Liquid-Cooled Chill Mold Sheet Metal Holders

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Solution Overview

Problem

The existing thick-walled copper permanent chill mold plates in continuous metal casting face challenges in shaping cooling gap geometry, thermal expansion, and securing thin-walled plates due to limited fastening options and space constraints, leading to stress and poor cooling in critical regions.

Innovation Solution

A liquid-cooled permanent chill mold design that uses sheet metal holders in the top and base regions to couple the chill mold plate to the adapter plate, allowing for thermal expansion and optimal cooling, while using fastening bolts and streamlined pedestals to secure the assembly with enhanced sealing and reduced stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the permanent chill mold plate is made thin-walled to improve cooling efficiency and reduce thermal expansion, then the cooling performance improves, but the structural strength and fixing reliability deteriorate due to limited fastening options and space constraints

Engineering Contradiction:

Improvecooling performanceVSAvoidfixing reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The connection system is segmented into multiple independent fastening elements: fastening bolts for general connection and sheet metal holders specifically for top and base regions. This segmentation allows each element to be optimized for its specific function, with sheet metal holders providing reliable fixing for thin-walled plates in critical regions without compromising cooling performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different fastening solutions are applied to different regions of the mold plate. Sheet metal holders are specifically used in top and base regions where thin-walled construction creates fixing difficulties, while fastening bolts are used in other areas. This local differentiation ensures reliable fixing where needed most while maintaining overall thin-walled design for cooling efficiency.

Inventive Principle:

Principle #3Local quality

2Strength

If fastening bolts are used to connect the permanent chill mold plate to the adapter plate, then the connection is secured, but sealing becomes complicated and additional uncooled regions are created

Engineering Contradiction:

Improveconnection strengthVSAvoidsealing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Sheet metal holders act as intermediary elements between the permanent chill mold plate and adapter plate. These holders provide both mechanical connection strength and integrated sealing functionality, eliminating the need for separate sealing components around fastening bolts. The intermediary structure simplifies manufacturing by combining connection and sealing functions in a single element.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If more fastening bolts are used to secure the mold plate in constrained areas, then the fixing strength improves, but the space for cooling channels is reduced and high pressure forces cannot be effectively managed

Engineering Contradiction:

Improvefixing strengthVSAvoidcooling channel space

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The fastening function is segmented between fastening bolts and sheet metal holders, with sheet metal holders specifically deployed in constrained top and base regions. This segmentation allows effective management of high pressure forces in space-constrained areas without requiring multiple large fastening bolts that would occupy cooling channel space.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system transitions from relying solely on large-diameter fastening bolts to incorporating sheet metal holders that provide equivalent or superior fixing strength in constrained regions. This parameter change enables effective force management while preserving cooling channel geometry and space.

Inventive Principle:

Principle #35Parameter changes

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 design ensures flawless connection and sealing of thin-walled chill mold plates, reduces material stress, and maintains efficient cooling, even in constrained areas, with improved assembly and disassembly, and allows for directed displacement to manage high pressure forces without compromising heat dissipation.

Implementation Method 1

liquid-cooled permanent chill mold

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

cooling channels

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

thermal expansions of the regions close to the casting surfaces, which are created as a result of heat inputs by the metal melt

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS8051893B2Liquid-cooled permanent chill mold for the continuous casting of metals

Publication Date: 2011.11.08 CUNOVA GMBH

AI summary

A liquid-cooled permanent chill mold for the continuous casting of metals, including a permanent chill mold plate (2) made of copper or a copper alloy and an adapter plate (3), on which the permanent chill mold plates (2) are fastened via fastening bolts (12). The permanent chill mold plates (3) are coupled to the adapter plates (3) via sheet metal holders (19) situated in their top regions and base regions (20, 21), in addition to via the fastening bolts (12).