Cooling Pipe Structure for Cast Heating Elements Under Molten Metal Pressure
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Solution Overview
Problem
Existing methods for manufacturing cooling modules using aluminum alloys face challenges such as deformation and misalignment of cooling pipes during the insert injection molding process due to high pressure from molten metal, and aluminum alloys have low strength, making it difficult to achieve effective cooling performance.
Innovation Solution
The use of a cooling pipe with a cross-sectional shape where the first pipe thickness is greater in one direction than the second direction, parallel to the mold's flow direction, and integrated with a plate portion and protrusion extensions, along with a cooling pin structure, to prevent deformation and enhance cooling efficiency by ensuring proper alignment and filling of molten metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling pipe is installed in a mold cavity for insert injection molding, then cooling performance can be provided, but the cooling pipe deforms and moves out of position due to high pressure from molten metal
Solution Approach 1:
The cooling pipe is pre-installed in the mold cavity before injection molding begins. The mold design includes positioning structures that secure the cooling pipe in its correct position prior to the injection process, preventing deformation and displacement when molten metal is injected at high pressure
Solution Approach 2:
Positioning structures act as intermediary elements between the cooling pipe and the mold cavity. These structures provide mechanical support and constraint to the cooling pipe during the injection process, mediating the high pressure forces to prevent pipe deformation and position shifts
2Temperature
If aluminum alloy is used for the cooling pipe, then high thermal conductivity and excellent cooling performance are achieved, but the low strength makes it difficult to manufacture using insert injection molding
Solution Approach 1:
The cooling pipe cross-sectional dimensions are optimized to balance thermal performance and mechanical strength. The pipe thickness and outer diameter are specifically designed to provide sufficient structural strength to resist deformation during injection molding while maintaining high thermal conductivity for effective cooling
3Ease of manufacture
If the cooling pipe has uniform thickness, then manufacturing is simplified, but the pipe deforms under high pressure from molten metal flow
Solution Approach 1:
The cooling pipe employs asymmetric wall thickness distribution, with thicker walls at specific locations and thinner walls at others. This asymmetric design strategically reinforces areas subjected to highest pressure from molten metal flow while maintaining overall manufacturing feasibility and cooling efficiency
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 prevents deformation and misalignment of the cooling pipe during manufacturing, enhances cooling efficiency by ensuring full burial and exposure of the pipe, and maintains the shape of the cooling pipe under high pressure, thereby improving the overall cooling performance of the casting products.
Implementation Method 1
a cooling pipe providing a path through which a cooling fluid flows
Data Source
AI summary
Provided are casting products for cooling heating elements, the casting products including: a body made of a metal material; and a cooling pipe providing a path through which a cooling fluid flows, and being made of an aluminum alloy material, wherein the body includes a plate-shaped plate portion, protrusion extensions protruding from the plate portion and extending along the cooling pipe so that at least part of the cooling pipe is fully buried, and a cooling pin structure formed integrally with the plate portion, and the cooling pipe is formed in such a way that a first pipe thickness of the cooling pipe having a cross-sectional shape in a first direction is greater than a second pipe thickness in a second direction perpendicular to the first direction, and the first direction is in parallel to the plate portion, and the second direction is a thickness direction of the plate portion.