Filter Element for Flow Calming and/or Purification of a Melt Obtained During Casting and a Method for Producing a Filter Element

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This invention relates to a filter element used in metal casting for calming (laminarizing) and purifying molten metal as it flows. The filter is built as a three-dimensional lattice (rib structure) with precisely defined channels through which the melt passes. The structure is made by bonding casting-grade particles with a binder and then coating the outer surface with a polymer resin. Moreover, the invention introduces a new manufacturing technique using additive (layer-wise) methods to custom-make these filters.

Use CasesContent extracted from patent full text and abstract with AI.

• Filtration and flow stabilization of molten metal (e.g., aluminum) during industrial casting processes to improve product quality.
• Customization of filter geometry for specific casting operations or metal alloys using additive manufacturing.
• Reduction of impurities (oxides, inclusions) in metal castings for critical applications such as automotive, aerospace, or electronics.
• Environmentally friendly recycling of used filter materials in foundries due to the thermal decomposition properties of the filter's binder and structure.
• Use in both large-scale (mass production) and small-batch or prototype casting applications.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables the flow of molten metal to be transformed from turbulent to laminar, reducing casting defects.
• Effectively removes impurities from molten metal, resulting in higher purity castings.
• Additive manufacturing allows for highly customizable filter geometries for optimized flow and filtration.
• The filter can be designed to break down after use, allowing for easier recycling of material and recovery of residual metal.
• Uses less energy and has a smaller environmental footprint compared to traditional ceramic foam filter manufacturing.
• Lower production and disposal costs due to simplified processes and recyclable components.
• Improved safety and reliability in casting operations by reducing the risk of filter breakage during use.

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Patent Abstract

In a filter element in which, for flow stabilisation and/or purifying a melt used during casting, the melt is guided through the filter element, the filter element is designed as three-dimensional rib structures with openings as flow channels through which liquid melt is guided. The ribs of the rib structure are formed by particles made of a material that can be used as a mould material in casting technology, and by a binder by means of which the particles can be integrally bonded. The ribs are also provided on their surface with a coating of a polymer resin.