Fluid Permeable Mold Cooling via Varied Pressure
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Solution Overview
Problem
The cooling rate of molten material in sand molds limits the mass production of metal parts, as it determines the time required to produce each part and thus restricts the number of parts that can be produced in a given time period using a single mold.
Innovation Solution
A method involving a mold made of fluid-permeable material, where a cooling fluid is delivered at varying pressures through nozzles arranged in voids to permeate and solidify the molten material, forming a solidified outer skin and facilitating directional solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sand molds are used to form molten material, then the mold is easy and inexpensive to make, but the cooling rate of the molten material is limited, which increases production time and reduces productivity
Solution Approach 1:
The patent applies porous materials by using a sand mold with controlled porosity to allow fluid permeation. The sand mold maintains its traditional ease of manufacture while incorporating voids and permeable structures that enable cooling fluid to pass through, thereby increasing the cooling rate and productivity without sacrificing the ease of mold fabrication.
2Productivity
If the cooling rate is increased to improve productivity, then more parts can be produced in a given time period, but the mold structure becomes more complex requiring fluid delivery systems
Solution Approach 1:
The patent uses an intermediary cooling fluid (such as gas or liquid) that passes through the sand mold to transfer heat away from the molten material. This intermediary medium enables enhanced cooling and increased productivity while avoiding the need for complex internal cooling channels within the mold structure itself, thus limiting the increase in device complexity.
3Manufacturing precision
If cooling fluid is delivered through nozzles in the mold, then directional solidification can be achieved, but the delivery system requires precise pressure control
Solution Approach 1:
The patent applies parameter changes by varying the pressure, temperature, and flow rate of the cooling fluid delivered through nozzles into the sand mold. By dynamically adjusting these parameters, the system achieves precise control over directional solidification and manufacturing precision while using relatively simple pressure control mechanisms rather than complex systems.
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 method enhances the cooling and solidification rate of molten material, allowing for faster production of defect-free molded objects with controlled delivery pressure, thereby increasing the efficiency of mass production.
Implementation Method 1
delivering a fluid to the fluid permeable material such that the fluid permeates through the fluid permeable material and solidifies the molten material
Implementation Method 2
a mold made of fluid-permeable material, where a cooling fluid is delivered at varying pressures through nozzles arranged in voids to permeate and solidify the molten material
Implementation Method 3
the cooling fluid permeates through the fluid permeable material and solidifies the molten material to form a solidified outer skin
Implementation Method 4
The cooling fluid is delivered to the mold at a delivery pressure that is intentionally varied
Implementation Method 5
delivering a cooling fluid to the fluid permeable material via the nozzles such that the cooling fluid permeates through the fluid permeable material, cools the molten material
Data Source
AI summary
A molding system includes a mold and a fluid delivery system. The mold includes a fluid permeable material that defines a mold cavity and is permeable to a cooling fluid. The mold is configured to mold a molten material arranged in the mold cavity. The fluid delivery system is in fluid communication with the fluid permeable material, and is configured to deliver the cooling fluid via nozzles to the fluid permeable material. When the molten material is arranged in the mold cavity, the fluid delivery system delivers the cooling fluid to the fluid permeable material at a delivery pressure that is intentionally varied, such that the cooling fluid permeates through the fluid permeable material to cool and solidify the molten material arranged in the mold cavity to form a solidified outer skin. The delivery pressure may be varied, e.g. increased, as a thickness of the solidified outer skin increases.