Single-Piece Casting Flow Passage for EV Power Converters
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for forming castings with flow passages are complex and prone to defects or leakage, which can lead to malfunction and fire risks in power converting components, particularly in electric vehicles, due to the need for mechanical coupling of two separate parts and the use of gaskets.
Innovation Solution
A method involving a high-pressure casting process using a tubular pipe filled with a filler as a core, which is bent to form the flow passage shape and inserted into a mold, allowing for a single-piece casting with enhanced robustness and reduced production costs, where the tubular pipe and molten metal are made of the same material, typically aluminum, and the filler is removed post-casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate parts with flow passages are formed through casting processes and coupled with bolts and gaskets, then the flow passage can be formed in power converting components, but the production process becomes complex and the risk of leakage increases
Solution Approach 1:
The patent merges two separate casted parts into a single integrated casting by forming the flow passage directly within the casting body. This eliminates the need for mechanical coupling with bolts and gaskets, thereby simplifying the production process and eliminating leakage risks at interfaces between separate parts.
Solution Approach 2:
The patent employs preliminary action by forming the flow passage structure during the initial casting process itself, rather than adding it later through assembly. The flow passage is created as an integral part of the casting, preventing leakage before the component is even assembled into the power converting component.
2Reliability
If two separate parts are coupled mechanically with bolts and gaskets, then the flow passage structure can be assembled, but the production cost increases and the robustness of the flow passage decreases
Solution Approach 1:
The patent combines the flow passage structure with the main casting into a single integrated component. This eliminates the need for separate parts, bolts, and gaskets, thereby reducing production costs associated with multiple casting operations, assembly processes, and fastening components while simultaneously enhancing the robustness of the flow passage.
Solution Approach 2:
The patent extracts the flow passage structure from being a separate assembled component and integrates it directly into the casting body. This extraction of the flow passage from the assembly process and its integration into the casting eliminates potential failure points and enhances overall robustness while reducing manufacturing complexity and cost.
3Reliability
If gaskets are used to secure airtightness at the interface, then leakage can be prevented, but the system becomes vulnerable to malfunction and fire risks if the gasket is damaged
Solution Approach 1:
The patent removes the gasket component entirely from the system by forming the flow passage as an integral part of the casting. This elimination of the gasket eliminates the failure mode where gasket damage could lead to water permeation, system malfunction, and fire risks, while maintaining airtightness through the integrated casting structure.
Solution Approach 2:
The patent applies beforehand cushioning by designing the flow passage to be inherently leak-proof through integration into the casting structure. This prevents the possibility of gasket failure and subsequent harmful effects before they can occur, eliminating the need for protective measures against gasket damage.
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 approach results in a robust, single-piece casting with improved thermal conductivity and reduced production costs, minimizing the risk of leakage and enhancing cooling performance, while preventing vehicle fires by eliminating the need for mechanical coupling and gaskets.
Implementation Method 1
the core which includes a tubular pipe filled with a filler... performing a casting process by injecting molten metal into the cavity... through a high-pressure casting process
Implementation Method 2
forming a core obtained by filling a tubular pipe with a filler... The filler may be any one or more selected from salt, sand, iron powder, and a resin coated sand
Implementation Method 3
performing a casting process by injecting molten metal into the cavity... allowing for a single-piece casting
Implementation Method 4
the tubular pipe and molten metal are made of the same material, typically aluminum... improved thermal conductivity
Data Source
AI summary
A method of forming a casting with a flow passage may include forming a core obtained by filling a tubular pipe with a filler; inserting the core into a mold having a cavity corresponding to a shape of the casting to be formed; performing a casting process by injecting molten metal into the cavity; and removing the filler from the core, wherein the casting process is performed through a high-pressure casting process.