Description:FIELD OF THE INVENTION

[0001] The present invention relates to a customizable mold casting device that is capable of providing a means to cast mold of different patterns from metallic chips as per user-specified type of pattern without any chances of cast defects in the mold with proper solidification of the molds, thus providing good quality casting products.

BACKGROUND OF THE INVENTION

[0002] Metallic mold casting plays a vital role in manufacturing complex metal parts with high precision and consistency. This process involves pouring molten metal into a pre-formed mold made from durable materials like steel or cast iron, which withstand the high temperatures of the molten metal. Once the metal cools and solidifies, it takes the shape of the mold, allowing for the creation of intricate designs, detailed features, and complex geometries that would be difficult or impossible to achieve with other methods like machining or forging. Metallic mold casting is widely used in industries such as automotive, aerospace, and machinery, as it enables the production of both small and large-scale components with high strength, dimensional accuracy, and surface finish. The method also allows for the efficient use of material, minimizing waste while offering cost-effective solutions for mass production.

[0003] Traditionally, the user uses tools for casting metallic mold includes crucibles, ladles, and molds made of materials such as steel, iron, and graphite that are essential for melting and pouring molten metal into the mold cavity to create the desired shape. The process requires careful handling to ensure the metal flows smoothly and evenly into the mold without any defects. Proper temperature control is also crucial to achieve the desired results in the final product. Further, the temperature of the molten metal should be observed to prevent overheating or cooling too quickly, which result in casting defects. Additionally, proper ventilation and safety precautions should be taken when working with molten metal to avoid any accidents or injuries.

[0004] US3604497A discloses a series of molds, each having a casting cavity defined by a plurality of movable mold blocks, are positionable to be successively filled with molten metal from a movable ladle. After the metal in each mold solidifies, the mold blocks are moved and the enclosed casting is transported to another location for processing. Cleaning and coating apparatuses are provided to recondition the mold blocks after each pour. The reconditioned blocks are then repositioned to define a casting cavity and moved into a pouring location to be again filled with molten metal.

[0005] WO2002064285A3 relates to a casting mould comprising a die cavity and a casting mould body which dissipates heat and forms said die cavity. Said casting mould is used for casting parts of metal according to a mould casting method and contains a coating in the form of a coating body on the surface forming the die cavity. Said coating has a thickness of less than 5 mm. The coating body is made of a skeleton-shaped, highly porous solid body made of a heat-proof material exhibiting more than 50 % porosity and a thermal conductivity k to k < 1 W/mK.

[0006] Conventionally, many devices are disclosed in prior art that provide a way to cast different metallic molds having different size by using a single mold base with interchangeable inserts but lacks in providing a quick and efficient method for changing the inserts for different kind of the molds. Moreover, such devices lack in controlling formation of air bubble in molten liquid due to which there are huge chances of cast defects in mold.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of casting metallic mold into different pattern from metallic chips as per user-specified type of pattern without any formation of cast defects in mold and accordingly provides proper cooling air for solidifying of the molds in appropriate manner without any chances of error.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that is capable of casting mold of different patterns from metallic chips as per user-specified type of pattern without any chances of cast defects in the mold.

[0010] Another object of the present invention is to develop a device that is capable of preventing formation of any bubble in molten liquid and accordingly provide uniform cooling of the molten liquid in order to form the mold of proper quality.

[0011] Yet another object of the present invention is to develop a device that is capable of providing a means to adjust inner area of cylindrical shaped structure formed for casting in order to ease in casting multiple molds in the user-desired pattern in a single point of time.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a customizable mold casting device that is capable of casting mold of different patterns from metallic chips as per user-specified type of pattern without any formation of any bubble in molten liquid formed from the metallic chips in order to improve casting quality.

[0014] According to an embodiment of the present invention, a customizable mold casting device, comprises of a housing utilize to place over a fixed surface, a touch interactive display panel integrated with the housing enabling a user for giving input regarding a kind of pattern to be casted, a hopper assembled on the housing that is accessed by the user for feeding metallic chips inside the housing, an electric furnace assembled underneath the hopper for accommodating the metallic chips to heat the accommodated metallic chips in for melting the chips into molten metal, a steel conduit integrated underneath the furnace and secured with an electronically controlled swirl nozzle that is actuated by an inbuilt microcontroller for opening to dispense the molten metal in the conduit, a platform arranged at base of the housing and integrated with a motorized two-axis lid screw to translate one of multiple extendable rods assembled on the lid screw underneath the furnace for positioning end of the rod in proximity to end of the conduit, a tray interlinked at end of the rod and integrated with a pair of semi-circular molds that are translated towards each other by means of a pair of motorized sliding units integrated at lateral sides of the tray, multiple electromagnets integrated at ends of the molds for energizing to attach the molds.

[0015] According to another embodiment of the present invention, the proposed device further comprises of, multiple extendable pins integrated on inner periphery of the structure to extend/retract in a regulated manner for applying a pressure on a flexible coupling arranged inside the structure at a required pattern to form the user-selected kind of pattern, an electronically controlled outlet integrated at end of the conduit to get open for dispensing the molten metal into the coupling which results in solidification of the metal in the user-selected kind of pattern, a heating/cooling chamber assembled inside the housing and integrated with multiple Peltier units to heat air inside the chamber, multiple electronically controlled valves integrated inside sides of the housing during filling of the molten liquid for preventing formation of any bubble during transferring the molten liquid, cool air from the chamber is directs towards the structure for solidification of the molten liquid, and a battery associated with the device for providing a continuous power supply to electronically powered components associated with the device.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a customizable mold casting device; and
Figure 2 illustrates another isometric view of a pair of semi-circular molds associated with the proposed device in deployed state.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to a customizable mold casting device that is capable of casting metallic molds of different pattern as per user-specified pattern without any improper melting of metallic chips, formation of air bubbles in the molten metallic chips and cooling effect thus produce good quality casting product for various purposes.

[0022] Referring to Figure 1 and 2, an isometric view of a customizable mold casting device and a pair of semi-circular molds associated with the proposed device in deployed state, respectively are illustrated, comprising a housing 101 integrated with touch interactive display panel 102, a hopper 103 arranged on the housing 101, an electric furnace 104 assembled underneath the hopper 103, a steel conduit 105 arranged underneath the furnace 104 and secured with an electronically controlled swirl nozzle 106, a platform 115 arranged at base of the housing 101 and integrated with a motorized two-axis lid screw 107, multiple extendable rods 118 mounted on the lid screw 107, a tray 108 arranged at end of the rod 118 and integrated with a pair of semi-circular molds 109, a pair of motorized sliding units 110 integrated at lateral sides of the tray 108, multiple electromagnets 119 integrated at ends of the molds 109, multiple extendable pins 116 integrated on inner periphery of the structure, an electronically controlled outlet 111 integrated at end of the conduit 105, a heating/cooling chamber 112 arranged inside the housing 101 and integrated with multiple Peltier units 113, and multiple electronically controlled valves 114 integrated with the chamber 112, and flexible coupling 117 arranged on the pins 116.

[0023] The proposed device comprises of housing 101 made up of any material that includes but not limited to metallic material, alloy, alike that sustains all heating effect produced during casting operation for molding of metallic chips that typically aluminum material. Herein, the housing 101 is utilized to place over a fixed surface and encased with various components associated with the device arrange in sequential manner that aids in casting mold from the metallic chips with different pattern with different units at a single point of the time. Upon placing the housing 101 over the fixed surface, the user accesses a hopper 103 assembled on the housing 101 for feeding metallic chips inside the housing 101 that gets transfer in an electric furnace 104 arranged underneath the hopper 103. After that the user activates the device manually by pressing a switch button associated with the device and integrated with the housing 101.

[0024] The button mentioned herein is a type of a switch that is internally connected with the device via multiple circuits that upon pressing by the user, the circuits get closed and starts conducting electricity that tends to activate the device and vice versa. After activation of the device by the user, a microcontroller associated with the device generates a commands to operate the device accordingly. After activating of the device, the microcontroller activates a touch interactive display panel 102 integrated with the housing 101 to give access to the user for selecting a kind of pattern to be casted.

[0025] The display panel 102 mentioned herein works by using LCD (liquid crystals) that are manipulated by electric currents to control the passage of light through the display unit. When an electric current is applied, the liquid crystals align in a way that either allows light to pass through or blocks it, creating the images and colors that are visible in the LCD of the display panel 102 regarding the kind of pattern to be casted that is further change the electric charge at the location of the touch to register as input. The input is then stored in the microcontroller to process the input.

[0026] Upon processing the input given by the user, the microcontroller generates commands to actuate the electric furnace 104 to heat the accommodated metallic chips for melting the chips into molten metal. The electric furnace 104 operates by converting electrical energy into heat through the process of resistance heating. In the resistance heating process, an electric current passes through a resistive heating element, typically made from materials like metal or ceramic, which has a high resistance to the flow of electricity. As the current flows through the heating element, the electrical resistance causes the metallic chips to heat up to a temperature having range from 600 to 700 degree Celsius required for melting the chips. The heat is then transferred inside the furnace 104, raising the temperature to melt the chips into molten metal.

[0027] Simultaneously, the microcontroller actuates an electronically controlled swirl nozzle 106 integrated with a steel conduit 105 for dispensing of the molten metal in the conduit 105. The swirl nozzle 106 herein operates by utilizing a controlled, rotating motion to create a vortex in the molten metal as the molten metal passes through the swirl nozzle. This rotation is achieved by directing pressurized air or gas through the swirl nozzle at an angle, causing the molten metal to swirl as it exits. The swirling motion aids to atomize the molten metal, breaking into fine droplets ensures a more uniform and controlled dispensing of the molten metal by adjusting parameters like flow rate and rotation speed to dispense out the molten metal in the conduit 105.

[0028] Simultaneously, the microcontroller generates commands to actuate a motorized two-axis lid screw 107 integrated with a platform 115 assembled at base of the housing 101 to translate one of multiple extendable rods 118 mounted on the lid screw 107 underneath the furnace 104. The lead screw 107 coupled with a motor that is activated by the microcontroller to rotate the screw 107 with specified speed in order to translate the bar in X-axis direction as well as in Y-direction axis to move one of rod 118 underneath the furnace 104. After that the microcontroller actuates a pneumatic unit integrated with the rod 118 to extend for positioning end of the rod 118 in proximity to end of the conduit 105.

[0029] The pneumatic unit comprises of an air compressor, air cylinder, air valves i.e. Inlet and outlet valve and piston that works in collaboration to aid extension and retraction of the rod. The air compressor is coupled with a motor that gets activated by the microcontroller to compress the air from surroundings upon entering from the inlet valve to compressed and pumped out via the outlet valve. The air valve allows entry or exit of the compressed air from the compressor. Furthermore, the valve opens and the compressed air enters inside the cylinder thereby increasing the air pressure of the cylinder.

[0030] The piston is connected to the cylinder and due to the increase in the air pressure, the piston moves. And upon closing of the valve, the compressed air exit out from the cylinder thereby decreasing the air pressure of the cylinder. The increasing and decreasing of the air pressure from the cylinder aids in movement of the piston in a to and fro direction that turns in aiding extension and retraction of the rod 118 to positon a tray 108 arranged at end of the rod 118 in proximity to end of the conduit 105. Simultaneously, the microcontroller actuates a pair of motorized sliding units 110 integrated at lateral sides of the tray 108 to translate a pair of semi-circular molds 109 that typically made up of aluminum material assembled over the sliding unit 110 towards each other.

[0031] The sliding unit 110 mentioned herein consists of a rail unit that provides a guided path for linear movement. The rail unit usually includes a pair of parallel rails or tracks, along which the unit 110 moves. The slider carriage, also called a stage or platform equipped with a mechanism to minimize friction and ensure smooth motion. The sliding unit 110 incorporates a motor and a drive mechanism to generate linear motion. The motor is connected to a drive mechanism, such as a belt, lead screw, or ball screw. The drive mechanism converts the rotational motion of the motor into linear motion, propelling the slider carriage along the rail unit to translate the molds 109 towards each other.

[0032] Simultaneously, the microcontroller actuates multiple electromagnets 119 integrated at ends of the molds 109 for energizing to intact the molds 109 with each other for forming a cylindrical shaped structure. The electromagnet comprises of a conducting coil, when the electric current is passed across the coil that result in generation of the magnetic field around the coil and that results in the generation of the magnetic force due to which the electromagnets 119 get energized. When the current release, the electromagnets 119 get de-energized. The energization and de-energization of the electromagnets 119 resulting in attachment of ends of the molds 109 to form the cylindrical shaped structure.

[0033] After the forming of the cylinder structure, the microcontroller actuates a pneumatic unit integrated with each of multiple extendable pins 116 integrated on inner periphery of the structure to extend/retract in a regulated manner for applying a pressure on a flexible coupling 117 assembled inside the structure at a required pattern to form the user-selected kind of pattern. Herein, the pins provide a different kinds of replica due to different extension level if the pins over the flexible coupling to form different user-selected kind of pattern. After the formation of the user-selected kind of pattern, the microcontroller generates commands to actuate an electronically controlled outlet 111 integrated at end of the conduit 105 to open for dispensing the molten metal into the coupling 117 results for solidifying the metal in the user-selected kind of pattern.

[0034] The electronically controlled outlet 111 mentioned herein operates by using an electronic switch, such as a solenoid valve or a motorized actuator, to open or close the flow of molten metal through the conduit 105. Once the microcontroller receives the command to dispense the molten metal, the microcontroller activates the outlet 111 by energizing the electronic switch that opens the outlet 111, allowing the molten metal to flow out of the conduit 105 and into the molds 109 to solidify into the user-selected pattern. During filling of the molten liquid, the microcontroller actuates multiple Peltier units 113 integrated with a heating/cooling chamber 112 assembled inside the housing 101 to heat air inside the chamber 112.

[0035] The Peltier unit 113 mentioned herein comprises of junctions and a thermoelectric generator (TEG) that is a solid unit which converts the heat into electric energy by the phenomena of see beck effect that is also known as form of thermoelectric effect. Further when the current flows through the junctions, the heat is removed from one junction to regulate the temperature within the chamber 112 for heating air inside the chamber 112. Simultaneously, the microcontroller actuates multiple electronically controlled valves 114 integrated with the chamber 112 for releasing the hot air towards outer portion of the structure for solidification of the molten liquid. The valve 114 comprises of a diaphragm that is activated by the microcontroller to open orifices of the valve 114 to dispense out the hot air towards outer portion of the structure for preventing formation of any bubble in addition with actuation of the Peltier units 113 to provide cool air from the chamber 112 along the structure for solidifying the molds 109 appropriately.

[0036] A battery (not shown in figure) is associated with the device to offer power to all electrical and electronic components necessary for their correct operation. The battery is linked to the microcontroller and provides (DC) Direct Current to the microcontroller. And then, based on the order of operations, the microcontroller sends that current to those specific electrical or electronic components so they effectively carry out their appropriate functions.

[0037] The present invention works best in following manner that includes the housing 101 developed to be positioned on a fixed surface and arranged with the hopper 103 for feeding metallic chips inside the housing 101. After that the touch interactive display panel 102 that is accessed by the user for selecting a kind of pattern to be casted. Based on that the microcontroller actuates the electric furnace 104 to heat the accommodated metallic chips in view of melting the chips into molten metal. After that the electronically controlled swirl nozzle 106 that is actuated by the microcontroller to get open for allowing dispensing of the molten metal in the conduit 105. Also, the motorized two-axis lid screw 107 is actuated by the microcontroller to translate one of multiple extendable rods 118 underneath the furnace 104, followed by extension of the rod 118 to extend for positioning end of the rod 118 in proximity to end of the conduit 105. After that the pair of motorized sliding units 110 translates the semi-circular molds 109 towards each other, followed by energizing of multiple electromagnets 119 resulting in attachment of ends of the molds 109 to form a cylindrical shaped structure. After that the extendable pins 116 are actuated by the microcontroller to extend/retract in a regulated manner for applying a pressure on the flexible coupling 117 at a required pattern to form the user-selected kind of pattern, followed by actuation of the electronically controlled outlet 111 to get open for dispensing the molten metal into the coupling 117 which results in solidification of the metal in the user-selected kind of pattern. During this operation, the multiple Peltier units 113 are actuated by the microcontroller to heat air inside the chamber 112 which is directed towards outer portion of the structure by means of the electronically controlled valves 114 in view of preventing formation of any bubble while transferring the molten liquid. Also, the cool air from the chamber 112 is directs towards the structure for allowing solidification of the molten liquid.

[0038] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A customizable mold casting device, comprising:

i) a housing 101 developed to be positioned on a fixed surface, wherein said housing 101 is arranged with a touch interactive display panel 102 that is accessed by a user for selecting a kind of pattern to be casted;
ii) a hopper 103 arranged on said housing 101 that is accessed by said user for feeding metallic chips inside said housing 101, wherein an electric furnace 104 is arranged underneath said hopper 103 for accommodating said metallic chips, followed by actuation of said furnace 104 to heat said accommodated metallic chips in view of melting said chips into molten metal;
iii) a steel conduit 105 arranged underneath said furnace 104 and secured with an electronically controlled swirl nozzle 106 that is actuated by an inbuilt microcontroller to get open for allowing dispensing of said molten metal in said conduit 105, wherein a platform 115 is arranged at base of said housing 101 and integrated with a motorized two-axis lid screw 107 that is actuated by said microcontroller to translate one of multiple extendable rods 118 mounted on said lid screw 107 underneath said furnace 104, followed by extension of said rod 118 to extend for positioning end of said rod 118 in proximity to end of said conduit 105;
iv) a tray 108 arranged at end of said rod 118 and integrated with a pair of semi-circular molds 109 that are translated towards each other by means of a pair of motorized sliding units 110 integrated at lateral sides of said tray 108, followed by energizing of multiple electromagnets 119 integrated at ends of said molds 109 resulting in attachment of ends of said molds 109 to form a cylindrical shaped structure; and
v) plurality of extendable pins 116 integrated on inner periphery of said structure that are actuated by said microcontroller to extend/retract in a regulated manner for applying a pressure on a flexible coupling 117 arranged inside said structure at a required pattern to form said user-selected kind of pattern, followed by actuation of an electronically controlled outlet 111 integrated at end of said conduit 105 to get open for dispensing said molten metal into said coupling 117 which results in solidification of said metal in said user-selected kind of pattern.

2) The device as claimed in claim 1, wherein a heating/cooling chamber 112 is arranged inside said housing 101 and integrated with multiple Peltier units 113 that are actuated by said microcontroller to heat air inside said chamber 112 which is directed towards outer portion of said structure by means of multiple electronically controlled valves 114 integrated inside sides of said housing 101 during filling of said molten liquid in view of preventing formation of any bubble while transferring said molten liquid.

3) The device as claimed in claim 1 and 2, wherein cool air from said chamber 112 is directs towards said structure, post filling of said molten liquid, in view of allowing solidification of said molten liquid.