Inverted Conical Vent for Aluminium Casting Clogging

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Solution Overview

Problem

Conventional vents for permanent moulds in aluminium casting are prone to clogging due to the penetration of molten aluminium, leading to porosity defects, reduced productivity, and high replacement costs, as they are designed with parallel or inclined holes that allow aluminium to penetrate and clog, necessitating frequent replacements.

Innovation Solution

A vent design with grooves or holes featuring an inverted inclination, where the larger dimension is on the outer face and the smaller dimension is inside, preventing aluminium penetration and clogging, manufactured using various materials like carbon steel, stainless steel, brass, or bronze alloys, allowing for flexible design and reduced clogging frequency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional vents with parallel or inclined holes are used, then air outlet function is provided, but aluminium penetration and clogging occurs

Engineering Contradiction:

Improvevent functionalityVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent inverts the conventional groove geometry by making the larger dimension on the external surface and the smaller dimension on the internal surface, creating an inverted conical shape that prevents aluminium penetration while maintaining air outlet function

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The vent structure implements different groove characteristics at different locations: the external surface has larger groove dimensions to prevent clogging, while the internal surface has smaller dimensions to maintain sealing and functionality

Inventive Principle:

Principle #3Local quality

2Reliability

If vents are frequently replaced due to clogging, then air outlet function is maintained, but productivity decreases

Engineering Contradiction:

Improveair outlet functionalityVSAvoidcasting production

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The inverted groove geometry prevents aluminium accumulation that would require frequent replacements, thereby maintaining continuous production without interruptions for vent replacement

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If vents with standard conical grooves are used, then manufacturing is simplified, but aluminium clogging still occurs

Engineering Contradiction:

Improvevent fabricationVSAvoidresistance to clogging

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent inverts the conventional conical groove design to create an inverted conical shape that is equally simple to manufacture but effectively prevents aluminium penetration by directing it away from the groove interior

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The groove dimensional parameters are changed from the conventional configuration (smaller external, larger internal) to the inverted configuration (larger external, smaller internal), fundamentally altering the interaction with molten aluminium

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

The new vent design significantly increases the resistance to aluminium clogging, enhancing casting quality and productivity by maintaining air outlet functionality, reducing vent replacement frequency, and lowering production costs through extended service life and competitive pricing.

Implementation Method 1

A vent (15) is comprised of a cylindrical body provided with a plurality of grooves (16) having an inclination 'Ao', so that the larger opening (18) is on the external surface of the vent (15) and the smaller opening (19) is inside of said vent (15)... the unique constructive arrangement of the grooves, which instead of presenting holes with parallel or inclined dimensions in a standard configuration... are provided with an inverted inclination wherein the larger dimension is on the outer face of the vent

Methodology Applied

Scientific EffectCapillary pressure: Capillary Pressure

Data Source

PatentEP2719483B1Vent for mould for permanent aluminium casting

Publication Date: 2017.02.01 ZANATTA

AI summary

The patent relates to the field of metallurgical products and comprises a cylindrical body (15) provided with a plurality of slots (16), with a taper "A" designed such that the larger opening (18) is at the outer surface of the breather (15) and the smaller opening (19) is located internally with respect to the breather (15), so that the aluminium component (5), when removed from the mould (6), brings with it the burr (17), leaving the slots (16) of the breather (15) always free, and also a breather (29) comprising a cylindrical body constituted from a plurality of holes (21), with a conicity "A" designated such that the larger opening (22) is at the outer surface of the breather (20) and the smaller opening (23) is located internally with respect to the breather (20).