# US 11,305,337 B2 · Method of forming casting with flow passage, and casting formed by the same

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- Number: US 11,305,337 B2
- Document ID: US11305337B2
- Status: Granted
- Kind: B2
- Application number: 16/693,987
- Filed: 2019-11-25
- Published: 2020-06-04
- Granted: 2022-04-19
- Earliest claimed: 2018-12-04
- Assignees: Hyundai Motor Company; Kia Motors Corporation
- Applicants: Hyundai Motor Company; Kia Motors Corporation
- Inventors: Ji-Yong Lee; Cheol-Ung Lee; Young-Rae Jo; Jin-Ho Yoo
- Web page: https://patentgrep.com/patent/US11305337B2

## CPC

- B22C 9/10: Cores; Manufacture or installation of cores {(breaker cores B22C9/084)}
- B22C 9/106: {Vented or reinforced cores}
- B22D 17/00: Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D 19/00: Casting in, on, or around objects which form part of the product (B22D23/04 takes precedence; alumino-thermic welding B23K23/00; coating by casting molten material on the substrate C23C6/00)
- B22D 19/0072: {for making objects with integrated channels}
- B22D 21/007: {with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C}
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)

## Abstract

A method of forming a casting with a flow passage may include forming a core obtained by filling a tubular pipe with a filler; inserting the core into a mold having a cavity corresponding to a shape of the casting to be formed; performing a casting process by injecting molten metal into the cavity; and removing the filler from the core, wherein the casting process is performed through a high-pressure casting process.

## Claims

### Claim 1

A method of forming a casting with a flow passage, comprising:
forming a core obtained by filling a tubular pipe with a filler;
inserting the core into a mold having a cavity corresponding to a shape of the casting to be formed;
performing a casting process by injecting a molten metal into the cavity; and
removing the filler from the core,
wherein the casting process is performed through a high-pressure casting process,
wherein the forming the core comprises:
filling the tubular pipe with the filler; and
drawing and extruding the tubular pipe filled with the filler.

### Claim 2 (depends on 1)

The method of claim 1, wherein the forming the core further comprises:
bending the tubular pipe in a shape corresponding to a shape of the flow passage to be formed in the casting.

### Claim 3 (depends on 1)

The method of claim 1, wherein the molten metal and the tubular pipe are composed of an identical material.

### Claim 4 (depends on 3)

The method of claim 3, wherein the tubular pipe includes aluminum.

### Claim 5 (depends on 1)

The method of claim 1, wherein the filler comprises any one or more selected from salt, sand, iron powder, or a resin coated sand.

### Claim 6 (depends on 1)

The method of claim 1, wherein a thickness of the tubular pipe is greater than 1.25 mm or more and less than 4 mm.