Jacketed Core Catalyst Integration in Molded Components
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Solution Overview
Problem
Existing methods for forming components with internal passages require separate catalyst beds, increasing system size, manufacturing, and operating costs, as catalyzed reactions are not efficiently integrated within the components themselves.
Innovation Solution
A method involving a jacketed core with a hollow structure formed from a material and catalyst, positioned within a mold to define internal passages, where the catalyst is strategically distributed using additive manufacturing, ensuring it is integrated along the passage during component formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate dedicated catalyst bed component is used, then catalytic reaction function is achieved, but system size and manufacturing cost increase
Solution Approach 1:
The patent combines the catalyst bed function directly into the component wall structure by forming a hollow structure from catalyst material during the casting process. This eliminates the need for a separate dedicated catalyst bed component, thereby reducing system size while maintaining the catalytic reaction function. The catalyst is strategically distributed within the hollow structure to provide the necessary catalytic activity.
Solution Approach 2:
The component is designed to serve multiple functions: it acts as both a structural component and a catalyst bed. The hollow structure formed from catalyst material allows the component to perform catalytic reactions while maintaining its structural integrity, thereby eliminating the need for separate dedicated components and reducing overall system complexity.
2Reliability
If a separate dedicated catalyst bed component is used, then catalytic reaction function is achieved, but manufacturing cost increases
Solution Approach 1:
The catalyst bed function is merged into the component manufacturing process itself. The hollow structure is formed from catalyst material during the casting process, eliminating the need for separate manufacturing steps and assembly operations. This integration reduces manufacturing cost while ensuring the catalytic reaction function is achieved.
Solution Approach 2:
The catalyst material is prepared and positioned in advance as part of the hollow structure before the final component is cast. This preliminary action allows the catalyst to be strategically distributed within the component wall, ensuring proper catalytic function while simplifying the overall manufacturing process and reducing costs.
3Manufacturing precision
If traditional core methods are used, then internal passage is formed, but core fragility issues occur during handling
Solution Approach 1:
The hollow structure is formed from catalyst material that provides both the necessary structural support for handling and the catalytic function. This composite approach, where the catalyst material itself forms the hollow structure, eliminates the need for separate fragile cores while maintaining internal passage formation capability and improving handling stability.
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 reduces fragility issues during core handling and enables reliable, cost-effective integration of catalysts within internal passages, even for complex shapes, improving catalytic performance and reducing system costs.
Implementation Method 1
The hollow structure is formed from a first material and a first catalyst
Implementation Method 2
The first catalyst is strategically distributed within the hollow structure such that the first catalyst lines an internal passage when the component is formed in the mold
Data Source
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AI summary
A method (2000) of forming a component (80) having an internal passage (82) defined therein includes positioning (2002) a jacketed core (310) with respect to a mold (300). The jacketed core (310) includes a hollow structure (320) formed from at least a first material (322) and a first catalyst (362), and an inner core (324) disposed within the hollow structure (320). The method also includes introducing (2004) a component material (78) in a molten state into a cavity (304) of the mold (300), and cooling (2006) the component material (78) in the cavity (304) to form the component (80). The inner core (324) defines the internal passage (82) within the component (80).