Lattice Reinforcing Element in Casting Core for Strength
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Solution Overview
Problem
Existing casting manufacturing methods for producing automotive components lack sufficient mechanical strength, which is essential for improving the efficiency and reducing the environmental impact of motor vehicles.
Innovation Solution
A manufacturing method that involves arranging a reinforcing element with a lattice structure inside a core box, immersing it in a refractory material, and then casting a metal around the core to create a product with enhanced structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional casting manufacturing methods are used, then the production process is simple and inexpensive, but the mechanical strength of the products is insufficient
Solution Approach 1:
The patent applies composite materials by combining a reinforcing element (such as metal fibers, meshes, or three-dimensional structures) with the base metal material being cast. The reinforcing element is pre-placed in the core box before introducing the molten metal, creating a composite structure that significantly enhances mechanical strength, stiffness, and impact resistance while maintaining the simplicity of the casting process
Solution Approach 2:
The reinforcing element is arranged in the core box before the casting process begins. This preliminary placement ensures that the reinforcement is properly positioned within the final product structure, allowing the molten metal to flow around and integrate with the reinforcement during casting, thereby achieving enhanced mechanical properties without adding complex post-processing steps
2Strength
If a reinforcing element is integrated into the casting, then the structural strength increases, but the demoulding process becomes more difficult
Solution Approach 1:
The core box serves as an intermediary tool that facilitates the placement of the reinforcing element and the casting process. After casting, the core box and its contents (including the reinforced structure) are removed as a unit from the mould cavity. This approach simplifies demoulding by allowing the entire core assembly to be extracted together, avoiding the need to disassemble or break apart the reinforced structure
Solution Approach 2:
The manufacturing process is segmented into distinct phases: preparing the core box with the reinforcing element, casting the metal around it, and then removing the entire core box assembly. This segmentation allows the reinforcing element to remain intact during demoulding since it is never separated from the core box structure, thereby maintaining both structural integrity and manufacturing ease
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 method significantly increases the structural strength of the products by integrating the lattice reinforcing element with the metal casting, while also improving heat exchange behavior and simplifying the demoulding process.
Implementation Method 1
pouring a material in a molten state into said cavity in such a way that it flows in contact with said portion of the reinforcing element
Data Source
AI summary
A method of manufacturing a product is described, the method comprising the steps of arranging a reinforcing element inside a core box, introducing a refractory material inside the core box so as to immerge at least part of the reinforcing element in the refractory material, manufacturing a core from the refractory material and the reinforcing element arranged in the core box, arranging the core inside the cavity of a mould of the product, pouring a material in a molten state into the cavity in such a way that it flows in contact with a portion of the reinforcing element, wherein the portion protrudes from the volume of refractory material of the core, and removing the refractory material.