Description:FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus for pouring a molten metal, for example, in to a mould. More specifically, the present invention relates to an apparatus for bottom-pouring a molten metal into mould using gravity die casting method.
BACKGROUND OF THE INVENTION
[0002] The introduction of molten metal into mould constitutes a critical juncture in the metal casting process, wherein the characteristics of the liquid metal during pouring and subsequent solidification play a determinate role in shaping the quality and integrity of the ultimate cast article. Within the framework of this intricate procedure, the selection and performance of the pouring instrument emerge as pivotal considerations.
[0003] Historically, ladles have served as indispensable vessels for the transfer of molten metal into mould. However, a notable drawback persists in the conventional practice of pouring metal from the upper aspect of the ladle. This customary methodology gives rise to inherent challenges, most notably the occurrence of drossing a term grounded in metallurgical parlance denoting the formation of solid scum on the surface of molten metal upon exposure to atmospheric oxygen during the pouring phase.
[0004] The ramifications of such an occurrence extend beyond mere superficial defects, potentially jeopardizing the structural integrity of the cast product and, consequently, its overall functional performance. The prevalent upper-side pouring methodology of traditional ladles inadvertently facilitates the interaction of atmospheric oxygen with the molten metal, instigating the undesirable formation of solid scum.
[0005] Therefore, there is a necessity to address the aforementioned limitations associated with traditional ladles or apparatus.
OBJECTS OF THE INVENTION
[0006] Some of the objects of the presently disclosed invention, of which at the minimum one object is fulfilled by at least one embodiment disclosed herein, are as follows.
[0007]An object of the present invention is to provide an alternative, which overcomes at least one drawback encountered in the existing prior art.
[0008]Another object of the present invention is to provide an apparatus for pouring molten metal.
[0009] Still another object of the present invention is to provide an apparatus for bottom pouring molten metal.
[00010]Other objects and benefits of the present invention will be more apparent from the following description, which is not intended to bind the scope of the present invention.
SUMMARY OF THE INVENTION
[00011]In one version, this invention involves a tool designed for pouring molten metal from the bottom. The tool has a container with an enclosed space, surrounded by a side wall and a sealed bottom. The side wall has protruding lugs, each having a hole for holding a bolt and a spring. The sealed bottom has openings for controlled pouring of molten metal. Heaters are placed inside the container, and a movable plate below the sealed bottom has openings that can align or misalign with the sealed bottom openings to control the pouring. A mechanism is connected to the plate to enable its movement. A back plate holds the movable plate, and the bolt and spring hold everything together while allowing plate movement.
[00012]In a related version, the tool includes a mechanism with a pneumatic cylinder connected to a source of compressed fluid. The cylinder has a chamber with a piston connected to the movable plate through a link. Introducing compressed fluid displaces the piston, moving the plate.
[00013]In another aspect, the mentioned mechanism is improved with a fluid control valve connected between the source of compressed fluid and the cylinder.
[00014]Additionally, in this version, the compressed fluid used in the pneumatic mechanism can be steam, air, carbon dioxide, or nitrogen.
[00015]In a different version, the tool, as described earlier, has rotatable elements in holes between the movable plate and the back plate. These elements allow the plate to move between aligned and misaligned positions.
[00016]In this version, these rotatable elements can have various shapes and be made of materials like metal or ceramic, capable of withstanding temperatures from 100°C to 600°C.
[00017]In another version, the spring mentioned earlier can be a regular spring or a shape memory alloy, both capable of withstanding temperatures from 100°C to 600°C.
[00018]Also, in this version, a heat-resistant plate is placed between the container and the back plate, made of Bakelite.
[00019]Furthermore, this version includes situations where the molten metal can be zinc, lead, or alloys of zinc and lead.
[00020]Finally, in one practical use, the tool, as described earlier, is placed in a furnace for melting metal to get molten metal. This molten metal is then molded to create parts for a battery.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
[00021]The present invention will now described with reference to the accompanying drawing, wherein:
[00022]FIG. 1 illustrates a perspective view of an apparatus for bottom-pouring of a molten metal in accordance with the embodiment of the present invention.
[00023]FIG. 2 illustrates an exploded view of the apparatus of FIG. 1.
[00024]FIG. 3 illustrates a top view of the apparatus of FIG. 1.
[00025]FIG. 4 illustrates a bottom view of the apparatus of FIG. 1.
[00026]FIG. 5 illustrates a front view of the apparatus of FIG. 1
[00027]FIG. 6 illustrates a back view of the apparatus of FIG. 1.
[00028]FIG. 7 illustrates a side view of the apparatus of FIG. 1.
LIST OF NUMERALS
[00029]The following is the list of numerals and their meaning as used in the present specification.
100 - Apparatus 106 - Lugs 116 - Mechanism
102 - Vessel 106h - Through aperture 118 - Back plate
104 - Interior space 108 - Heaters 118h - Holes
104b - Closed bottom 110 - Bolt 118l - Lugs
104h - Through holes 112 - Biasing member 118lh - Hole
104s - Outer surface 114 - Slide plate 118s - Longitudinal slot
104w - Peripheral wall 114h - Through holes 120 - Sliding elements
122 - Heat resistant plate
DETAILED DESCRIPTION
[00030]All the terms and expressions, which may be technical, scientific, or otherwise, as used in the present invention have the same meaning as understood by a person having ordinary skill in the art to which the present invention belongs, unless and otherwise explicitly specified.
[00031]In the present specification, and the claims, the articles “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[00032]The term “comprising” as used in the present specification and the claims will be understood to mean that the list following is non-exhaustive and may or may not include any other extra suitable features or elements or steps or constituents as applicable.
[00033]Further, the terms “about” or “approximately” used in combination with ranges relating to sizes of parts, or any other physical properties or characteristics, are meant to include small variations that may occur in the upper and/or lower limits of the ranges of the sizes.
[00034]Ladles have played an indispensable role as vessels for transferring molten metal into molds. Nevertheless, a notable drawback inherent in conventional metal pouring practices from the upper aspect of the ladle has persisted. This customary approach gives rise to challenges, notably the occurrence of drossing—a term grounded in metallurgical parlance denoting the formation of solid scum on the molten metal's surface upon exposure to atmospheric oxygen during the pouring phase.
[00035]Recognizing the shortcomings of traditional ladles, an apparatus is disclosed herein, configured for the controlled discharge of molten metal from its lower section. The apparatus comprises a vessel with a confined cavity, delimited by a circumferential sidewall and a hermetically sealed base. Protruding lugs on the sidewall, each featuring a hole for a bolt and a spring, enhance the apparatus's functionality. The sealed base, equipped with openings for regulated molten metal discharge, addresses the challenges associated with drossing.
[00036]Internally, heaters are strategically disposed within the receptacle, ensuring optimal temperature control. A movable plate positioned beneath the sealed base incorporates openings that can align or misalign with those in the sealed base, affording precise control over the pouring process. A connected mechanism enables the plate's movement, providing a controlled and efficient pouring mechanism.
[00037]Structurally, a back plate secures the movable plate, while the bolt and spring collectively maintain cohesion, allowing for the necessary plate movement. By adopting this inventive apparatus, the inadvertent interaction of atmospheric oxygen with the molten metal is mitigated, minimizing the formation of undesirable solid scum and enhancing the overall quality and structural integrity of the cast product.
[00038]The present invention is now described with reference to the accompanying drawing wherein FIG. 1 illustrates a perspective view of an apparatus for bottom-pouring of a molten metal in accordance with the embodiment of the present invention, FIG. 2 illustrates an exploded view of the apparatus of FIG. 1, FIG. 3 illustrates a top view of the apparatus of FIG. 1, FIG. 4 illustrates a bottom view of the apparatus of FIG. 1, FIG. 5 illustrates a front view of the apparatus of FIG. 1, FIG. 6 illustrates a back view of the apparatus of FIG. 1, and FIG. 7 illustrates a right-hand side view of the apparatus of FIG. 1.
[00039]The bottom-pouring apparatus (100) for molten metal comprises a vessel (102) that encompasses an interior space (104) defined by a peripheral wall (104w) and a closed bottom (104b). Lugs (106) extend orthogonally from the outer surface of the peripheral wall, each featuring a through aperture (106h) designed to receive a bolt (110) along with a biasing member (112). Heaters (108) are strategically placed within the interior space to maintain the molten state of the metal.
[00040]Beneath the closed bottom (104b), a moveable slide plate (114) is positioned, featuring through holes (114h) that selectively align with through holes (104h) in the closed bottom. The mechanism (116), coupled to the slide plate (114), facilitates controlled movement, enabling the slide plate to transition between registering and non-registering positions. A back plate (118) receives the slide plate and is equipped with a longitudinal slot (118s) aligning with the through holes (104h, 114h). Lugs (118l) extending from the periphery of the back plate register with the lugs (106) of the vessel, creating a secure connection. Holes (118h) formed in proximity to the longitudinal slot provide additional structural support.
[00041]The entire assembly is held together by a bolt (110) passing through the holes in the lugs and biasing member, allowing the vessel, slide plate, and back plate to function as an integrated unit. In operation, when the slide plate is in the registering position, the aligned through holes permit the controlled egress of molten metal. Conversely, in the non-registering position, misalignment of the holes prevents egress, offering precise control over the pouring process. This embodiment provides a versatile and efficient system for bottom-pouring molten metal, ensuring enhanced control and flexibility in various metalworking applications.
[00042]In accordance with one embodiment of the present invention, the bottom-pouring apparatus (100) is equipped with a temperature control module for even greater precision in maintaining the molten state of the metal. Additional sensors may be incorporated within the vessel (102) to monitor and regulate the temperature. The temperature control module, connected to the heaters (108), adjusts the heating intensity in real-time based on the monitored temperature. This enhancement ensures a consistently optimal molten state, contributing to improved casting quality and reduced energy consumption.
[00043]In accordance with one embodiment of the present invention, the bottom-pouring apparatus (100) features a slide plate for enhanced flexibility in controlling the flow of molten metal. In one embodiment, the moveable slide plate (114) may be designed with interchangeable modules, each with a unique pattern of through holes. These modules may be easily swapped to achieve different flow patterns during the pouring process. The modular slide plate system allows operators to adapt the apparatus for diverse casting requirements, providing a customizable and versatile solution for various metalworking applications.
[00044]In one embodiment of the present invention, the mechanism (116) incorporates a pneumatic system featuring a pneumatic cylinder in communication with a compressed fluid source. The pneumatic cylinder consists of a cylindrical chamber housing a piston that moves freely within. Upon the introduction of compressed fluid, the piston is displaced within the cylindrical chamber. This displacement is facilitated by the connection between the piston and the slide plate (114) through a coupling member, ultimately causing the slide plate to move accordingly.
[00045]The cylindrical chamber and piston together form a component of the apparatus, which enables controlled movement. Notably, this pneumatic mechanism is configured to be responsive to changes in fluid pressure, contributing to the precision and adaptability of the overall system.
[00046]The piston is intricately connected to the slide plate (114) through a coupling member. This coupling member serves as the linkage between the pneumatic mechanism and the movable slide plate. Consequently, as the piston undergoes displacement within the cylindrical chamber, the coupling member transmits these movements to the slide plate.
[00047]This interconnected design ensures that the displacement of the piston translates directly into the controlled movement of the slide plate. The coupling member acts as the intermediary, facilitating a seamless and responsive interaction between the pneumatic mechanism and the critical components responsible for regulating the egress of molten metal.
[00048]The interconnected components work synergistically to facilitate a controlled and adaptive bottom-pouring process for molten metal.
[00049]In continuation of the aforementioned embodiment, a pivotal feature is incorporated into the operational mechanism (116) of the present invention. This additional element enhances the control and adaptability of the pneumatic system, further refining the precision of the bottom-pouring apparatus.
[00050]Within this specific embodiment, a fluid control valve is seamlessly integrated into the mechanism. This valve is strategically positioned between the source of compressed fluid and the cylindrical chamber of the pneumatic cylinder. The introduction of this fluid control valve introduces a new layer of control, enabling operators to modulate and regulate the flow of compressed fluid into the cylindrical chamber with precision.
[00051]The fluid control valve acts as a gatekeeper, allowing operators to finely tune the pressure and rate at which compressed fluid enters the pneumatic cylinder. This meticulous control over fluid dynamics contributes to the nuanced adjustments in the displacement of the piston within the cylindrical chamber. As a result, the movement of the slide plate (114) becomes even more tailored, offering operators the capability to optimize the pouring process based on specific casting requirements.
[00052]Thus, it is possible to obtain fine-tuned control in the bottom-pouring apparatus, by incorporation of a fluid control valve thereby adding an additional layer of adaptability. Operators can now dynamically adjust the system's response to changing casting conditions, ensuring a level of precision that is essential in various metalworking applications.
[00053]Continuing with the refined features of the present invention, an aspect involves the selection of the compressed fluid for the pneumatic mechanism within the operational mechanism (116). This choice further tailors the functionality and adaptability of the bottom-pouring apparatus.
[00054]In accordance with this embodiment, the compressed fluid utilized in the pneumatic system is meticulously chosen from a group of options. The available choices include steam, air, carbon dioxide, and nitrogen. Each of these compressed fluids offers distinct characteristics that can be strategically leveraged based on the specific requirements of the metal casting process.
[00055]The utilization of steam introduces the element of heat into the pneumatic system, potentially influencing the temperature dynamics within the apparatus. Air, being a commonly available and cost-effective option, provides a balance between efficiency and practicality. Carbon dioxide and nitrogen, known for their inert properties, may offer advantages in specific casting scenarios where avoiding chemical reactions with the molten metal is critical.
[00056]In accordance with one embodiment of the present invention, sliding elements (120) are rotatably received in the holes (118h) between the slide plate (114) and the back plate (118) which allow the slide plate (114) to move in the registering and non-registering positions.
[00057]The incorporation of sliding elements (120) within the system enhances the fluidity and precision of the apparatus's movements, specifically in relation to the slide plate (114) and the back plate (118).
[00058]The sliding elements (120) are strategically positioned within the holes (118h) that form the interface between the slide plate and the back plate. These elements are ingeniously designed to be rotatable, introducing an additional degree of freedom in the movement of the apparatus. This dynamic feature allows the slide plate to smoothly transition between registering and non-registering positions, aligning with the demands of different phases within the metal pouring process.
[00059]The shapes of these sliding elements (120) are carefully selected from a diverse array, including options such as spherical, spheroidal, cylindrical, semi-spherical, and elliptical. This intentional variety enables operators to customize the movement characteristics of the apparatus based on specific casting requirements. The choice of shape influences the degree of rotational freedom and the ease of movement, contributing to the overall adaptability of the bottom-pouring system.
[00060]Moreover, the sliding elements are constructed from materials renowned for their durability and resilience under high-temperature conditions. Options include metals and ceramics, ensuring that the sliding elements can withstand the demanding thermal environments encountered during metal casting processes. This durability is paramount in maintaining the structural integrity and longevity of the apparatus, particularly in applications where temperatures can range from 100°C to 600°C. In specific embodiment, the sliding elements (120) are made of a material capable of withstanding a temperature in the range of 100 C to 600 C.
[00061]By incorporating rotatable sliding elements, the apparatus achieves a level of precision and flexibility which aids in achieving controlled and efficient metal pouring. The versatility introduced by the shape and material options of the sliding elements further enhances the adaptability of the apparatus across a spectrum of metalworking scenarios.
[00062]Building upon the intricacies of the bottom-pouring apparatus, another component that contributes to the controlled movement and stability of the system is the biasing member (112). This embodiment further refines the design by introducing a dual-functionality aspect to the biasing member, ensuring resilience and adaptability under varying temperature conditions within the range of 100°C to 600°C.
[00063]In this embodiment, the biasing member is ingeniously designed to be a spring, a resilient component known for its capacity to store and release energy, contributing to the controlled displacement of the piston and, consequently, the slide plate (114). The spring imparts a robust and predictable force, creating a dynamic equilibrium within the system.
[00064]Additionally, recognizing the diverse thermal environments encountered in metal casting processes, the embodiment incorporates shape memory alloys into the design of the biasing member. These alloys possess the unique ability to return to a predefined shape or state when subjected to specific temperature changes. The selection of shape memory alloys capable of withstanding temperatures within the range of 100°C to 600°C ensures that the biasing member retains its functional properties across the varying thermal conditions inherent in metalworking applications.
[00065]Continuing the refinement of the bottom-pouring apparatus, this embodiment introduces a component aimed at addressing the challenges posed by high temperatures and thermal transfer within the system. In accordance with this embodiment, a heat-resistant plate (122) is strategically positioned between the vessel (102) and the back plate (118), offering a specialized solution to enhance the overall durability and thermal management of the apparatus.
[00066]The heat-resistant plate serves as a protective barrier, effectively mitigating heat transfer between the vessel and the back plate. This strategic placement is particularly crucial in metal casting processes, where elevated temperatures could otherwise compromise the structural integrity of the apparatus components. The heat-resistant plate acts as a buffer, reducing the direct impact of high temperatures on critical elements, thereby extending the operational lifespan of the apparatus.
[00067]The heat-resistant plate is constructed from Bakelite, a thermosetting plastic known for its excellent heat resistance and insulating properties. Bakelite exhibits remarkable stability even in demanding thermal environments, making it an ideal material for this specific application. Its insulation characteristics contribute to minimizing heat conduction, ensuring that the apparatus remains thermally insulated and retains its functionality under prolonged exposure to high temperatures.
[00068]By incorporating a heat-resistant plate made of bakelite, the apparatus not only ensures robust thermal insulation but also introduces a lightweight and durable component, further enhancing its overall reliability in various metal casting scenarios. The thoughtful selection of materials and placement of the heat-resistant plate showcase the commitment to addressing the thermal challenges inherent in metalworking applications.
[00069]The apparatus is capable of handling molten metals such as zinc, lead, and alloys composed of zinc and lead. This wide range of metal compatibility expands the applicability of the apparatus across diverse metalworking scenarios, from general casting processes to more specialized alloy production, showcasing its adaptability in meeting the demands of different industrial applications.
[00070]The working of the apparatus (100) in now explained in detail herein below:
[00071]Molten metal such as lead is either heated in the vessel or molten metal is poured into the vessel (102). In this step, the slide plate (114) is in a non-registrable position and the holes of the vessel and the slide plate do not register. Thus, the molten metal stays within the vessel.
[00072]The pneumatic mechanism when actuated, moves the slide plate (114) such that the holes of the slide plate, and holes of the vessel now register. The molten metal flows through and passes through the longitudinal slot in the back plate and into a mould (not shown in the figures). The timing of the slide plate movement, and the flow of the molten metal can be controlled precisely using the presently disclosed apparatus.
[00073]Using the pneumatic mechanism, the flow of the molten metal and the amount of the molten metal can be controlled which provides an enhanced sophistication.
TECHNICAL ADVANCES AND ECONOMICAL SIGNIFICANCE OF THE PRESENT INVENTION
[00074]The following are few of the technical and economical significance of the present invention:
?Reduced or no drossing ?Reduced material waste
?Precision and control ?Increased operational efficiency
?Versatility and adaptability ?Product consistency and quality
?Thermal management and durability ?Market competitiveness
?Efficiency in battery manufacturing ?Technological advancements in battery manufacturing
?Cost-effective and sustainable casting , Claims:We claim:
1.An apparatus (100) for bottom-pouring of a molten metal, the apparatus (100) characterized by having:
-a vessel (102) enclosing an interior space (104) wherein the vessel receiving molten metal from a molten metal source
othe interior space (104) defined by a peripheral wall (104w), and a closed bottom (104b);
othe peripheral wall (104w) having an outer surface (104s) from which lugs (106) extends orthogonally away from the outer surface (104s);
?the lugs (106) having a through aperture (106h) formed thereon, the through aperture (106h) receiving a bolt (110) along with a biasing member (112) therein;
othe closed bottom (104b) having through holes (104h) formed thereon, the through holes (106h) selectively facilitating egress of molten metal therethrough;
-heaters (108) disposed within the interior space (104) in the vessel (102);
-a slide plate (114) being moveable, is received below the closed bottom (104b) of the vessel (102), the slide plate (114) having through holes (114h) formed thereon, the through holes (114h) selectively register with the through holes (104h) of the closed bottom (104b) to selectively:
ofacilitate egress of the molten metal therethrough upon sliding the slide plate (114) in a registering position; and
oprevent egress of the molten metal therethrough upon sliding the slide plate (114) in a non-registering position;
-a mechanism (116) coupled to the slide plate (114) to move the slide plate (114) to one of the registering position, and non-registering position;
-a back plate (118) receiving the slide plate (114) thereon,
othe slide plate (114) being moveable over the back plate (118);
othe back plate (118) having
?a longitudinal slot (118s) formed thereon, the longitudinal slot (118s) registering with the through holes (104h) and the through holes (114h);
?holes (118h) formed in proximity of and on either side of the longitudinal slot (118s);
?lugs (118l) extending orthogonally from the periphery of the back plate (118), the lugs (118l)
?registering with the lugs (106);
?having a hole (118lh) formed thereon, the hole (118lh) receiving the bolt (110) therein;
wherein the bolt (110) along with the biasing member (112) holds the vessel (102), the slide plate (114), and the back plate (118) together, while allowing the slide plate (114) to move in the registering and non-registering positions.
2.The apparatus as claimed in claim 1, wherein the mechanism (116) includes a pneumatic mechanism comprising a pneumatic cylinder in fluidic communication with a source of compressed fluid, the pneumatic cylinder comprising a cylindrical chamber with a piston slidably disposed therein, wherein the compressed fluid upon introducing displaces the piston in the cylindrical chamber, wherein the piston is connected to the slide plate (114) through a coupling member, which results in displacement of the slide plate (114).
3.The apparatus as claimed in claim 2, wherein the mechanism (116) includes a fluid control valve connected between the source of compressed fluid and the cylindrical chamber.
4.The apparatus as claimed in claim 2, wherein the compressed fluid is one selected from the group consisting of steam, air, and carbon dioxide, nitrogen.
5.The apparatus as claimed in claim 1, wherein sliding elements (120) are rotatably received in the holes (118h) between the slide plate (114) and the back plate (118) which allow the slide plate (114) to move in the registering and non-registering positions.
6.The apparatus as claimed in claim 5, wherein
the sliding elements (120) having one shape selected from the group consisting of spherical, spheroidal, cylindrical, semi-spherical, and elliptical;
the sliding elements (120) are made of one material selected from the group consisting of metal, and ceramic; and
the sliding elements (120) are made of a material capable of withstanding a temperature in the range of 100 C to 600 C.
7.The apparatus as claimed in claim 1, wherein the biasing member (112) is a spring, and shape memory alloys capable of withstanding a temperature in the range of 100 C to 600 C.
8.The apparatus as claimed in claim 1, wherein a heat resistant plate (122) is disposed between the vessel (102) and the back plate (118), and wherein the material of the heat resistant plate (122) is Bakelite.
9.The apparatus as claimed in claim 1, wherein the molten metal is zinc, lead, and alloys of zinc and lead.
10.The apparatus as claimed in claim 1 is disposed within a furnace for melting the metal to obtain the molten metal, and the molten metal is moulded to obtain components of a battery.
Dated this 24 December 2023
For the applicant: Luminous Power Technologies Private Limited

Abhishek Choudury
Patent Agent for the Applicant
Reg. No. IN/PA - 1578
To,
The Controller of Patents,
The Patent Office, At Delhi