HYBRID CHILL WITH ENHANCED HEAT TRANSFER

Abstract

A hybrid chill with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle is provided. The hybrid chill comprises a base comprising an outer wall having a first side and a second side. Each of the first and second sides extends from a first longitudinal end to an opposite second longitudinal end. The outer wall is closed to define a hollow portion. The base further comprises a heat transfer fluid in a liquid phase disposed in the hollow portion. The heat transfer fluid has a boiling point of between 320 C. and 400 C. at 1 bar for enhanced heat transfer during casting. The chill further comprises a plurality of crankcase members. Each member is disposed on the first side. Each member is spaced apart from a respective adjacent member defining an open recess.

Claims

1. A hybrid chill with enhanced heat transfer for casting of a sand cast aluminum part of a vehicle, the hybrid chill comprising: a base comprising an outer wall having a first side and a second side opposite the first side, each of the first and second sides extending from a first longitudinal end to an opposite second longitudinal end and along a first lateral end and a second lateral end opposite the first lateral end, the outer wall being closed to define a hollow portion, the base further comprising a heat transfer fluid in a liquid phase disposed in the hollow portion, the heat transfer fluid having a boiling point of between 320 Celsius ( C.) and 400 C. at 1 bar for enhanced heat transfer during casting; and a plurality of crankcase members, each member disposed on the first side and extending from the first lateral end to the second lateral end of the outer wall, each member being parallel to and spaced apart from a respective adjacent member defining an open recess extending between adjacent members from the first lateral end to the second lateral end, wherein the outer wall is gray iron comprising 2.8 to 2.9 weight percent (wt %) carbon (C), 1.2 to 1.3 wt % silicon (Si), 0.9 to 1.1 wt % manganese (Mn), less than 0.15 wt % phosphorus (P), and less than 0.12 wt % sulfur (S), wherein at least one crankcase member comprises an inner cavity formed therein and in fluid communication with the hollow portion of the body, the inner cavity comprising heat transfer fluid for increased heat transfer, wherein the inner cavity of the at least one crankcase member is formed by the outer wall having an inner surface, the inner surface having peaks and valleys defining an open region between each respective peak for enhanced heat transfer.

2-5. (canceled)

6. The chill of claim 1 where the second side of the base comprises a plurality of fins formed thereacross from the first lateral end to the second lateral end, each fin being spaced apart from a respective adjacent fin to define an open portion extending between adjacent fins from the first lateral end to the second lateral end for enhanced heat transfer.

7. The chill of claim 1 wherein the heat transfer fluid is a silicon-based heat transfer fluid in the liquid phase.

8. The chill of claim 1 wherein the heat transfer fluid is a silicon-based heat transfer fluid comprising polydimethylsiloxane.

9. A hybrid chill with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle, the hybrid chill comprising: a base comprising an outer wall having a first side and a second side opposite the first side, each of the first and second sides extending from a first longitudinal end to an opposite second longitudinal end and along a first lateral end and a second lateral end opposite the first lateral end, the outer wall being closed to define a hollow portion, the base further comprising a silicon-based heat transfer fluid in a liquid phase disposed in the hollow portion, the heat transfer fluid having a boiling point of between 320 Celsius ( C.) and 400 C. at 1 bar for enhanced heat transfer during casting, and a plurality of crankcase members, each member disposed on the first side and extending from the first lateral end to the second lateral end of the outer wall, each member being parallel to and spaced apart from a respective adjacent member defining an open recess extending between adjacent members from the first lateral end to the second lateral end, wherein the outer wall is gray iron comprising 2.8 to 2.9 weight percent (wt %) carbon (C), 1.2 to 1.3 wt % silicon (Si), 0.9 to 1.1 wt % manganese (Mn), less than 0.15 wt % phosphorus (P), and less than 0.12 wt % sulfur (S), wherein at least one crankcase member comprises an inner cavity formed therein and in fluid communication with the hollow portion of the body, the inner cavity comprising heat transfer fluid for increased heat transfer, wherein the inner cavity of the at least one crankcase member is formed by the outer wall having an inner surface, the inner surface having peaks and valleys defining an open region between each respective peak for enhanced heat transfer.

10-12. (canceled)

13. The chill of claim 9 where the second side of the base comprises a plurality of fins formed thereacross from the first lateral end to the second lateral end, each fin being spaced apart from a respective adjacent fin to define an open portion extending between adjacent fins from the first lateral end to the second lateral end for enhanced heat transfer.

14. The chill of claim 1 wherein the heat transfer fluid is a silicon-based heat transfer fluid comprising polydimethylsiloxane.

15. A hybrid chill with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle, the hybrid chill comprising: a base comprising an outer wall having a first side and a second side opposite the first side, each of the first and second sides extending from a first longitudinal end to an opposite second longitudinal end and along a first lateral end and a second lateral end opposite the first lateral end, the outer wall being closed to define a hollow portion, the base further comprising a heat transfer fluid in a liquid phase disposed in the hollow portion, the heat transfer fluid having a boiling point of between 320 C. and 400 C. at 1 bar for enhanced heat transfer during casting, the heat transfer fluid being a silicon-based heat transfer fluid comprising polydimethylsiloxane; and a plurality of crankcase members, each member disposed on the first side and extending from the first lateral end to the second lateral end of the outer wall, each member being parallel to and spaced apart from a respective adjacent member defining an open recess extending between adjacent members from the first lateral end to the second lateral end, wherein the outer wall is gray iron comprising 2.8 to 2.9 weight percent (wt %) carbon (C), 1.2 to 1.3 wt % silicon (Si), 0.9 to 1.1 wt % manganese (Mn), less than 0.15 wt % phosphorus (P), and less than 0.12 wt % sulfur (S), wherein at least one crankcase member comprises an inner cavity formed therein and in fluid communication with the hollow portion of the body, the inner cavity comprising heat transfer fluid for increased heat transfer, wherein the inner cavity of the at least one crankcase member is formed by the outer wall having an inner surface, the inner surface having peaks and valleys defining an open region between each respective peak for enhanced heat transfer.

16-19. (canceled)

20. The chill of claim 15 where the second side of the base comprises a plurality of fins formed thereacross from the first lateral end to the second lateral end, each fin being spaced apart from a respective adjacent fin to define an open portion extending between adjacent fins from the first lateral end to the second lateral end for enhanced heat transfer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0025] FIG. 1 is a perspective view of a hybrid chill with enhanced heat transfer in accordance with one embodiment of the present disclosure.

[0026] FIG. 2 is an environmental cross-sectional end view of the hybrid chill in FIG. 1 taken along lines 2-2.

[0027] FIG. 3 is a cross-sectional side view of a conceptual image of the hybrid chill in FIG. 1 having a hollow portion with heat transfer fluid in accordance with one embodiment of present disclosure.

[0028] FIG. 4 is a cross-sectional side view of a conceptual image of the hybrid chill in FIG. 1 having an inner cavity with heat transfer fluid in accordance with another embodiment.

[0029] FIG. 5A is a cross-sectional side view of a conceptual image of the hybrid chill in FIG. 1 having an inner surface with a surface roughness in accordance with yet another embodiment.

[0030] FIG. 5B is an enlarged view of the inner surface in circle 5B of FIG. 5A.

[0031] FIG. 6 is a cross-sectional side view of a conceptual image of the hybrid chill in FIG. 1 having fins formed thereacross for enhanced heat transfer in accordance with still another embodiment.

DETAILED DESCRIPTION

[0032] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0033] Aspects of the present disclosure provide a hybrid chill with enhanced heat transfer capability for casting of a sand aluminum part of a vehicle. The hybrid chill comprises a heat transfer fluid (preferably silicon-based) disposed in a hollow portion thereof. The heat transfer fluid is in a liquid phase to provide enhanced heat transfer during solidification of the part.

[0034] FIGS. 1 and 2 illustrate a hybrid chill 10 with enhanced heat transfer for casting of a sand aluminum engine block 11 of a vehicle in accordance with one embodiment of the present disclosure. As shown, the hybrid chill 10 comprises a base 12 comprising an outer wall 14. In this embodiment, the outer wall 14 has a first side 16 and a second side 18, opposite the first side 16.

[0035] As depicted in FIGS. 1-2, each of the first and second sides 16, 18 extends from a first longitudinal end 20 to a second longitudinal end 22. In this embodiment, the second longitudinal end 22 is disposed opposite the first longitudinal end 20. Moreover, each of the first and second sides 16, 18 extends along a first lateral end 24 and a second lateral end 26, opposite the first lateral end 24. As it can be seen in FIG. 2, the outer wall 14 is closed to define a hollow portion 30.

[0036] Referring to FIG. 2, the base 12 further comprises a heat transfer fluid 32 in a liquid phase disposed in the hollow portion 30. In this aspect, the heat transfer fluid 32 has a boiling point of between 320 Celsius ( C.) and 400 C. at 1 bar for enhanced heat transfer during casting. Preferably, the heat transfer fluid 32 is a silicon-based heat transfer fluid in the liquid phase. More specifically, the heat transfer fluid 32 may be a silicon-based heat transfer fluid comprising polydimethylsiloxane.

[0037] As shown in FIGS. 1-2, the chill 10 further comprises a plurality of crankcase members 34. Each member 34 is disposed on the first side 16 and extends from the first lateral end 24 to the second lateral end 26 of the outer wall 14. Additionally, each member 34 is preferably parallel to and spaced apart from a respective adjacent member 34 defining an open recess 36 formed between adjacent members 34. As shown, the open recess 36 extends from the first lateral end 24 to the second lateral end 26.

[0038] In one embodiment, the outer wall 14 is comprised of gray iron (Fe) comprising 2.8 to 3.3 weight percent (wt %) carbon (C), 1.2 to 1.7 wt % silicon (Si), 0.8 to 1.2 wt % manganese (Mn), less than 0.15 wt % phosphorus (P), and less than 0.12 wt % sulfur (S).

[0039] Preferably, the outer wall 14 may have a thickness of between 30 millimeters (mm) and 50 mm. In this embodiment, the outer wall is gray iron comprising 2.9 to 3.2 weight percent (wt %) C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.

[0040] Moreover, the outer wall 14 may have a thickness of greater than 50 mm. In this embodiment, the outer wall is gray iron comprising 2.8 to 3.1 weight percent wt % C, 1.2 to 1.5 wt % Si, 1.0 to 1.2 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.

[0041] Additionally, the outer wall 14 may have a thickness of less than 30 mm. In this embodiment, the outer wall is gray iron comprising 3.0 to 3.3 weight percent wt % C, 1.4 to 1.7 wt % Si, 0.8 to 1.0 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.

[0042] FIG. 3 illustrates a conceptual image of the hybrid chill 10 depicted in FIGS. 1-2 in accordance with one embodiment of the present disclosure. Hybrid chill 110 of FIG. 3 comprises the same or similar components of the hybrid chill 10 of FIGS. 1-2. For example, the base 112, the outer wall 114, the first side 116, the second side 118, the first longitudinal end 120, the second longitudinal end 122, the hollow portion 130 and the heat transfer fluid 132 shown in FIG. 3 correspond to the base 12, the outer wall 14, the first side 16, the second side 18, the first longitudinal end 20, the second longitudinal end 22, the hollow portion 30 and the heat transfer fluid 32, respectively, depicted in FIGS. 1-2.

[0043] As shown in FIG. 3, the base 112 of the chill 110 comprises the heat transfer fluid 132 in a liquid phase disposed in the hollow portion 130. In this embodiment, the heat transfer fluid 132 has a boiling point of between 320 Celsius ( C.) and 400 C. at 1 bar for enhanced heat transfer during casting. More preferably, the boiling point of the heat transfer fluid may be between 340 C. and 360 C. Even more preferably, the boiling point of the heat transfer fluid may be one of 330 C., 340 C., 350 C., 360 C., 370 C., 380 C., and 390 C. In this embodiment, the heat transfer fluid is a silicon-based heat transfer fluid in the liquid phase. More specifically, the heat transfer fluid may be a silicon-based heat transfer fluid comprising polydimethylsiloxane.

[0044] In this embodiment, portions of the outer wall 114 may have a thickness greater than 50 mm in thickness and may be comprised of gray iron (Fe) comprising 2.8 to 3.1 weight percent wt % C, 1.2 to 1.5 wt % Si, 1.0 to 1.2 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portions of the outer wall 114 may have a thickness of between 30 mm and 50 mm. As such, the outer wall 114 is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.

[0045] FIG. 4 illustrates a conceptual image of the hybrid chill 10 depicted in FIGS. 1-2 in accordance with another embodiment of the present disclosure. Hybrid chill 210 of FIG. 4 comprises the same or similar components of the hybrid chill of FIGS. 1-2. For example, the base 212, the outer wall 214, the first side 216, the second side 218, the first longitudinal end 220, the second longitudinal end 222, the hollow portion 230 and the heat transfer fluid 232 shown in FIG. 3 correspond to the base 12, the outer wall 14, the first side 16, the second side 18, the first longitudinal end 20, the second longitudinal end 22, the hollow portion 30 and the heat transfer fluid 32, respectively, depicted in FIGS. 1-2.

[0046] Referring to FIG. 4, at least one crankcase member 234 (here, all crankcase members shown) comprises an inner cavity 240 formed therein and in fluid communication with the hollow portion 230 of the base 212. As in the hollow portion 230, the inner cavity 240 comprises heat transfer fluid 232 for increased heat transfer. Preferably, the heat transfer fluid 232 is a silicon-based heat transfer fluid in the liquid phase. More specifically, the heat transfer fluid 232 may be a silicon-based heat transfer fluid comprising polydimethylsiloxane.

[0047] In this embodiment, a portion of the outer wall 214 may be less than 30 mm in thickness and comprised of gray iron (Fe) comprising 3.0 to 3.3 weight percent wt % C, 1.4 to 1.7 wt % Si, 0.8 to 1.0 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portions of the outer wall 214 may have a thickness of between 30 mm and 50 mm. As such, the outer wall 214 is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.

[0048] FIG. 5A depicts a conceptual image of the hybrid chill 10 depicted in FIGS. 1-2 in accordance with another embodiment of the present disclosure. Hybrid chill 310 of FIG. 5A comprises the same or similar components of the hybrid chill 10 of FIGS. 1-2. For example, the base 312, the outer wall 314, the first side 316, the second side 318, the first longitudinal end 320, the second longitudinal end 322, the hollow portion 330 and the heat transfer fluid 332 shown in FIG. 3 correspond to the base 12, the outer wall 14, the first side 16, the second side 18, the first longitudinal end 20, the second longitudinal end 22, the hollow portion 30 and the heat transfer fluid 32, respectively, depicted in FIGS. 1-2.

[0049] Referring to FIG. 5A, the inner cavity 340 of the at least one crankcase member is formed by the outer wall 314 having an inner surface 342. As shown in FIGS. 5A-5B, the inner surface 342 has a surface roughness to increase surface area for enhanced heat transfer. Preferably but not necessarily, the inner surface 342 has peaks 344 and valleys 346 defining an open region 348 between each respective peak 344 for further enhanced heat transfer. Other formations may be applied to the inner surface 342 to increase surface area thereof thereby enhancing heat transfer without departing from the scope or spirit of the present disclosure.

[0050] In this embodiment, a portion of the outer wall 314 may be less than 30 mm in thickness and comprised of gray iron (Fe) comprising 3.0 to 3.3 weight percent wt % C, 1.4 to 1.7 wt % Si, 0.8 to 1.0 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portion of the outer wall 314 may have a thickness of between 30 mm and 50 mm. As such, the outer wall is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.

[0051] FIG. 6 depicts a conceptual image of the hybrid chill 10 depicted in FIGS. 1-2 in accordance with another embodiment of the present disclosure. Hybrid chill 410 of FIG. 6 comprises the same or similar components of the hybrid chill 10 of FIGS. 1-2. For example, the base 412, the outer wall 414, the first side 416, the second side 418, the first longitudinal end 420, the second longitudinal end 422, the hollow portion 430 and the heat transfer fluid 432 shown in FIG. 3 correspond to the base 12, the outer wall 14, the first side 16, the second side 18, the first longitudinal end 20, the second longitudinal end 22, the hollow portion 30 and the heat transfer fluid 32, respectively, depicted in FIGS. 1-2.

[0052] Referring to FIG. 6, the second side 418 of the base 412 comprises a plurality of fins 440 formed thereacross from the first lateral end to the second lateral end. In this embodiment, each fin 440 is spaced apart from a respective adjacent fin 440 to define an open portion 442 extending between adjacent fins 440 from the first lateral end to the second lateral end for enhanced heat transfer.

[0053] In this embodiment, a portion of the outer wall 414 is less than 30 mm in thickness and comprised of gray iron (Fe) comprising 3.0 to 3.3 weight percent wt % C, 1.4 to 1.7 wt % Si, 0.8 to 1.0 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portion of the outer wall 414 may have a thickness of between 30 mm and 50 mm. As such, the outer wall is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portions of the outer wall 414 may have a thickness greater than 50 mm in thickness and may be comprised of gray iron (Fe) comprising 2.8 to 3.1 weight percent wt % C, 1.2 to 1.5 wt % Si, 1.0 to 1.2 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.

[0054] It is to be understood that the hybrid chill may be used for various castings of any sand cast aluminum part of a vehicle such as a transmission block, a differential block or any other suitable vehicular part without departing from the spirit or scope of the present disclosure.

[0055] The description of the present disclosure is merely exemplary in nature and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.