib is at least 70% of the boss diameter, and each main rib extends from the peripheral boss with a draft angle of at least 3° relative to the peripheral boss.

[0019] The system also includes a feeding mechanism arranged around and in fluid communication with the mold cavity. In this aspect, the feeding mechanism includes a runner arranged around and in fluid communication with the mold cavity; and includes a plurality of ingates in fluid communication with the runner and the mold cavity. Each ingate has a first side connected to the runner, the first side extending to a second side connected to the mold cavity.

[0020] In this respect, the feeding mechanism also includes: multiple main risers connected to and in fluid communication with the cavity of the casting mold. Each main riser is connected at one point in the riser contact area to the first outer edge of a support leg and is disposed adjacent to a peripheral boss. Moreover, each main riser is vertically disposed above a peripheral boss relative to the vertical casting orientation of the frame.

[0021] The system also includes a furnace configured to melt a first metallic material at a predetermined temperature to confine the molten metallic material. The system further includes a tilting device movably connected to the casting mold and the feeding mechanism. The tilting device is configured to move the casting mold and the feeding mechanism from a horizontal casting orientation to a vertical casting orientation about a rotation axis, while simultaneously feeding the molten metallic material into the cavity of the casting mold through a flow channel.

[0022] The system also includes a cooling zone configured to solidify molten metal material in the mold during a first solidification time and molten metal material in multiple risers during a second solidification time, thereby defining the risers having the dimensions of a cast aluminum fuel cell support and the solidified metal material in the mold. The second solidification time is longer than the first solidification time, causing shrinkage of the solidified metal material in the risers farther from the mold.

[0023] The system also includes a separation unit configured to separate the solidified metal material from the anodized mold to define the cast aluminum tilted fuel cell support.

[0024] The system also includes a controller, which is connected to the molding unit, furnace, feeding mechanism, tilting device, and separating unit. The controller is configured to control the molding unit, furnace, feeding mechanism, tilting device, and separating unit.

[0025] The system also includes a power supply, which is configured to power the molding unit, furnace, feeding mechanism, tilting device, separation unit and controller.

[0026] In one embodiment, each main riser has a height at least twice the diameter of the boss. In another embodiment, each main riser has a width greater than the diameter of the boss.

[0027] In one embodiment, the bracket further includes at least one second boss disposed adjacent to a peripheral boss on a second side of the frame and disposed downward from the peripheral boss relative to a vertical casting orientation. Each second boss has a boss diameter. In one example of this embodiment, the bracket further includes a second rib disposed on the second side of the frame. The second rib is disposed adjacent to the second boss and extends vertically upward to the peripheral boss relative to a vertical casting orientation. In one example, the second rib has a width of at least 70% of the boss diameter and extends from the second boss with a draft angle of at least 3° relative to the second boss.

[0028] In one embodiment, at least one support leg is positioned vertically relative to the vertical casting orientation defining the second leg. In this embodiment, the feeding mechanism further includes a side riser disposed to the second leg of the casting mold and in fluid communication with the second leg of the casting mold at a corresponding riser contact area. The side riser is configured to have a connector through which molten metal material flows. The connector has a neck in fluid communication with at least one molding cavity. Furthermore, the connector has an open end configured to extend to at least one molding cavity at the riser contact area, the riser contact area defining a riser connection angle of at least 45° relative to the horizontal plane.

[0029] In another embodiment, the first metallic material comprises: 7.0 wt% silicon (Si), 0.4 wt% magnesium (Mg), 0.14 wt% iron (Fe), and the balance being aluminum (Al).

[0030] According to another aspect of this disclosure, a cast aluminum inclined fuel cell support is provided for a fuel cell. The support includes a plurality of support legs interconnected to define a frame having a first side and a second side for supporting the fuel cell. The frame has horizontal and vertical casting orientations for casting the support. Each support leg has a peripheral edge surrounding it. Moreover, each support leg has a first outer ridge and a second outer ridge formed on the peripheral edge relative to the vertical casting orientation on the second side of the frame. Furthermore, each of the outer ridges extends along the second side therefrom. At least one support leg has an inner ridge formed away from the peripheral edge and extends across it on the second side.

[0031] The support also includes multiple peripheral bosses formed on the second side of the frame for structural attachment. Each peripheral boss has a boss diameter. Furthermore, each peripheral boss is formed on one of the support legs and abuts one of the first outer ridge and inner ridge.

[0032] The support also includes multiple main ribs arranged on the second side of the frame to achieve structural integrity. Each main rib is arranged adjacent to a peripheral boss and extends vertically upward relative to the vertical casting orientation defining the riser contact area to the first outer ridge. Moreover, the width of each main rib is at least 70% of the boss diameter, and each main rib extends from the peripheral boss with a draft angle of at least 3° relative to the peripheral boss.

[0033] In one embodiment, the bracket further includes at least one second boss arranged adjacent to a peripheral boss on a second side of the frame and disposed downward from the peripheral boss relative to the vertical casting orientation. Each second boss has a boss diameter.

[0034] In another embodiment, the support further includes a second rib disposed on a second side of the frame. The second rib is disposed adjacent to the second boss and extends vertically upward relative to the vertical casting orientation to the peripheral boss.

[0035] In yet another embodiment, the second rib has a width of at least 70% of the boss diameter and extends from the second boss with a draft angle of at least 3° relative to the second boss.

[0036] Further applicability will become apparent from the description provided herein. It should be understood that the specification and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0037] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0038] Figure 1 This is a schematic diagram of a system for fabricating a cast aluminum inclined casting fuel cell support according to an embodiment of the present disclosure.

[0039] Figure 2A According to one embodiment Figure 1 Front view of the mold for the feeding mechanism and fuel cell support of the central system.

[0040] Figure 2B for Figure 2A Rear view of the feeding mechanism and the casting mold.

[0041] Figure 2C for Figure 2A and Figure 2B A front view of a cast aluminum inclined casting fuel cell support made by a casting mold.

[0042] Figure 3 for Figure 2B Enlarged view of the feeding mechanism and the casting mold in circle 3.

[0043] Figure 4 for Figure 2B Enlarged view of the feeding mechanism and the casting mold in circle 4.

[0044] Figure 5 for Figure 2B Enlarged view of the feeding mechanism and the casting mold in circle 5.

[0045] Figure 6 for Figure 2B Enlarged view of the feeding mechanism and the casting mold in circle 6.

[0046] Figure 7 This is a partial side view of the feeding mechanism and the casting mold according to another embodiment of the present invention.

[0047] Figure 8 for Figure 2B Enlarged view of the feeding mechanism and the casting mold in circle 8.

[0048] Figure 9 This is a flowchart illustrating a method for fabricating a cast aluminum tilted fuel cell support according to an example of this disclosure. Detailed Implementation

[0049] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses.

[0050] This disclosure provides a system and method for manufacturing an enhanced cast aluminum tilt-cast fuel cell support for a vehicle, wherein the support has high elasticity and high strength. The system and method provide a way to compensate for the shrinkage of the cast aluminum in the mold during solidification in the support casting process. Therefore, metal shrinkage occurs in the mold away from the overflow riser.

[0051] Figure 1 A system 10 for manufacturing a low-porosity cast aluminum inclined cast fuel cell support for a vehicle is shown according to one embodiment of the present disclosure. As shown, system 10 includes a molding unit 12 configured to have a cast aluminum inclined cast fuel cell support 100 ( Figure 2C ) casting mold 30 ( Figure 2A and Figure 2B The casting mold 30 includes at least one molding cavity, preferably multiple molding cavities, having one or more patterns to define the dimensions of the cast aluminum inclined casting fuel cell support. In one example, the casting mold 30 has a pattern made of wet sand or chemically bonded sand. A core assembly is then arranged within the casting mold 30 to further define the dimensions or structure of the pattern. It should be understood that the casting mold 30 can be made by any other suitable means without departing from the spirit or scope of this disclosure.

[0052] refer to Figure 1-2B The size of the casting mold 30 defines a support frame, which includes a plurality of support legs 32 interconnected to define a frame 34 having a first side 36 and a second side 38 for supporting the fuel cell. In this embodiment, the first side 36 ( Figure 2A ) is the front side of frame 34, and the second side 38 ( Figure 2B ( ) is the rear side of frame 34. As shown in the figure, the rear side of frame 34 includes a waffle structure, which will be described in more detail below.

[0053] Frame 34 has horizontal and vertical casting orientations for casting supports. Figure 2A and Figure 2B In the image, frame 34 is shown along a vertical plane in a vertical casting orientation. In one embodiment, the vertical plane defines the front cut half and the rear lower half of the mold. Figure 2A and Figure 2B As shown, frame 34 has a rotation axis X. In the method of manufacturing the support, frame 34 can move, tilt or rotate about the rotation axis X (as discussed below).

[0054] refer to Figure 2B Each support leg 32 has a peripheral edge 40 formed around it. Furthermore, each support leg 32 has a first outer ridge 42 and a second outer ridge 44 formed on the peripheral edge 40 of the second side 38 of the frame 34. In this embodiment, each of the outer ridges extends along the second side 38. Additionally, at least one support leg 32 has an inner ridge 46 formed away from the peripheral edge 40 and extends across it on the second side 38. As shown, the inner ridge 46 may be formed perpendicular to or parallel to one of the outer ridges. As shown, at least one support leg 32 is positioned relative to the defining second leg 48 (…). Figure 7 The vertical position of the vertical casting orientation.

[0055] like Figure 2B As shown, the support also includes a plurality of peripheral bosses 50 formed on the second side 38 of the frame 34 for structural attachment. Each peripheral boss 50 has a boss diameter. Moreover, each peripheral boss 50 is formed on one of the support legs 32 and abuts one of the first outer ridge 42 and inner ridge 46.

[0056] The support also includes a plurality of main ribs 52 arranged on the second side 38 of the frame 34 to achieve structural integrity. Each main rib 52 is arranged adjacent to a peripheral boss 50 and extends vertically upward relative to the vertical casting orientation defining the riser contact area 54 to the first outer ridge 42. In this respect, the width of each main rib 52 is at least 70% of the boss diameter.

[0057] Furthermore, each main rib 52 extends from the peripheral boss 50 to the first outer ridge 42 relative to the first rib side 62 defining its first plane 64 with a first draft angle 60 (e.g., at least 3°). Additionally, each main rib 52 extends from the peripheral boss 50 to the first outer ridge 42 relative to the second rib side 68 defining its second plane 69 with a second draft angle 66 (e.g., at least 3°). In this embodiment, the first draft angle 60 is at least 3° relative to the first plane 64, and the second draft angle 66 is at least 3° relative to the second plane 69.

[0058] refer to Figure 2B and Figure 6-7 The bracket also includes at least one second boss 70, which is arranged adjacent to a peripheral boss 50 on the second side 38 of the frame 34. As shown, at least one second boss 70 is disposed downward from a peripheral boss 50 relative to a vertical casting orientation. Each second boss 70 has a boss diameter. Figure 2B and Figure 7 As shown, the bracket also includes a second rib disposed on the second side 38 of the frame 34. The second rib is disposed adjacent to the second boss 70 and extends vertically upward relative to the vertical casting orientation to the peripheral boss 50. In one example, the width of the second rib is at least 70% of the boss diameter.

[0059] Furthermore, each second rib extends from the second boss 70 to the peripheral boss 50 relative to the third side 75 defining its third plane 76 with a third draft angle 74 (e.g., at least 3°). Additionally, each second rib extends from the second boss 70 to the peripheral boss 50 relative to the fourth side 78 defining its fourth plane 79 with a fourth draft angle 77 (e.g., at least 3°). In this embodiment, the third draft angle 74 is at least 3° relative to the third plane 76, and the fourth draft angle 77 is at least 3° relative to the fourth plane 79.

[0060] refer to Figure 1 and Figure 2BThe system 10 also includes a feeding mechanism 14 configured to feed molten metal material into at least one cavity of a casting mold 30 that defines the dimensions of the support to be cast. In this embodiment, the feeding mechanism 14 is arranged around the casting mold 30 and in fluid communication with its cavities. In one example, the feeding mechanism 14 includes a ladle (not shown), a runner (not shown), a filter (not shown) in fluid communication with the runner, and a flow channel 80 in fluid communication with the runner and the casting mold 30. As shown, the flow channel is arranged around the casting mold 30. In this example, the ladle contains molten metal material (e.g., aluminum alloy) for pouring the molten metal material into the runner with the filter to remove oxygen from the molten metal material. As described above, the runner is in fluid communication with the flow channel (here, a dual flow channel with a first wing and a second wing), and the molten metal material flows from the filter through the flow channel.

[0061] like Figure 2B and Figure 3 As shown, the feeding mechanism 14 also includes a plurality of ingates 82 which are in fluid communication with the runner and the cavity of the mold 30. Each ingate 82 has a first ingate side 84 which is connected to and in fluid communication with the runner 80. The first ingate side 84 extends to a second ingate side 86 which is connected to and in fluid communication with the mold 30.

[0062] refer to Figure 2B and Figure 4-6 The feeding mechanism 14 also includes a plurality of main risers 90 connected to and in fluid communication with the cavity of the casting mold 30. Each main riser 90 is connected at one of the riser contact areas 54 to the first outer edge of a support leg 32. Furthermore, each main riser 90 is disposed adjacent to a peripheral boss 50. Additionally, each main riser 90 is vertically disposed above a peripheral boss 50 relative to the vertical casting orientation of the frame 34. Preferably, each main riser 90 has a height H (relative to the vertical orientation) at least twice the diameter of the boss. Additionally, each main riser 90 has, preferably, a width greater than the diameter of the boss.

[0063] like Figure 2B and Figure 8 As shown, the feeding mechanism 14 also includes a side riser 92 disposed to the second leg 48 of the casting mold 30 and in fluid communication with the second leg 48 of the casting mold 30 at a corresponding riser contact area 54. The side riser 92 is configured to have a connector 94 through which molten metal material flows. The connector 94 has a neck 96 in fluid communication with at least one molding cavity. Moreover, the neck 96 has an open end 98 configured to extend at the riser contact area 54 to at least one molding cavity, the riser contact area 54 defining a riser connection angle of at least 45° relative to the horizontal plane.

[0064] As shown in the figure, the horizontal plane can be defined relative to the vertical casting orientation of frame 34. Therefore, the riser connection angle can be defined by the wall and the horizontal plane of neck 96, as... Figure 8 As shown. Therefore, each riser of the feeding mechanism 14 is configured to accommodate the overflow of molten metal material from the casting mold 30 at its respective riser connection angle, thereby enabling contraction to occur in the riser away from the casting mold 30.

[0065] Refer again Figure 1 System 10 also includes a furnace 16 configured to melt a first metallic material at a predetermined temperature to define the molten metallic material. In one example, the temperature of furnace 16 may be between 650°C and 900°C. In one embodiment, furnace 16 may be filled with aluminum. Without departing from the spirit or scope of this disclosure, furnace 16 may be an electric arc furnace, an induction furnace, or any other suitable furnace. Moreover, the first metallic material may include: 7.0 wt% silicon (Si), 0.4 wt% magnesium (Mg), 0.14 wt% iron (Fe), and the balance being aluminum (Al).

[0066] like Figure 1 As shown, system 10 also includes a tilting device 18 movably connected to the casting mold 30 and the feeding mechanism 14. The tilting device 18 is configured to move the casting mold 30 and the feeding mechanism 14 from a horizontal casting orientation to a vertical casting orientation about a rotation axis, while simultaneously feeding molten metal material into the cavity of the casting mold 30 through a flow channel. The tilting device 18 is configured to control the speed, for example, 2° per second. o / sec), causing the casting mold 30 and the feeding mechanism 14 to move or tilt. It should be understood that, without departing from the spirit or scope of this disclosure, the controlled speed can be between 1... o / sec and 10 o Between / sec, it can be 1 o / sec、2 o / sec, 4 o / sec、6 o / sec、8 o / sec or any other suitable control speed. The tilting device 18 may have a clamp, base, or rod mechanism attached to the frame 34 and the casting mold 30. Such a mechanism may have a motor configured to rotate the frame 34 and the casting mold 30 about a rotation axis at a controlled speed.

[0067] Then, the casting mold 30 is sealed or gated with chemically bonded sand. Subsequently, the molten metal material can be cooled to a set temperature, for example, about 450°C, in a designated cooling zone (discussed below) within the casting mold 30 and the riser to solidify the molten metal material in the multiple molding cavities of the casting mold 30, thereby forming the target part with the support dimensions. Preferably, the support is made of an aluminum alloy comprising the components discussed above.

[0068] refer to Figure 1 System 10 further includes a cooling zone 20 configured to solidify molten metal material in the mold 30 during a first solidification time and molten metal material in a plurality of risers during a second solidification time, thereby defining risers having the dimensions of a cast aluminum fuel cell support and solidified metal material in the mold 30. It should be understood that the second solidification time is longer than the first solidification time, resulting in shrinkage of the solidified metal material in the risers farther from the mold 30. That is, during the solidification of the molten metal material, shrinkage is compensated for by shrinkage occurring on the respective risers farther from the mold 30. This compensation is partly caused by riser geometry (e.g., riser height), rib geometry (e.g., rib width), and riser connection angles of the side risers 92 (e.g., 45°).

[0069] In one example, the first metallic material of the support is preferably made of an aluminum alloy, such as A356. In another example, the cured metallic material has a Young's modulus or elastic modulus (E) of approximately 75 GPa. Preferably, the ultimate tensile strength (UTS) of the cured metallic material is approximately 310 MPa, the yield strength (YS) is greater than 250 MPa, and the elongation (EL) is between 5% and 12%. Moreover, the porosity of the cured metallic material is preferably less than 10%.

[0070] refer to Figure 1 System 10 also includes a separation unit 22 configured to separate the solidified metal material from the casting mold 30 to define a cast aluminum tilted fuel cell support. In one embodiment, the separation unit 22 is configured to desand or remove the casting mold 30, which includes chemically bonded sand, from the target component. To achieve removal of the casting mold 30 from the target component, an automated unit can be used to break the mold and obtain the target component therefrom. For example, a vibrating unit or table with a bottom-catching screen for receiving mold particles from the mold can be used. It should be understood that any other suitable method can be used to break the mold without departing from the spirit or scope of this disclosure.

[0071] In this embodiment, the separation unit 22 is further configured to remove the gate of the target component after removing the mold 30 from the target component. As is known in the art, removing the gate of the target component may involve removing a portion of the adhesive sand used to fill the mold 30 during casting and gate filling.

[0072] In one embodiment, the separation unit 22 is further configured to clean the target part after gate removal. In one example, a shot blasting machine can be used to apply or fire beads (e.g., metal beads) onto the surface of the target part. To meet alloy design expectations, the separation unit 22 may also include an inspection area where the mechanical dimensions, mechanical properties, chemical composition, and microstructure of the target part are inspected. In one example, a computerized system, such as a coordinate measuring machine (CMM), can be used to measure the mechanical dimensions of the target part, thereby defining the support 100, such as... Figure 2C As shown. Without departing from the spirit or scope of this disclosure, any suitable method and apparatus may be used to evaluate the size, mechanical properties, chemical composition and microstructure of the stent.

[0073] like Figure 1 As shown, system 10 also includes at least one controller 24, which is connected to molding unit 12, furnace 16, feeding mechanism 14, tilting device 18, and separation unit 22. Controller 24 is configured to control molding unit 12, furnace 16, feeding mechanism 14, tilting device 18, and separation unit 22. System 10 also includes a power supply 26, which is configured to supply power to molding unit 12, furnace 16, feeding mechanism 14, tilting device 18, separation unit 22, and controller 24.

[0074] Figure 9 A method 110 for manufacturing a low-porosity cast aluminum tilted fuel cell support for a vehicle is shown according to an example of this disclosure. In this example, it can be manufactured by... Figure 1 System 10 implements method 110. Method 110 includes: providing a casting mold 30 with cavities in a housing 112 to form a support. The casting mold 30 includes at least one molding cavity, preferably multiple molding cavities, to define a cast aluminum tilt-cast fuel cell support. The casting mold 30 includes a pattern with dimensions of the cast aluminum support. In one example, the casting mold 30 has a pattern made of wet sand or chemically bonded sand. A core assembly is then arranged within the casting mold 30 to further define the size or structure of the pattern. It should be understood that the casting mold 30 can be made by any other suitable means without departing from the spirit or scope of this disclosure.

[0075] As discussed above and as... Figure 2A-2CAs shown, the support includes a plurality of support legs 32, which are interconnected to define a frame 34 having a first side 36 and a second side 38 for supporting the fuel cell. As described above, the first side 36 is the front side of the frame 34, and the second side 38 is the rear side of the frame 34. Moreover, the rear side of the frame 34 includes a waffle structure, as will be described in more detail below.

[0076] Frame 34 has horizontal and vertical casting orientations for casting supports. Figure 2A and Figure 2B In the diagram, frame 34 is shown along a vertical plane in a vertical casting orientation. In one embodiment, the vertical plane defines the front cut half and the rear lower half of the support. As discussed above, frame 34 has an axis of rotation, and in the method of manufacturing the support, frame 34 can move, tilt, or rotate about the axis of rotation.

[0077] like Figure 2B As shown, each support leg 32 has a peripheral edge 40 formed around it. Furthermore, each support leg 32 has a first outer ridge 42 and a second outer ridge 44 formed on the peripheral edge 40 in a vertical casting orientation relative to a second side 38 of the frame 34. In this respect, each of the outer ridges extends along the second side 38. Additionally, at least one support leg 32 has an inner ridge 46 formed away from the peripheral edge 40 and extends across it on the second side 38.

[0078] refer to Figure 2B The support also includes a plurality of peripheral bosses 50 formed on the second side 38 of the frame 34 for structural attachment. Each peripheral boss 50 has a boss diameter. Moreover, each peripheral boss 50 is formed on one of the support legs 32 and abuts one of the first outer ridge 42 and inner ridge 46.

[0079] like Figure 2B and Figure 4-6 As shown, the support also includes a plurality of main ribs 52 arranged on the second side 38 of the frame 34 to achieve structural integrity. Each main rib 52 is arranged adjacent to a peripheral boss 50 and extends vertically upward relative to the vertical casting orientation defining the riser contact area 54 to the first outer ridge 42. In this respect, the width of each main rib 52 is at least 70% of the boss diameter, and each main rib 52 extends from the peripheral boss 50 with a draft angle of at least 3° relative to the peripheral boss 50 (as discussed above).

[0080] refer to Figure 2B and Figure 7The bracket also includes at least one second boss 70, which is arranged adjacent to a peripheral boss 50 on the second side 38 of the frame 34 and is disposed downward from the peripheral boss 50 relative to a vertical casting orientation. Each second boss 70 has a boss diameter. In one example of this embodiment, the bracket also includes a second rib disposed on the second side 38 of the frame 34. The second rib is disposed adjacent to the second boss 70 and extends vertically upward to the peripheral boss 50 relative to a vertical casting orientation. In one example, the second rib has a width of at least 70% of the boss diameter and extends from the second boss 70 with a draft angle of at least 3° relative to the second boss 70.

[0081] like Figure 9 As shown, method 110 further includes providing a feeding mechanism 14 in a box 114, which is arranged around the casting mold 30 and in fluid communication with its cavity. Figure 1 The feeding mechanism 14 of system 10 can be performed in method 110. Preferably, the feeding mechanism 14 is configured to feed molten metal material into at least one cavity of the casting mold 30 that defines the size of the support to be cast.

[0082] As discussed above, the feeding mechanism 14 includes a ladle (not shown), a runner (not shown), a filter (not shown) in fluid communication with the runner, and a flow channel in fluid communication with the runner and the casting mold 30. As shown, the flow channel is arranged around the casting mold 30. In this example, the ladle contains molten metal material (e.g., aluminum) for pouring the molten metal material into the runner with the filter to remove oxygen from the molten metal material. As described above, the runner is in fluid communication with the flow channel (here, a dual flow channel with a first wing and a second wing), and the molten metal material flows from the filter through the flow channel.

[0083] As stated above, and as Figure 2B-3 As shown, the feeding mechanism 14 also includes a plurality of ingates 82 that are in fluid communication with the runner and the cavity of the mold 30. Each ingate 82 has a first ingate side 84 connected to the runner 80, which extends to a second ingate side 86 connected to the mold 30. Figure 2B As shown, the feeding mechanism 14 also includes a plurality of main risers 90 connected to and in fluid communication with the cavity of the casting mold 30. Each main riser 90 is connected at one of the riser contact areas 54 to the first outer edge of a support leg 32 and is disposed adjacent to a peripheral boss 50. Moreover, each main riser 90 is vertically disposed above a peripheral boss 50 relative to the vertical casting orientation of the frame 34. Preferably, each main riser 90 has a height at least twice the diameter of the boss. Furthermore, each main riser 90 has, preferably, a width greater than the diameter of the boss.

[0084] As discussed above, the feeding mechanism 14 also includes side risers 92, which are arranged in and fluidly communicate with the second leg 48 of the mold 30 at their respective riser contact areas 54. The side risers 92 are configured to have connectors 94 through which molten metal material flows. The connectors 94 have necks 96 in fluid communication with at least one molded cavity. Furthermore, the necks 96 have open ends 98, which are configured to extend to at least one molded cavity at the riser contact areas 54, which define a riser connection angle of at least 45° relative to the horizontal plane, as discussed above. Therefore, each riser of the feeding mechanism 14 is configured to receive an overflow of molten metal material from the mold 30 at its respective riser connection angle, thereby enabling contraction in the risers away from the mold 30.

[0085] refer to Figure 9 Method 110 further includes: melting a first metallic material at a predetermined temperature in a container 116 to define the molten metallic material. The melting step can be performed by... Figure 1 The furnace 16 of the system 10 is implemented. Therefore, the furnace 16 is configured to melt a first metallic material at a predetermined temperature to define the molten metallic material. In one example, the temperature of the furnace 16 can be between 650°C and 900°C. In one embodiment, the furnace 16 can be filled with aluminum. Without departing from the spirit or scope of this disclosure, the furnace 16 can be an electric arc furnace, an induction furnace, or any other suitable furnace. Furthermore, the first metallic material may include: 7.0 wt% silicon (Si), 0.4 wt% magnesium (Mg), 0.14 wt% iron (Fe), and the balance aluminum (Al).

[0086] like Figure 9 As shown, method 110 further includes: within the container 118, moving the casting mold 30 and the feeding mechanism 14 from a horizontal casting orientation to a vertical casting orientation about a rotation axis, while simultaneously feeding molten metal material into the cavity of the casting mold 30 through a runner. In one example, the following is performed: Figure 1 The system 10 includes a tilting device 18 for moving the casting mold 30 and the feeding mechanism 14. As discussed above, the tilting device 18 is movably connected to the casting mold 30 and the feeding mechanism 14. The tilting device 18 is configured to move the casting mold 30 and the feeding mechanism 14 from a horizontal casting orientation to a vertical casting orientation about a rotation axis, while simultaneously feeding molten metal material into the cavity of the casting mold 30 through a runner. The tilting device 18 is configured to move or tilt the casting mold 30 and the feeding mechanism 14 at a controlled speed, for example, 2° per second.

[0087] Then, the casting mold 30 is sealed or gated with chemically bonded sand. Subsequently, the molten metal material can be cooled to a set temperature, for example, about 450°C, in a designated cooling zone (discussed below) within the casting mold 30 and the riser to solidify the molten metal material in the multiple molding cavities of the casting mold 30, thereby forming the target part with the support dimensions. Preferably, the support is made of an aluminum alloy comprising the components discussed above.

[0088] refer to Figure 9 Method 110 further includes: cooling molten metal material in the casting mold 30 within a first curing time in a chamber 120, and cooling molten metal material in a plurality of risers within a second curing time to define risers having the dimensions of a cast aluminum fuel cell support and cured metal material in the casting mold 30. In one example, Figure 1 The cooling zone 20 of system 10 is configured to solidify the molten metal material in the mold 30 during a first solidification time and the molten metal material in the multiple risers during a second solidification time. It should be understood that the second solidification time is longer than the first solidification time, causing shrinkage of the solidified metal material in the risers farther from the mold 30. That is, during the solidification of the molten metal material, shrinkage occurs in each riser farther from the mold 30 to compensate for the shrinkage of the metal material. This compensation is partly caused by the riser geometry, rib geometry, and riser connection angle of the side risers 92.

[0089] In one example, the first metallic material of the support is preferably made of an aluminum alloy, such as A356. Furthermore, the cured metallic material has a Young's modulus or elastic modulus (E) of approximately 75 GPa. Additionally, the cured metallic material has an ultimate tensile strength (UTS) of approximately 310 MPa, a yield strength (YS) greater than 250 MPa, and an elongation (EL) between 5% and 12%. Moreover, the porosity of the cured metallic material is less than 10%.

[0090] Figure 9 Method 110 is also shown, which further includes: separating the solidified metal material from the casting mold 30 within a housing 122 to define a cast aluminum tilted fuel cell support. The separation step can be performed by... Figure 1The separation unit 22 of the intermediate system 10 is implemented. As discussed above, the separation unit 22 is configured to separate the solidified metal material from the casting mold 30 to define the cast aluminum tilted casting fuel cell support. In one embodiment, the separation unit 22 is configured to desand or remove the casting mold 30, which includes chemically bonded sand, from the target component. To remove the casting mold 30 from the target component, an automated unit can be used to break the casting mold 30 and obtain the target component therefrom. For example, a vibrating unit or table with a bottom-catching screen for receiving mold particles from the mold can be used. It should be understood that any other suitable method can be used to break the mold without departing from the spirit or scope of this disclosure.

[0091] In this example, the separation unit 22 is also configured to remove the gate of the target part after the mold 30 is removed from the target part. As is known in the art, removing the gate of the target part may involve removing a portion of the adhesive sand used to fill the mold 30 during casting and gate filling. Furthermore, the separation unit 22 is also configured to clean the target part after gate removal. As discussed above, a shot blasting machine can be used to apply or fire beads (e.g., metal beads) onto the surface of the target part. To meet alloy design expectations, the separation unit 22 may also include an inspection area in which the mechanical dimensions, mechanical properties, chemical composition, and microstructure of the target part are inspected. In one example, a computerized system, such as a coordinate measuring machine (CMM), can be used to measure the mechanical dimensions of the target part, thereby defining the support. Without departing from the spirit or scope of this disclosure, any suitable methods and apparatus can be used to evaluate the dimensions, mechanical properties, chemical composition, and microstructure of the support.

[0092] It should be understood that the term "about" as used herein means up to + / - 10% of the parameter value. For example, about 270°C can include a range between 243°C and 297°C. In another example, about 40 micrometers can include a range between 36 micrometers and 44 micrometers.

[0093] The descriptions in this disclosure are merely exemplary in nature, and changes that do not depart from the essential points of this disclosure are intended to be included within its scope. Such changes are not considered to be departing from the spirit and scope of this disclosure.

Claims

1. A method for fabricating a cast aluminum tilted fuel cell support for a fuel cell, the method comprising: A casting mold with a cavity is provided to form a support, the support comprising: Multiple support legs are interconnected to define a frame for supporting the fuel cell having a first side and a second side. The frame has horizontal and vertical casting orientations for casting the support. Each support leg has a peripheral edge surrounding it. Each support leg has a first outer ridge and a second outer ridge formed on the peripheral edge with a vertical casting orientation relative to the second side of the frame. Each of the outer ridges extends along the second side. At least one support leg has an inner ridge formed away from the peripheral edge and extends across it on the second side. Multiple peripheral bosses are formed on the second side of the frame for structural attachment. Each peripheral boss has a boss diameter and is formed on one of the support legs and adjacent to one of the first outer ridge and the inner ridge. Multiple main ribs are arranged on the second side of the frame to achieve structural integrity. Each main rib is arranged adjacent to a peripheral boss and extends vertically upward relative to the vertical casting orientation that defines the riser contact area to the first outer ridge. The width of each main rib is at least 70% of the diameter of the boss, and each main rib extends from the peripheral boss with a draft angle of at least 3° relative to the peripheral boss. A feeding mechanism is provided, arranged around the casting mold and in fluid communication with its cavity, the feeding mechanism comprising: A flow channel is arranged around the casting mold and is in fluid communication with the casting mold; Multiple ingates are in fluid communication with the runner and the cavity of the mold, each ingate having a first side connected to the runner, the first side extending to a second side connected to the mold. Multiple main risers are connected to and in fluid communication with the cavity of the casting mold. Each main riser is connected to the first outer edge of a support leg at one of the riser contact areas and is adjacent to the outer peripheral boss. Each main riser is vertically positioned above the outer peripheral boss relative to the vertical casting orientation of the frame. The first metallic material is melted at a predetermined temperature to limit the molten metallic material; Around the rotation axis, the casting mold and the feeding mechanism are moved from the horizontal casting orientation to the vertical casting orientation, while the molten metal material is fed into the cavity of the casting mold through the flow channel; The molten metal material in the casting mold is cooled during a first curing time, and the molten metal material in the plurality of main risers is cooled during a second curing time to define the main risers having the dimensions of the cast aluminum inclined cast fuel cell support and the cured metal material in the casting mold. The second curing time is longer than the first curing time, thereby causing the cured metal material in the main risers away from the casting mold to shrink. Separate the solidified metal material from the casting mold to define the cast aluminum tilted fuel cell support.

2. The method for fabricating a cast aluminum inclined fuel cell support for a fuel cell according to claim 1, wherein, Each main riser has a height that is at least twice the diameter of the boss.

3. The method for fabricating a cast aluminum inclined fuel cell support for a fuel cell according to claim 1, wherein, Each main riser has a width greater than the diameter of the boss.

4. The method for fabricating a cast aluminum inclined fuel cell support for a fuel cell according to claim 1, wherein, The bracket further includes at least one second boss, which is arranged adjacent to a peripheral boss on a second side of the frame and is disposed downward therefrom relative to the vertical casting orientation; each second boss has the boss diameter.

5. A method for fabricating a cast aluminum inclined fuel cell support for a fuel cell according to claim 4, wherein, The bracket also includes a second rib disposed on the second side of the frame; the second rib is disposed adjacent to the second boss and extends vertically upward relative to the vertical casting orientation to the peripheral boss.

6. A method for fabricating a cast aluminum inclined fuel cell support for a fuel cell according to claim 5, wherein, The second rib has a width that is at least 70% of the diameter of the boss and extends from the second boss with a draft angle of at least 3° relative to the second boss.

7. The method for fabricating a cast aluminum inclined fuel cell support for a fuel cell according to claim 1, wherein, At least one support leg is positioned vertically relative to the vertical casting orientation defining the second leg; and wherein the feeding mechanism further includes a side riser disposed to the second leg of the casting mold and in fluid communication with the second leg of the casting mold at a corresponding riser contact area; the side riser is configured to have a connector through which molten metal material flows; the connector has a neck in fluid communication with the at least one molding cavity; the connector has an open end configured to extend to the at least one molding cavity at the riser contact area, the riser contact area defining a riser connection angle of at least 45° relative to the horizontal plane.

8. The method for fabricating a cast aluminum inclined fuel cell support for a fuel cell according to claim 1, wherein, The first metallic material comprises: 7.0 wt% silicon (Si), 0.4 wt% magnesium (Mg), 0.14 wt% iron (Fe) and the balance being aluminum (Al).

9. A system for fabricating a cast aluminum tilted-cast fuel cell support for a fuel cell, the system comprising: A molding unit is configured to form a casting mold for the inclined cast aluminum fuel cell support, the mold including at least one molding cavity having a pattern with dimensions of the inclined cast aluminum fuel cell support, the support comprising: Multiple support legs are interconnected to define a frame for supporting the fuel cell having a first side and a second side. The frame has horizontal and vertical casting orientations for casting the support. Each support leg has a peripheral edge surrounding it. Each support leg has a first outer ridge and a second outer ridge formed on the peripheral edge with a vertical casting orientation relative to the second side of the frame. Each of the outer ridges extends along the second side. At least one support leg has an inner ridge formed away from the peripheral edge and extends across it on the second side. Multiple peripheral bosses are formed on the second side of the frame for structural attachment. Each peripheral boss has a boss diameter and is formed on one of the support legs, adjacent to one of the first outer ridge and the inner ridge; and Multiple main ribs are arranged on the second side of the frame to achieve structural integrity. Each main rib is arranged adjacent to a peripheral boss and extends vertically upward relative to the vertical casting orientation that defines the riser contact area to the first outer ridge. The width of each main rib is at least 70% of the diameter of the boss, and each main rib extends from the peripheral boss with a draft angle of at least 3° relative to the peripheral boss. A feeding mechanism is arranged around the casting mold and in fluid communication with its cavity, the feeding mechanism comprising: A flow channel is arranged around the casting mold and is in fluid communication with the casting mold; Multiple ingates are provided, in fluid communication with the runner and the cavity of the mold, each ingate having a first side connected to the runner, the first side extending to a second side connected to the mold; and Multiple main risers are connected to and in fluid communication with the cavity of the casting mold. Each main riser is connected to the first outer edge of a support leg at one of the riser contact areas and is adjacent to the outer peripheral boss. Each main riser is vertically positioned above the outer peripheral boss relative to the vertical casting orientation of the frame. A furnace is configured to melt a first metallic material at a predetermined temperature, thereby confining the molten metallic material; A tilting device is movably connected to the casting mold and the feeding mechanism. The tilting device is configured to move the casting mold and the feeding mechanism from the horizontal casting orientation to the vertical casting orientation around the rotation axis, while feeding molten metal material into the cavity of the casting mold through the flow channel. A cooling zone is configured to solidify the molten metal material in the casting mold during a first solidification time and the molten metal material in the plurality of main risers during a second solidification time, thereby defining the solidified metal material in the casting mold and the main risers having the dimensions of the cast aluminum fuel cell support. The second solidification time is longer than the first solidification time, thereby causing shrinkage of the solidified metal material in the main risers away from the casting mold; and A separation unit is configured to separate the solidified metal material from the casting mold to limit the cast aluminum tilted casting fuel cell support; A controller is configured to communicate with the molding unit, the furnace, the feeding mechanism, the tilting device, and the separation unit, wherein the controller is configured to control the molding unit, the furnace, the feeding mechanism, the tilting device, and the separation unit; and The power supply is configured to power the molding unit, the furnace, the feeding mechanism, the tilting device, the separation unit, and the controller.

10. A system for fabricating a cast aluminum inclined casting fuel cell support for a fuel cell according to claim 9, wherein, Each main riser has a height that is at least twice the diameter of the boss.

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