Reusable Filter Holder for Molten Metal Casting
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Solution Overview
Problem
Existing methods for producing cast articles using molds with integrated filters face challenges such as limited applicability to large and heavy articles, high disposal costs, filter breakage, and contamination issues due to the instability of uncured mold sand and thermal strain.
Innovation Solution
A method utilizing a filter holder composed of organic fibers, inorganic fibers, and a thermosetting resin, integrated with a heat-resistant filter, which provides sufficient strength and flexibility to prevent filter breakage and contamination, while being lightweight and reusable, allowing for efficient removal of impurities from molten metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a filter holder made of sintered fire-resistant material is used, then the filter holder has high heat resistance and erosion resistance, but it becomes non-reusable waste after frame release requiring disposal effort and cost
Solution Approach 1:
The filter holder is designed to be reusable by withstanding the casting process conditions and being easily removed from the mold after casting. The holder can be recovered and reused for multiple casting cycles, eliminating the need for continuous disposal and replacement of fire-resistant material components.
Solution Approach 2:
The filter holder is constructed as a composite structure combining fire-resistant material with mold sand and binder, allowing it to maintain heat resistance during casting while being integrally formed with the mold cavity for easy removal and reuse without generating waste disposal issues.
2Object-affected harmful factors
If a runner tube made of fire-resistant material is used to avoid sand contamination, then sand contamination is reduced, but the tube becomes non-reusable waste requiring disposal effort and cost
Solution Approach 1:
The runner tube is designed as an integrally formed part of the mold cavity using mold sand and binder, allowing it to be easily removed with the mold after casting and reused in subsequent casting cycles, eliminating continuous disposal requirements while maintaining its function in preventing sand contamination.
Solution Approach 2:
The runner tube structure serves multiple functions simultaneously: it guides molten metal flow, prevents sand contamination from the mold cavity, and is designed to be easily removed and reused with the mold itself, making the system self-sufficient without requiring separate disposable components.
3Ease of manufacture
If uncured mold sand is used for positioning the filter holder, then positioning is simplified, but the uncured sand is unstable causing filter breakage and sand contamination
Solution Approach 1:
The filter holder is positioned and fixed within the mold cavity using uncured mold sand and binder before the casting process begins. The binder then cures to stabilize the position, preventing filter breakage and sand contamination during molten metal pouring while maintaining the ease of initial positioning.
Solution Approach 2:
The mold sand transitions from an uncured, easily workable state during positioning to a cured, stable state during casting. This parameter change in the binder material allows the system to achieve both ease of manufacture during assembly and reliability during the casting process.
4Manufacturing precision
If a filter with small mesh is used to remove small impurities, then removal efficiency of small impurities increases, but running resistance increases limiting its use
Solution Approach 1:
The filter is designed with varying mesh sizes in different regions or zones, with finer mesh in areas where small impurity removal is critical and coarser mesh in areas where maintaining low running resistance is more important. This local variation optimizes both impurity removal efficiency and molten metal flow characteristics.
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 solution enables the production of high-strength, high-quality cast articles with reduced defects and lower production costs by preventing filter breakage and contamination, and simplifying waste disposal, while being applicable to larger and heavier castings.
Implementation Method 1
a filter holder constituted of a structure containing organic fibers, inorganic fibers and a thermosetting resin
Implementation Method 2
a part for removing impurities from a molten metal in casting... a heat-resistant filter
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention arranges the part for removing impurities from a molten metal containing a filter holder constituted of a structure containing an organic fiber, an inorganic fiber and thermosetting resin and a heat-resistant filter in the runner of the mold.