Modular Casting Core With Internal Cooling Ducts
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Solution Overview
Problem
Current methods for producing hot bodies as castings in modular molds are inefficient and costly, particularly in miniaturized devices where heat dissipation is critical, due to complex geometries and the need for multiple assembly steps.
Innovation Solution
A core for producing castings with thermally activatable portions and fluid-tight ducts, incorporating inserts with high thermal conductivity materials like metals and graphene, designed to facilitate efficient heat exchange by allowing counter-current fluid flow through the ducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple assembly steps and joining techniques are used to produce hot bodies with complex geometries, then the functionality and heat dissipation capability are improved, but the manufacturing cost and production complexity increase significantly
Solution Approach 1:
The patent combines multiple previously separate manufacturing steps (mold assembly, core insertion, casting, and cooling duct formation) into a single integrated casting process. The modular mold system with removable cores allows complex internal cooling ducts to be formed directly during casting, eliminating the need for subsequent assembly operations and joining techniques.
Solution Approach 2:
The patent implements preliminary action by pre-assembling the modular mold components and inserting the cores before the casting process begins. This preparation allows the complex internal geometries and cooling ducts to be formed in a single casting operation, rather than requiring post-casting modifications or assemblies.
2Volume of moving object
If traditional casting methods are used for miniaturized devices, then the device dimensions are reduced, but the heat concentration increases and becomes difficult to dissipate
Solution Approach 1:
The patent addresses heat dissipation in miniaturized devices by transitioning from surface-level cooling to internal three-dimensional cooling. The modular mold system enables the formation of complex internal cooling ducts that extend throughout the casting volume, allowing heat to be dissipated from the interior of the device rather than relying solely on external surface area.
Solution Approach 2:
The patent utilizes a modular mold system with removable cores that create internal voids and channels within the casting. These internal passages function similarly to porous structures by providing extensive internal surface area for heat exchange, enabling efficient heat dissipation from the interior of miniaturized devices.
3Productivity
If fusion type technologies are used to produce hot bodies as castings, then the manufacturing cost and production time are reduced, but the ability to produce complex geometries with internal cooling ducts becomes challenging
Solution Approach 1:
The patent applies segmentation by dividing the mold into modular components that can be independently assembled and configured. This modular approach allows the mold to accommodate complex internal geometries and cooling ducts while maintaining the efficiency of a single-casting process. The segmented mold design with removable cores enables precise formation of internal features without requiring complex post-processing.
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
This solution enables effective heat dissipation in miniaturized devices by ensuring consistent cooling across the casting, reducing manufacturing costs and simplifying the production process while maintaining high performance.
Implementation Method 1
at least one insert shaped to define at least two passages for said fluid inside it and therefore within said duct
Data Source
AI summary
A core (1) for producing castings (100) in a modular mold; each casting (100) having at least one thermally activatable portion (102) shaped so that it can face a heat source (HS); each casting (100) having at least one duct (106) contained inside the portion (102); the duct (106) being fluid tight so that a fluid can flow through it; the core (1) having a suitable shape to form, in negative, the duct (106); the core (1) including at least one insert (20)(20′)(20″) shaped so as to define at least two passages (200)(200′) for the fluid inside the duct (106).