Segmented Salt Mold Casting for Complex Electrical Coils
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Solution Overview
Problem
The production of complex geometries in electrical coils by casting is limited due to geometric requirements that prevent demolding, often resulting in surface defects like streaks and grooves, and the need for draft angles in traditional casting methods.
Innovation Solution
A method using a casting mold composed of more than two mold segments, where at least one segment is a lost mold made from salt or a salt mixture, allowing for the production of components with undercuts and high surface quality without draft angles, enabling smooth surfaces and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional casting methods with permanent molds are used to produce electrical coils, then the component can be manufactured with defined geometry, but draft angles are required which cause surface defects like streaks and grooves
Solution Approach 1:
The mold is divided into multiple segments (at least three segments) that can be separated after casting. This segmentation allows the mold to be opened and the cast part to be removed without requiring draft angles, thereby eliminating surface defects while maintaining complex geometry.
Solution Approach 2:
The invention uses a lost mold approach where the mold segments are consumed or destroyed after a single use. This disposable mold approach eliminates the need for draft angles and permanent mold structures, allowing production of high-precision components with complex geometries without surface defects.
2Adaptability or versatility
If complex geometries with undercuts are produced by casting, then the component design freedom is increased, but the mold design becomes more complex and demolding is prevented
Solution Approach 1:
The mold is segmented into at least three separate parts that can be arranged to form complex geometries with undercuts. After casting, the segments are removed individually, allowing demolding of complex shapes that would be impossible with a single-piece permanent mold.
Solution Approach 2:
Instead of designing a permanent mold that must be opened for demolding, the invention uses a lost mold approach where the mold is intentionally designed to be destroyed or dissolved after casting. This inverts the traditional approach and eliminates demolding constraints entirely.
3Manufacturing precision
If more than two mold segments are used to define complex geometries, then the component can be produced with high surface quality without draft angles, but the mold assembly complexity increases
Solution Approach 1:
The use of at least three mold segments allows the creation of complex geometries with high surface quality by eliminating the need for draft angles. The segmented structure enables the mold to be opened in multiple directions, facilitating demolding while maintaining precision.
Solution Approach 2:
The lost mold segments are discarded after a single use, which simplifies the overall process by eliminating the need for complex permanent mold structures. The investment in creating precise lost mold segments is offset by the elimination of expensive permanent mold manufacturing and maintenance.
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
Enables the production of electrical coils with high surface quality and complex geometries without draft angles, reducing post-processing needs and mechanical reworking, while simplifying the production process and scaling of components.
Implementation Method 1
The model is melted out of the hardened investment material
Implementation Method 2
at least one molded part is designed as a lost mold, which is produced from a salt or a salt mixture
Data Source
Figure 1
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Figure 4~5
AI summary
The present invention relates to a method for casting a component (10) of complex geometry, in which a mold is used, at least one mold part (1, 5) of which is designed as a expendable mold. The at least one mold part (1, 5) designed as an expendable mold is made from a salt or a salt mixture. In the method, at least one outer or inner part of the mold, which defines the outer or inner geometry of the component, is composed of more than two mold segments (1), which are preferably stacked on top of each other. The method enables the cost-effective casting of components of complex geometry with high surface quality.