CN112829178A - Apparatus and method for die casting metal - Google Patents
Apparatus and method for die casting metal Download PDFInfo
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- CN112829178A CN112829178A CN202011317367.8A CN202011317367A CN112829178A CN 112829178 A CN112829178 A CN 112829178A CN 202011317367 A CN202011317367 A CN 202011317367A CN 112829178 A CN112829178 A CN 112829178A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14008—Inserting articles into the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/14—Machines with evacuated die cavity
- B22D17/145—Venting means therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/30—Accessories for supplying molten metal, e.g. in rations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/32—Controlling equipment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/06—Vacuum casting, i.e. making use of vacuum to fill the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/08—Controlling, supervising, e.g. for safety reasons
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1642—Making multilayered or multicoloured articles having a "sandwich" structure
- B29C2045/1651—Independent injection runners or nozzles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C2045/1696—Making multilayered or multicoloured articles injecting metallic layers and plastic material layers
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention relates to a device for die casting metal, comprising a casting chamber, a casting chamber and a casting channel, wherein the device is designed such that an inner melt surface and an outer melt surface can be produced by receiving a metal melt in the casting chamber, and a pressure difference can be generated between an internal pressure acting on the inner melt surface and an external pressure acting on the outer melt surface in order to introduce the metal melt from the casting chamber into the casting chamber through the casting channel, and the pressure difference can be generated by reducing the internal pressure and/or by increasing the external pressure, and a negative pressure can be produced in the casting chamber in order to reduce the internal pressure acting on the inner melt surface and/or a fluid can be introduced into the outer volume in order to increase the external pressure acting on the outer melt surface. The invention also relates to a method for die casting metal.
Description
Technical Field
The invention relates to a device for die casting metal, comprising: a casting chamber for containing molten metal; a casting cavity for hardening the molten metal in a defined shape; and a casting passage connecting the casting chamber with the casting cavity. The invention also relates to a method for die casting metal.
Background
Die casting is a casting process in which liquid metal is introduced under pressure into a casting cavity in order to solidify or harden there in the shape defined by the casting cavity. Before the molten metal enters the casting chamber, also referred to as the casting cavity, the molten metal is initially introduced into a casting chamber connected to the casting chamber and is pressurized there, for example, by a pressure piston. Due to the pressure acting on the melt stored in the casting chamber, the melt enters the casting chamber through the casting channel, so that the desired metal cast is formed there after hardening. In the case of hot-chamber die casting, the melt in the casting chamber is additionally kept warm, as a result of which the method can be automated and accelerated better. In low-pressure casting, a casting chamber for receiving the molten metal is usually arranged below the casting chamber and the pressurization of the molten metal is carried out by compressed air, so that the molten metal rises into the casting chamber against gravity.
DE102012010923a1 relates, for example, to a conveying device for molten metal in a metal casting machine. The conveying device has a holding container for the molten metal and a conveying channel, in which the molten metal is conveyed to the mold cavity. It is provided here that the conveying channel comprises a cylinder bore in which a piston is arranged in an axially displaceable manner.
DE102012009790a1 relates to a method in which a liquid metal component is introduced into a mold cavity by means of a nozzle. It is provided that the transition region between the nozzle and the mold cavity is cooled after the metal component has entered the mold cavity in such a way that the metal in the gate region solidifies. In a subsequent method step, the gate region is heated again, so that the metal present in the gate region liquefies again.
A disadvantage of the known injection molding methods is that slag is formed in the melt over time, which can lead to fluctuations in the mold filling or can be mixed into the casting channel. This problem is further exacerbated by the use of pressure pistons which move in the melt. The melt is also typically aggressive to the materials used, for example, in the melting crucible and piston. Furthermore, due to these problems, it may become difficult to reliably seal portions that are movable relative to each other. Even in low-pressure casting in which the melt is pressurized with compressed air, there is a problem of slag formation in principle. In addition, low pressure casting has the disadvantage that it is difficult to meter and control the solution flow.
Disclosure of Invention
The object of the present invention is therefore to provide a device and a method for die casting, in which the formation of slag is avoided or reduced and which at the same time ensure good metering and control of the melt when it is introduced into the casting chamber.
Die casting or low-pressure casting according to DIN8580 involves forming or preliminary forming from a liquid state, for example a molten metal. In contrast, the plastic is formed from a plastic state, for example by injection molding or injection compression molding.
Against this background, it is an aspect of the object of the invention to design a metal injection molding process as a plastic injection molding process with process safety and low maintenance costs, in order to provide a multicomponent method with a plastic injection molding component and a metal injection molding component, which method forms an efficient composite process. In this respect, as already explained, the aim is to reduce or avoid the formation of slag and to improve the metering and control of the melt flow in order to keep the maintenance effort for the die casting to a minimum. On the other hand, metal diecasting without sprues and without overflows should also be carried out in order to avoid separating sprues and overflows before or after the injection molding process steps and thus to accelerate and simplify the compounding process.
The object of the invention is achieved by the solution of the independent claims. Advantageous embodiments of the invention are defined in the dependent claims.
The invention relates to a device for die casting metal, comprising: a casting chamber for containing molten metal; a casting mould with a casting cavity for hardening the molten metal in a defined shape; and a casting channel connecting the casting chamber to the casting cavity in such a way that a metal melt can be introduced from the casting chamber through the casting channel into the casting cavity to harden there in a defined shape.
When the casting chamber is sufficiently filled with the molten metal, the molten metal already partially enters the casting channel. In other words, the apparatus or its casting chamber or casting channel is configured such that, when the molten metal is contained in the casting chamber, an inner molten surface facing inwards, i.e. communicating with the casting cavity, and an outer molten surface facing outwards, i.e. communicating with a region called the outer volume, can be produced.
In order to be able to introduce the melt into the casting chamber, a cylinder or a piston can be used in order to generate a pressure acting on the outer melt surface. However, the apparatus is usually designed such that a pressure difference can be caused between the internal pressure acting on the inner melt surface and the external pressure acting on the outer melt surface in order to introduce the metal melt from the casting chamber through the casting channel into the casting chamber.
In order to cause the pressure difference between the internal pressure and the external pressure, the device is designed such that the internal pressure acting on the inner melt surface can be reduced and/or the external pressure acting on the outer melt surface can be increased. In other words, it is possible on the one hand to actively reduce the internal pressure (without actively changing the external pressure, i.e. the external pressure remains unchanged or drops). But on the other hand it is also possible to actively increase the external pressure (without actively changing the internal pressure, i.e. the internal pressure remains the same or increases). It is also possible to actively increase the external pressure and simultaneously actively reduce the internal pressure.
For this purpose, the device is designed in particular in such a way that, in order to reduce the internal pressure acting on the inner melt surface, a negative pressure can be generated in the casting chamber and/or in the casting channel, i.e. in particular air or, more generally, fluid present therein can be discharged, so that the negative pressure can reduce the pressure on the inner melt surface and/or in order to increase the external pressure acting on the outer melt surface, a fluid, in particular an incompressible liquid, can be introduced into the outer volume, so that the fluid pressurizes the outer melt surface.
By actively generating a negative pressure in the casting chamber, the casting chamber can be gradually evacuated such that the molten metal flows into the casting chamber through the casting channel, wherein movable parts, such as pistons, in the molten metal can advantageously be omitted and a good metering and control of the molten metal flow can be achieved. In particular, the formation of slag can be reduced or avoided, since movable parts can be omitted. For example, the melt flow is optimized compared to low-pressure casting with active supply of compressed air from the outside, since the internal pressure is not increased when the melt is introduced into the chamber.
On the other hand, the external pressure can be actively increased by means of a fluid, in particular a liquid, so that the molten metal can likewise flow into the casting chamber and movable parts in the molten metal (slag formation avoidance) are advantageously omitted here and good metering and control of the molten metal flow is achieved. For example, metering and control are optimized compared with low-pressure casting with active supply of compressed air, since incompressible fluids, in particular liquids, can be used, which enable the pressure to be transmitted to the outer melt surface without or with little delay and without loss. Furthermore, the fluid can counteract slag formation in such a way that the outer melt surface is closed before undesired contact with oxygen or other substances that contribute to slag formation.
The following alloys are particularly considered as molten metals: indium tin eutectic 52In (melting point of 48Sn about 117 ℃), bismuth tin eutectic 58Bi (melting point of 42Sn about 138 ℃), tin solder Sn (melting point: about 180 ℃ to 232 ℃), and other lower or higher melting point alloys. In particular, the casting chamber (hot chamber device) and/or the casting channel can be heated at least to the melting point temperature of the alloy up to approximately 70 ℃. Preferably, all the materials that are in contact with the melt are resistant to the melt (dealloying) in order to avoid the materials used (e.g., metals) dissolving in the melt, enriching the melt with foreign substances and/or necessitating replacement of components. With the invention, in particular, metal components in the melt (for example pistons) can be avoided, whereby this disadvantageous effect can be avoided.
In a first embodiment of the device for die casting metal, the casting chamber has an outlet for pumping out gas present in the casting chamber in order to generate a negative pressure in the casting chamber, wherein the outlet is arranged in particular at the end of the flow path. The outlet is preferably designed such that the melt of the metal to be introduced into the casting chamber cannot flow into the outlet. The cavity can thus be filled in an advantageous manner without sprue and without overflow, so that metal diecasting can be simplified and accelerated and, as a result, maintenance costs and process safety can be reduced in a manner similar to plastic injection molding.
One possibility for ensuring that the molten metal to be introduced into the casting chamber cannot flow into the outlet consists in limiting the cross-sectional area of the outlet. The cross-sectional area is preferably between 0.0001 and 10 square millimeters, particularly preferably between 0.001 and 1 square millimeter. The outlet, for example in the form of a gap or a bore, may for example have a diameter of about 0.05mm to 1 mm. Furthermore, a plurality of outlets is also possible, which may in particular be connected in parallel. The outlet may also be formed by a porous region of the casting cavity, for example a porous mold insert.
Alternatively or additionally, it can be provided that the device comprises a cooling device for cooling the outlet, so that the molten metal hardens at the outlet, so that the molten metal to be introduced into the casting chamber does not flow into the outlet. In other words, active cooling can be provided in the region of the outlet or of the porous insert in order to ensure rapid solidification of the melt. Additionally, materials with good thermal conductivity, for example materials with a high copper content, can be used for this purpose. However, if the penetration of the melt into the outlet is still minimal, it is also possible to provide an ejector which is arranged in the outlet in order to clean the outlet from the residues of the penetrating melt after each shot.
The first embodiment of the apparatus for die casting metal can furthermore comprise a vacuum pump, in particular a vacuum pump, which is connected to the outlet of the casting chamber in order to pump out the gas present in the casting chamber through the outlet. The (negative) pressure may in particular lie in the range between-1.1 and-0.7 bar, for example approximately-0.9 bar.
In particular with regard to avoiding or reducing slag formation, a first embodiment of the device for die casting metal comprises an outer vessel enclosing an outer volume for receiving a fluid, in particular a gas, covering the outer melt surface in order to ensure oxygen insulation of the outer melt surface. The outer vessel may house or be formed by a casting chamber. In particular, it can be provided that the fluid covering the outer melt surface does not cause an active pressurization of the outer melt surface in order to form an oxygen barrier. However, in order to avoid a pressure drop in the outer vessel when the melt is drawn into the casting chamber by the underpressure, the outer vessel preferably has an inlet for entraining a fluid, in particular a gas, in particular passively, so that the increase in the outer volume caused by the underpressure generated in the casting chamber can be compensated for with constant pressure.
In a second embodiment of the device for diecasting metal, which can be realized independently of or in combination with the features of the first embodiment, the device has an outer vessel enclosing an outer volume for receiving a fluid, in particular a liquid, covering the outer melt surface, in order to pressurize the outer melt surface, in particular actively, and preferably at the same time to ensure oxygen insulation (avoid slag formation) of the outer melt surface. The outer vessel preferably has an inlet for pumping in a fluid, in particular a liquid (under pressure), in order to increase the external pressure acting on the outer melt surface by generating a negative pressure in the outer vessel. In the case of incompressible liquids, advantageously no pressure loss occurs here. Although a gas may also be used. In the case of the second embodiment, which is implemented in conjunction with the first embodiment, the same outer container can be used for introducing the fluid, so that on the one hand oxygen insulation is achieved and on the other hand it serves as an actively pressurized medium.
The fluid introduced into the outer vessel can be configured as an inert medium, in particular a medium having a lower density than the melt, in particular when a medium for establishing pressure is used. Liquid media are preferably used, since due to their incompressibility, a more precise metering of the melt flow is achieved. But a gas can also be used. Furthermore, it is also possible to use a substance as a fluid in a targeted manner or to add a substance to the fluid in a targeted manner, which substance reduces a possible slag layer on the melt.
For example, oil is considered as the fluid introduced into the outer vessel, wherein different oils can be used depending on the alloy (and therefore the temperature) being processed. Hydraulic fluids based on phosphate esters or chloroarenes, in particular to, for example, 150 ℃, can be used, for example. Furthermore, silicone oils, in particular up to about 350 ℃, may be used, for example. The density of the oil used is preferably between 0.1 and 5g/cm3In the range of 0.7 to 1g/cm, preferably3So that the density of the melt, depending on the alloy, may lie, for example, between 5 and 7g/cm3Within the range of (1). The viscosity of the fluids used, in particular the oils, is preferably in the range from 0.1 to 500mPAs, even more preferably in the range from 0.5 to 100mPAs, and even more preferably in the range from 1 to 50 mPAs.
The second embodiment of the apparatus for die casting metal preferably comprises a pressure pump, for example a hydraulic or pneumatic pump, which is connected to the inlet of the outer vessel in order to pump a fluid, in particular a liquid, which pressurizes the outer melt surface into the outer vessel. The pressure pump is in particular designed to generate at least one pressure of 50bar, preferably at least 100bar, particularly preferably at least 150bar, for example approximately 200 bar.
The pressure pump preferably has a pump container for receiving the fluid and a pump piston for pressurizing the fluid in order to pump the fluid into the outer container. The pressure pump preferably has an overpressure valve for discharging the fluid, in order to be able to pump the fluid into the outer container under a defined, in particular constant, pressure. The overpressure valve is preferably designed such that the fluid discharged through the overpressure valve is returned to the pump container.
Depending on the fluid introduced into the outer vessel, for example in some oils, the temperature load may act substantially on the part of the fluid that is in direct contact with the melt, for example when the thermal conductivity of the fluid is in the range of about 0.1 to 0.15W/(mK). The apparatus, casting chamber and/or outer vessel may be configured such that convection within the oil is reduced. This has the advantage that further components of the device, in particular the pressure pump or the piston of the pressure pump or the overpressure valve, can be operated at room temperature or almost at room temperature.
In a third embodiment of the device for die-casting metal, the device is designed such that, on the one hand, a negative pressure is generated in the casting chamber in order to reduce the internal pressure acting on the inner melt surface and, on the other hand, a fluid, in particular a liquid, can be introduced into the outer volume in order to increase the external pressure acting on the outer melt surface. The third embodiment may comprise other possible additional features of the first and/or second embodiments described above.
The third embodiment may in particular have an outlet for pumping out gas in the casting chamber in order to generate a negative pressure in the casting chamber, and may comprise an outer vessel enclosing an outer volume for receiving a fluid, in particular a liquid, covering the outer melt surface in order to pressurize the outer melt surface.
In addition, the third embodiment can comprise in particular a negative pressure pump, in particular as described above, as well as a pressure pump, in particular as described above. In this case, the negative pressure pump and the pressure pump can preferably be configured as a pump unit. The pump unit may comprise a pump piston which is provided, for example, in such a way as to pressurize both the fluid to be pumped into the outer container and to pump out the gas present in the casting chamber, in that it acts on the pressurized fluid on the front side and is connected to the outlet of the casting chamber on the rear side.
In addition to the device described above, the invention also relates to a method for die casting metal, in particular by means of a device for die casting metal, comprising a casting chamber, a casting mold with a casting cavity, and a casting channel connecting the casting chamber to the casting cavity, preferably as explained above.
In the method according to the invention, the molten metal is introduced into the casting chamber in particular in such a way that an inner and an outer molten surface are produced, wherein the inner molten surface communicates with the casting chamber and the outer molten surface communicates with the outer volume.
Furthermore, the molten metal is introduced into the casting chamber through the casting channel from the casting chamber, in particular, in such a way that a pressure difference is produced between an internal pressure acting on the inner molten surface and an external pressure acting on the outer molten surface.
Furthermore, the method for die casting metal also comprises the further features explained above in the context of the device for die casting metal.
The pressure difference between the internal pressure and the external pressure is thus preferably caused, for example, by reducing the internal pressure acting on the surface of the internal melt in such a way that a negative pressure is generated in the casting chamber, so that this negative pressure reduces the internal surface, and the metal melt thus flows from the casting chamber through the casting channel into the casting chamber.
Alternatively or additionally, the pressure difference between the internal pressure and the external pressure is preferably caused by increasing the external pressure acting on the outer melt surface in such a way that a fluid is introduced into the outer volume, so that the fluid pressurizes the outer melt surface, so that the metal melt flows from the casting chamber through the casting channel into the casting chamber.
In a first method variant, a vacuum is generated in the casting chamber via an outlet for pumping out the gas present in the casting chamber, wherein the outlet is preferably designed such that the molten metal to be introduced into the casting chamber does not flow into the outlet, and wherein the outlet preferably has a cross-sectional area of between 0.0001 and 10 square millimeters, particularly preferably between 0.001 and 1 square millimeter, such that the molten metal to be introduced into the casting chamber does not flow into the outlet, and wherein the outlet is preferably cooled and the molten metal is thus hardened at the outlet such that the molten metal to be introduced into the casting chamber does not flow into the outlet.
Provision can be made for a fluid, in particular a gas, to be introduced into the outer volume in order to ensure oxygen insulation from the outer melt surface and for the fluid, in particular the gas, to preferably accompany the outer volume, in particular in order to constantly equalize the pressure increase of the outer volume due to the negative pressure occurring in the casting chamber.
In a second method variant of the method for diecasting metal, which can be implemented independently of or in combination with the features of the first method variant, a fluid, in particular a liquid, is introduced into the outer volume in order to pressurize the outer melt surface and preferably simultaneously to ensure oxygen insulation of the outer melt surface, wherein the fluid, in particular the liquid, is preferably pumped into the outer volume in order to increase the external pressure acting on the outer melt surface by generating an overpressure.
The method according to the invention can be used in particular in a multi-component method (composite process) with at least one plastic injection molding component and at least one metal injection molding component. In this case, the term diecasting, in particular with reference to molten metal, is clearly distinguished from the term injection molding, in particular with reference to plastic, according to DIN 8580.
In principle, in the method according to the invention, provision may first be made for the component to be inserted into the casting chamber before the molten metal is introduced into the casting chamber, so that the component is completely or at least partially encapsulated with the molten metal. In other words, a method for casting an encapsulating element is also specified within the scope of the disclosure.
In a step prior to the injection molding, the component can be at least partially encapsulated with plastic, so that a plastic injection molding compound is formed on the component before the component is inserted into the casting cavity. The plastic injection molding compound formed on the component can then be encapsulated at least partially with a molten metal in the context of injection molding, so that a metal casting compound is formed on the plastic injection molding compound.
Alternatively, the further, in particular external, plastic injection molding component can be formed on the metal casting component by at least partially encapsulating the metal casting component with plastic again after at least partially encapsulating the plastic injection molding component formed on the component with the molten metal.
In a specific application, the component inserted into the casting chamber can be an electrical connector, wherein the electrical connector comprises one or more line components belonging to at least one line or at least one plug connector and one or more shielding cans or shielding housings belonging to at least one line or at least one plug connector. Further details of the electrical connector refer to DE102015102703a1, which uses the same glossary of terms and is hereby incorporated by reference.
In a specific application of the method for such a connector, it can be provided that the line elements of the electrical connector can be at least partially encapsulated with plastic in order to form a plastic injection molding compound designed as an intermediate insulator, which protects the line elements during encapsulation with the molten metal.
Furthermore, it can be provided that the plastic injection-molded component forming the intermediate insulation is encapsulated at least partially with a molten metal in order to form a metal cast component forming the shielding housing, which metal cast component either connects a plurality of shielding shells to one another or connects at least one shielding shell to at least one shielding housing or a plurality of shielding housings to one another or forms part of a shielding housing.
Furthermore, it can be provided that the metal casting compound designed as a shielding housing is in turn at least partially encapsulated with plastic, so that an outer plastic injection molding compound is formed on the metal casting compound.
Drawings
The invention is explained in more detail below with the aid of the figures. In the figure:
FIG. 1 is a first embodiment of an apparatus for die casting metal;
FIG. 2 is a second embodiment of an apparatus for die casting metal;
FIG. 3 is a third embodiment of an apparatus for die casting metal;
FIG. 4 is a method step of a composite process with injection molding and die casting;
fig. 5 is a combined injection molding-casting mold.
Detailed Description
Fig. 1 shows a first embodiment of a die casting installation 10, also referred to as a casting assembly, comprising: a casting chamber 100; a two-part casting mold 301 with a casting cavity 300 therein and a casting passage 200 leading from the casting chamber 100 to the casting cavity 300.
A molten metal 110, in particular a low-melting metal alloy, is located in the heated casting chamber 100 (hot chamber), said molten metal being partially located in the casting channel 200 and forming an inner molten surface 120 therein, which communicates with the casting chamber 300 via the casting channel 200, and also forming an outer molten surface 130, which communicates with the outer volume 400.
The casting cavity 300 has an outlet 310 through which gas present in the casting cavity 300 can be pumped out in order to generate a negative pressure in the casting cavity 300, so that the inner melt surface 120 is depressurized and this inner melt surface is sucked into the casting cavity 300 through the casting channel 200. To generate the negative pressure in the casting chamber 300, the outlet 310 of the casting chamber 300 is connected to a negative pressure pump 500 or vacuum pump via a negative pressure line 510.
Furthermore, the apparatus 10 comprises an outer vessel 410 enclosing an outer volume 400 to contain a medium 405 having a density less than that of the melt 110 and may be used to protect the outer melt surface 130 from oxygen and thus to combat slag formation. When the outer volume 400 becomes larger as a result of the melt 110 flowing into the casting chamber 300, the medium 405 is fed in here via the inlet 420 or can be entrained via the inlet 420. The medium 405 may in principle also relate to ambient air.
As vacuum is applied by the vacuum pump 500, a pressure difference is generated between the internal pressure acting on the inner melt surface 120 and the external pressure acting on the outer melt surface 130, so that the casting chamber 300 is filled. In contrast to conventional low-pressure methods, the outer melt surface 130 is not actively pressurized by the external medium 405 at the present time. More specifically, the inner melt surface 120 is actively depressurized. The volume of melt which rises into the casting chamber 300 is thus delimited by the outlet 310. The outlet 310 is so small that the melt 110 flowing into the casting chamber 300 cannot flow into the outlet 310, but solidifies immediately after reaching it and closes the outlet 310. In this way, a sprue-free and overflow-free casting is achieved, so that the hardened cast part can be directly further processed.
Fig. 2 shows a second embodiment of the die casting device 10, which in turn has a casting chamber 100, a casting channel 200 and a casting cavity 300. In the casting chamber, there is again a molten metal 110, which in this example has already been completely introduced into the casting chamber 300.
For this purpose, the apparatus 10 comprises an outer vessel 410 into which a medium 405 actively pressurizing the outer melt surface 130 is pumped via an inlet 420. The pressurized medium 405 is preferably liquid and is configured, for example, as (almost) inert silicone oil.
In order to pump the pressurized medium 405 into the outer container 410, a pressure pump 600 is used, which pumps the medium 405 from a pump container 610 into the inlet 420 by means of a pump piston 620. This has the advantage that the movable piston is not arranged in the melt 110, but in the medium 405, as a result of which slag formation in the melt 110 is avoided.
In other words, the pressure difference between the inner melt surface and the outer melt surface is actively caused by the pressure pump 600, which is designed as a hydraulic pump, actively pressurizing and conveying the medium 405, which is designed as oil, and thus the melt 110, into the casting chamber 300. In the simplest case, the hydraulic pump may be a piston. Since the medium is preferably incompressible, it can be metered particularly precisely, similarly to the known method in which the piston is arranged directly in the melt.
The pressure pump 600 furthermore has an overpressure valve 630 or safety valve, through which the medium 405 is discharged back into the pump container 610 from a pressure threshold value, so that this pressure threshold value is not exceeded in the outer container 410 and a reliable, constant pressurization of the melt 110 is ensured. Preferably, a constant pressurization is also ensured by using an incompressible liquid as medium 405. The pressurized medium 405 is regulated, controlled or diverted to some extent by means of an overpressure valve 630. Any moving parts in the melt 110 are thereby avoided, and the pressurized medium 405 can also serve as an oxygen barrier.
The overpressure valve 630 also forms an outlet device or bypass which delimits the melt volume when filling the casting chamber 300 and which is arranged in the hydraulic circuit such that the medium 405 embodied as hydraulic oil is returned in the bypass into the hydraulic reservoir 610. In a corresponding arrangement, the entire hydraulic device can be operated almost at room temperature.
A medium 405, such as an inert oil, located above the melt 110 can also be used to seal the melt so that no oxidation processes occur. Instead of a liquid, however, a gas, for example nitrogen or argon, can also be used in a similar apparatus. Instead of the hydraulic pump, the gas is then preferably also removed from the pressure vessel, the bypass can be opened to the ambient air or the gas can be captured or reused.
Fig. 3 shows a third embodiment of the die casting device 10, which combines the first embodiment and the second embodiment. For this purpose, a pump unit 550 is provided, which forms both the vacuum pump 500 and the pressure pump 600. The pump unit therefore pressurizes the medium 405 on the one hand in order to increase the pressure acting on the melt 110 in the outer vessel 410 and at the same time is connected via a vacuum line 510 to the outlet 310 of the casting chamber 300 in order to generate a vacuum therein.
In particular, the rear side of the pump piston 620 can be used for this purpose to generate a negative pressure in the casting cavity 300. For this purpose, the piston 620 may have, for example, differently large active surfaces in order to convey larger air volumes, for example, for balancing leaks in mold separation (Formtrennung).
Fig. 4 shows a three-stage composite process, which includes injection molding of plastic (Druckgie β en) and die casting of metal (Druckgie β en), wherein the terms injection molding and die casting are defined in accordance with DIN8580 and are distinguished from one another.
In a first step (a), an injection mold 301 'with an injection cavity 300' is provided and plastic is injected into the injection mold 301 'through an injection line 200'. This results in a component with a plastic injection molding compound, which is then inserted into the casting chamber 300 of the casting mold 301 and encapsulated with metal in a second step (b) in such a way that the metal melt is introduced through the casting channel 200, in particular as described above, so that the metal casting compound is formed. This results in a two-component which can optionally be inserted again into the injection cavity 300 "of a further injection molding tool 301" in order to be encapsulated again by plastic.
Fig. 5 shows a two-part combined injection molding and casting mold 312, with which the previously described steps can also be carried out. The combined injection molding-casting mold 312 includes a first injection cavity 300 'for hardening the injected plastic, a separate casting cavity 300' for hardening the molten metal, and a separate second injection cavity 300 "for hardening the injected plastic.
The multi-component injection-casting-injection process in the composite system may be used, for example, to manufacture shielding structures for electrical connectors. The electrical connector is first injection-molded in plastic, then subsequently encapsulated with metal in order to produce the shielding structure, and then subsequently encapsulated again with plastic. With the inventive die casting method or the inventive die casting installation, a metal casting process can therefore be designed with process safety and low maintenance costs, as can a plastic injection molding process or two plastic injection molding processes. As already explained above, this enables in particular a sprue-free and overflow-free injection molding, so that there is no need to separate the sprue and the overflow before the subsequent injection molding process. The casting is inexpensive to maintain since the formation of slag in the molten metal is avoided, fluctuations in the mold filling during the casting process are advantageously avoided and mixing into the casting channel is avoided.
It will be appreciated by a person skilled in the art that the embodiments described hereinbefore are exemplary and that the invention is not limited thereto, but can be varied in a multitude of ways without departing from the scope of protection of the claims. The features of the first and second embodiment can be combined in particular explicitly with one another. It is also known that the features described define important parts of the invention individually, irrespective of whether they are disclosed in the description, the claims, the drawings or otherwise, even if they are described together with other features.
Claims (16)
1. An apparatus (10) for die casting metal, comprising:
a casting chamber (100) for receiving a molten metal (110),
a casting mould (301) having a casting chamber (300) for hardening a molten metal (110) in a defined shape, and
a casting channel (200) connecting the casting chamber (100) to the casting chamber (300) such that the molten metal (110) can be introduced from the casting chamber (100) through the casting channel (200) into the casting chamber (300) for hardening there in a defined shape,
wherein the device is configured such that an inner melt surface (120) and an outer melt surface (130) can be produced by accommodating a metal melt (110) in the casting chamber (100), wherein the inner melt surface (120) communicates with the casting chamber (300) and the outer melt surface (130) communicates with the outer volume (400), and
wherein the device is configured such that a pressure difference can be caused between an internal pressure acting on the inner melt surface (120) and an external pressure acting on the outer melt surface (130) in order to introduce the molten metal (110) from the casting chamber (100) through the casting channel (200) into the casting chamber (300), and
wherein the apparatus is configured such that the pressure difference can be caused between an internal pressure and an external pressure by reducing the internal pressure acting on the inner melt surface (120) and/or by increasing the external pressure acting on the outer melt surface (130), and
wherein the device is configured such that, in order to reduce the internal pressure acting on the inner melt surface (120), a negative pressure can be generated in the casting chamber (300), such that the negative pressure depressurizes the inner melt surface (120), and/or in order to increase the external pressure acting on the outer melt surface (130), a fluid (405) can be introduced into the outer volume (400), such that the fluid (405) pressurizes the outer melt surface (130).
2. Device (10) for die casting metal according to the preceding claim,
wherein the casting cavity (300) has an outlet (310) for pumping out gas in the casting cavity in order to generate a negative pressure in the casting cavity (300), and
wherein the outlet (310) is preferably designed such that the molten metal to be introduced into the casting chamber cannot flow into the outlet (310), and wherein
Wherein the outlet (310) preferably has a cross-sectional area of between 0.0001 and 10 mm, particularly preferably between 0.001 and 1mm, such that the molten metal (110) to be introduced into the casting chamber cannot flow into the outlet (310), and
wherein the device preferably comprises a cooling device for cooling the outlet (310), so that the molten metal (110) hardens at the outlet (310) and the molten metal (110) to be introduced into the casting chamber cannot flow into the outlet (310).
3. Apparatus for die casting metal according to the preceding claim, wherein the apparatus further comprises a negative pressure pump (500) connected to the outlet (310) of the casting cavity (300) for pumping out the gas in the casting cavity (300) through the outlet (310).
4. Device (10) for diecasting metal according to any one of the preceding claims,
wherein the device comprises an outer vessel (410) surrounding the outer volume (400) for receiving a fluid (405), in particular a gas, covering the outer melt surface (130) in order to ensure oxygen insulation against the outer melt surface (130), and
wherein the outer vessel (410) preferably comprises an inlet (420) for the wake of the fluid (405), in particular gas, in particular in order to constantly equalize the pressure and to enlarge the outer volume (400) due to the creation of the negative pressure in the casting cavity (300).
5. Device (10) for diecasting metal according to any one of the preceding claims,
wherein the device comprises an outer vessel (410) surrounding the outer volume (400) for receiving a fluid (405), in particular a liquid, covering the outer melt surface in order to pressurize the outer melt surface (130) and preferably simultaneously ensure oxygen insulation against the outer melt surface (130), and
wherein the outer vessel (410) preferably comprises an inlet (420) for pumping in a fluid (405), in particular a liquid, in order to increase the external pressure acting on the outer melt surface (130) by generating an underpressure in the outer vessel (410).
6. Device (10) for diecasting metal according to any one of the preceding claims,
wherein the apparatus comprises a pressure pump (600) which is connected to the inlet (420) of the outer vessel in order to pump a fluid (405), in particular a liquid, which pressurizes the outer melt surface (130) into the outer vessel (410), and
wherein the pressure pump (600) preferably comprises a pump container (610) for containing a fluid (405) and a pump piston (620) for pressurizing the fluid (405) in order to pump the fluid into the outer container (410), and
wherein the pressure pump (600) preferably comprises an overpressure valve (630) for discharging the fluid (405) in order to be able to pump the fluid into the outer container under a defined, in particular constant, pressure, and
wherein the overpressure valve (630) is preferably configured such that the fluid discharged through the overpressure valve is returned into the pump container (610).
7. Device (10) for diecasting metal according to any one of the preceding claims,
wherein the device comprises not only a negative pressure pump (500), in particular according to claim 3, but also a pressure pump (600), in particular according to claim 6, and
wherein the negative pressure pump (500) and the pressure pump (600) are preferably designed as a pump unit (550), and
wherein the pump unit (550) preferably comprises a pump piston which is provided for pressurizing not only the fluid (405) to be pumped into the outer container but also for pumping out the gas in the casting cavity (300).
8. Method for die casting metal, in particular by means of a device (10) for die casting metal, in particular a device (10) according to any one of claims 1 to 7, comprising a casting chamber (100), a casting mould (301) with a casting cavity (300) and a casting channel (200) connecting the casting chamber (100) with the casting cavity (300),
wherein a molten metal (110) is introduced into the casting chamber (100), in particular such that an inner molten surface and an outer molten surface are formed, wherein the inner molten surface (120) communicates with the casting cavity and the outer molten surface (130) communicates with the outer volume (400), and
wherein the molten metal (110) is introduced from the casting chamber (100) through the casting channel (200) into the casting chamber (300), in particular by means of a pressure difference between an internal pressure acting on the inner molten surface and an external pressure acting on the outer molten surface.
9. A method for die casting metal according to claim 8,
wherein the pressure difference between the internal pressure and the external pressure is caused by reducing the internal pressure acting on the inner melt surface (120) in such a way that a negative pressure is generated in the casting chamber, such that the negative pressure reduces the inner melt surface, so that the metal melt flows from the casting chamber through the casting channel into the casting chamber and/or
Wherein the pressure difference between the internal pressure and the external pressure is caused by increasing the external pressure acting on the outer melt surface (130) in such a way that a fluid is introduced into the outer volume, so that the fluid pressurizes the outer melt surface, so that the molten metal flows from the casting chamber through the casting channel into the casting cavity.
10. Method for diecasting metal according to claim 8 or 9,
wherein a negative pressure in the casting chamber is generated by an outlet (310) for pumping out gas in the casting chamber, and
wherein the outlet (310) is preferably designed in such a way that the molten metal to be introduced into the casting chamber cannot flow into the outlet, and wherein
Wherein the outlet (310) preferably has a cross-sectional area of between 0.0001 and 10 mm, particularly preferably between 0.001 and 1mm, such that the molten metal to be introduced into the casting chamber cannot flow into the outlet, and
the outlet (310) is preferably cooled, so that the molten metal hardens at the outlet, so that the molten metal introduced into the casting chamber cannot flow into the outlet.
11. Method for diecasting metal according to any of claims 8 to 10,
wherein a fluid (405), in particular a gas, is introduced into the outer volume (400) in order to ensure oxygen insulation of the outer melt surface, and
a fluid (405), in particular a gas, preferably a gas, is introduced into the outer volume (400), in particular in order to constantly compensate for the increase in the outer volume caused by the negative pressure generated in the casting chamber.
12. Method for diecasting metal according to any of claims 8 to 11,
wherein a fluid (405), in particular a liquid, is introduced into the outer volume (400) in order to pressurize the outer melt surface and preferably simultaneously ensure oxygen insulation of the outer melt surface, and
a fluid (405), in particular a liquid, is preferably pumped into the outer volume (400) in order to increase the external pressure acting on the outer melt surface by generating an overpressure.
13. Method for diecasting metal according to any of claims 8 to 12,
wherein a component is inserted into the casting chamber before the molten metal (110) is introduced into the casting chamber, and
wherein the component is at least partially encapsulated by a molten metal.
14. The method for injection molding plastic and die casting metal as claimed in claim 13,
wherein the component is at least partially encapsulated with plastic before being introduced into the casting cavity, so that a plastic injection molding compound is formed on the component, and
wherein the plastic injection-molding compound formed on the component is at least partially encapsulated with a molten metal in such a way that a metal casting compound is formed on the plastic injection-molding compound, and
optionally, after at least partial potting of the plastic injection molding compound formed on the component with the metal melt, the metal casting compound is at least partially encapsulated again with plastic, so that a further plastic injection molding compound is formed on the metal casting compound.
15. The method for injection molding plastic and die casting metal as claimed in claim 14,
wherein the component placed into the casting cavity is an electrical connector, wherein the electrical connector comprises:
one or more line components belonging to at least one line or at least one plug connector,
one or more shielding cans or shielding housings belonging to at least one line or at least one plug connector, and
wherein the line components of the electrical connector are at least partially encapsulated with plastic in order to form a plastic injection molding compound designed as an intermediate insulator, which protects the line components during encapsulation with a molten metal, and
the plastic injection-molded component, which is designed as an intermediate insulator, is at least partially encapsulated with a molten metal in order to form a metallic cast component, which is designed as a shielding housing and which either connects a plurality of shielding shells to one another or connects at least one shielding shell to at least one shielding housing or a plurality of shielding housings to one another or forms part of a shielding housing.
16. A combined injection molding and casting mold (312) having an injection cavity (300 ') for hardening the injected plastic and a separate casting cavity (300) for hardening the molten metal and preferably having a further separate injection cavity (300') for hardening the injected plastic, wherein the dimensions of the cavities are preferably increased such that one component of a batch of components can be encapsulated with plastic in the injection cavity, then encapsulated with metal in the casting cavity and optionally finally encapsulated again with plastic in the further injection cavity.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102019131648.0 | 2019-11-22 | ||
| DE102019131648 | 2019-11-22 |
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| CN112829178A true CN112829178A (en) | 2021-05-25 |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113634741A (en) * | 2021-08-09 | 2021-11-12 | 宿迁东润机械制造有限公司 | Pulley casting device, system and casting method thereof |
| CN114261054A (en) * | 2021-12-28 | 2022-04-01 | 江苏葑全新能源动力科技有限公司 | Method for manufacturing integrally formed vehicle door |
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| EP1645350A1 (en) * | 2004-10-08 | 2006-04-12 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Casting with integrated functional elements and manufacturing process |
| US20110000634A1 (en) * | 2007-12-21 | 2011-01-06 | Oskar Frech Gmbh + Co. Kg | Casting Machine System and Process for Producing Hybrid Metal/Plastic Articles |
| JP2016123987A (en) * | 2014-12-26 | 2016-07-11 | 日産自動車株式会社 | Casting apparatus, and casting method |
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2020
- 2020-11-11 DE DE102020129793.9A patent/DE102020129793A1/en active Pending
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| GB190813593A (en) * | 1908-06-27 | 1909-07-22 | Broughton Copper Company Ltd | An Improved Method of and Means for Casting Metals. |
| CN1538888A (en) * | 2001-06-06 | 2004-10-20 | 株式会社久保田 | Molten solution feeder |
| EP1645350A1 (en) * | 2004-10-08 | 2006-04-12 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Casting with integrated functional elements and manufacturing process |
| US20110000634A1 (en) * | 2007-12-21 | 2011-01-06 | Oskar Frech Gmbh + Co. Kg | Casting Machine System and Process for Producing Hybrid Metal/Plastic Articles |
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| CN113634741A (en) * | 2021-08-09 | 2021-11-12 | 宿迁东润机械制造有限公司 | Pulley casting device, system and casting method thereof |
| CN114261054A (en) * | 2021-12-28 | 2022-04-01 | 江苏葑全新能源动力科技有限公司 | Method for manufacturing integrally formed vehicle door |
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|---|---|
| DE102020129793A1 (en) | 2021-05-27 |
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