DE102017111690A1 - Method for producing a casting core for a sanitary fitting and a sanitary fitting - Google Patents

Abstract

The invention relates to methods and casting cores for providing a sanitary fitting (2) having a metallic housing (11) with an interior space (12) accessible via at least two housing openings (13), wherein a casting core (1) is provided in the interior space (12). from a plastic material (3) is positioned, which comprises at least one channel (15), via which the at least two housing openings (13) are fluidically connectable and wherein the casting core (1) is produced by means of internal pressure injection molding.

Description

The invention relates to the production of a sanitary fitting, in particular a water outlet fitting. Furthermore, methods for producing a casting core made of plastic and a housing for a sanitary fitting made of metallic material are proposed.

It is known to produce water outlet fittings in particular in the manner of a die-cast component, wherein in a die-casting of metal or a metal alloy, a base body is produced with a cavity in which a plurality of openings are provided.

Such a sanitary fitting or water outlet fitting may, for example, be a fitting with which water of a predetermined temperature and quantity can be dispensed as required. Such a sanitary fitting in particular comprises a housing which has at least one lateral tap and a central base body. The base body can have an opening in the housing in the lower area, via which the water supply lines can be introduced into the interior of the housing and / or the housing can be fastened with a washstand or the like. Opposite to the partially substantially cylindrically executed base body, a further opening in the housing is provided, via which at least one actuating element for operation of the sanitary fitting can protrude into an interior of the housing. There may be provided, for example, a single lever pivot mechanism. Starting from this base body, a type of tap or water spout may be formed, which ultimately provides a portion of a waterway of the water treated in the sanitary fitting and includes an outlet with, for example, a mousseur over which the water is dispensed with a desired spray pattern.

From the EP 2 662 163 a water outlet fitting is known, which is produced by die-casting. To produce a casting core is used, which remains in the interior of the die-cast component and then forms at least one channel for fluid guidance. It can be provided that the casting core has a melting point, which lies below the material from which the metallic housing is formed. It can further be provided that the casting core has a wall thickness which is significantly greater than the wall thickness of the housing. It is also possible that the casting core ribs or reinforcing structures for supporting the metallic housing is formed.

The casting cores proposed there are hitherto only suitable for a specific selection of design variants for water outlet fittings, in particular in the case of a substantially straight-line course of the channel for fluid guidance. For more complex design variants, curved taps or the like, it may be necessary to assemble the proposed plastic core of several parts, wherein the connectors must be additionally sealed.

On this basis, it is an object of the present invention to provide a method for producing a casting core or a sanitary fitting, with the particular cost of production should be reduced. At the same time as possible a metal-free water supply in the sanitary fitting should be realized. Especially in the foreground, to provide a brass-free water supply regardless of the material of the housing. Likewise, it is desired to provide a method for producing complex geometries for the internal water flow in the casting core, as well as additional design options for the inclusion of other components in the casting core.

These objects are achieved with the features of the methods and products of the independent claims. Particularly advantageous embodiments are specified in the dependent claims. It should be noted that the features listed individually in the claims can be combined with each other in any technologically meaningful way. In addition, the (individual) features of the claims can be combined with situations from the description and / or the description of the figures.

1. a) Einspritzen eines fließfähigen Kunststoffmaterials in eine Matrize,
2. b) Zugeben eines Füllmediums in die teilweise mit fließfähigem Kunststoffmaterial gefüllte Matrize, so dass das Kunststoffmaterial an der Matrize anliegt und das Füllmedium vom Kunststoffmaterial umgeben ist,
3. c) Erstarren des Kunststoffmaterials zu einem Gießkern,
4. d) Entfernen des Füllmediums, so dass mindestens ein Hohlraum im Gießkern gebildet ist.

A method for producing a casting core for a sanitary fitting, which comprises at least the following steps:

1. a) injecting a flowable plastic material into a die,
2. b) adding a filling medium into the die, which is partially filled with flowable plastic material, so that the plastic material bears against the die and the filling medium is surrounded by the plastic material,
3. c) solidification of the plastic material to a casting core,
4. d) removing the filling medium, so that at least one cavity is formed in the casting core.

In this case, at least one gas or a liquid can be added as filling medium.

The individual steps of the casting core manufacturing process can be performed in the order given. Nevertheless, it is possible that the steps are at least partially overlaid in time and / or repeated independently of each other.

For example, a flowable plastic material can be produced via an extruder which is injected into the matrix. Depending on the desired shape of the cavity and / or its orientation, the amount of the injected flowable plastic material may be adjusted. At a given time, in addition to or after switching off the flowable plastic material, a filling medium can be added to the matrix. This can be done via the same injection point, but it is also possible to do this via separate injection points. The filling medium, for example nitrogen and / or water, is added to the matrix or the flowable plastic material located in the matrix in such a way that the plastic material is pressed outwards and thus brought into contact in particular with the matrix at least partially or even completely. In this case, the filling medium can now form a bubble and / or delimited partial volume in an inner region of the plastic material, which is preferably virtually or virtually everywhere spaced from the matrix and thus surrounded only by the plastic material. If a predefined position of the filling medium in the plastic material is reached, the plastic material can solidify into a casting core and thus form a solid. The solidification process can be realized at different speeds depending on the filling medium. For example, the cooling process and thus the solidification process when using water as a filling medium is significantly faster than with a gaseous filling medium. If the outer walls of the casting core hardened or solid, now the internal filling medium can be removed, whereby at least one cavity is formed in the casting core. For this purpose, a micro-opening can now be produced or provided via which the filling medium is removed from the interior of the plastic core. Since usually the filling medium is added at a high pressure, for example with a pressure above 200 bar or up to 300 bar, it is easy to subsequently remove this filling material from the interior of the plastic material.

In particular, a casting core for a sanitary fitting with at least one one-piece, a closed cavity having body is proposed, which is formed with a plastic material. It is very particularly preferred that this casting core is a product from the method described above. It is also preferred that the process results in such a casting core. In particular, the casting core can be made exclusively of plastic material or of plastic material with filler material distributed therein (for example particles and / or fibers made of a non-plastic material, such as ceramic, for example). It can be provided that a single closed cavity is present, but it is also possible that there may be several closed cavities. The body preferably has an outer surface which is suitable for subsequently supporting or supporting the shaping of a metallic housing for the sanitary fitting during a die-casting process.

It can be provided that the casting core has at least one outer receptacle which has a receiving volume of at least 30% of the volume of the closed cavity. In the event that several closed cavities are provided, the total volume of all closed cavities for the definition of the receiving volume is set. In particular, the receptacle can only be reached via the outside of the body of the casting core or the receptacle is in contact exclusively with the external environment and, in particular, has no opening towards the cavity. The receptacle is particularly dimensioned such that it can at least partially accommodate a cartridge. The receptacle can be dimensioned so that it can accommodate at least one holder and / or a sealing arrangement for a cartridge.

The body of the casting core may have an at least partially approximately cylindrical base body from which an arm branches off laterally and locally. The closed cavity extends at least partially into the arm. It is possible that the cavity extends into both the arm and the base body. It is preferred that the receptacle extends only from the outer surface on the base body into inner regions of the body, wherein the receptacle and the cavity are spaced apart by at least one partition wall.

1. A) Einlegen eines Gießkerns (hergestellt mit dem hier vorgeschlagene Verfahren oder ausgebildet wie hier erläutert) in ein Gießwerkzeug,
2. B) Umgießen des Gießkerns mit einem metallischen Material,
3. C) Erstarren des metallischen Materials zu dem Gehäuse,
4. D) Ausbilden mindestens eines Kanals durch einen Hohlraum des Gießkerns, wobei der mindestens eine Kanal hin zu mindestens einer Gehäuseöffnung mündet.

Furthermore, a method for producing a sanitary fitting is proposed, which has at least one metallic housing with an interior which is accessible via at least two housing openings. The method comprises at least the following steps:

1. A) inserting a casting core (produced by the method proposed here or designed as explained here) into a casting tool,
2. B) casting over the casting core with a metallic material,
3. C) solidification of the metallic material to the housing,
4. D) forming at least one channel through a cavity of the casting core, wherein the at least one channel opens to at least one housing opening.

The sanitary fitting may be designed in particular in the manner of a water outlet fitting. The housing may be made with alloys comprising zinc, magnesium and / or aluminum. The wall thickness of the metallic housing may for example be in the range of 1.0 to 5 mm, in particular in the range of 2.0 to 3.5 mm. The enclosed housing volume of the metallic housing is preferably at least 80%, in particular at least 90% or even at least 95% of the interior, so a space that is not filled by the metallic housing. In the interior of the core or the cores, water pipes, valve assemblies, mixers or the like and sensors, a control unit or the like may be housed. The housing has at least two housing openings, in particular a housing opening for the inlet of water and a housing opening for the discharge of water. At least one further housing opening may be provided in order to provide adjusting elements for regulating the operation of the sanitary fitting, in particular with regard to the amount of water and / or the water temperature.

For the production of such a sanitary fitting, a casting tool is selected, which essentially images the outer contour or the outer surface of the desired housing. In this casting tool, the casting core is inserted from the plastic material, wherein in particular to the casting mold gaps are formed, in which then the metallic, flowable material can be poured. During the casting process, which may be designed as gravity casting or preferably as a die-cast, the metallic material flows around the casting core. If the metallic material has penetrated into an intended gap between the casting core and the casting tool, the solidification process begins, so that the housing is then formed with the metallic material. When choosing the materials of housing and casting core there is a great possibility of variation. In particular, it may be possible that the plastic casting core has a low, a same or a higher melting point than the metallic material of the housing. By an appropriate design of the casting process, in particular the speed of the curing process, it can be avoided that there is an undesirable damage to the casting core. After solidification of the housing, the casting core is enclosed in particular almost or completely unchanged and captive. It is preferred that the at least one casting core fills the interior space at least in the area of the water outlet and optionally also at least partially in the region of the base body of the sanitary fitting. Due to the fact that the casting core is designed with a closed cavity, this is very dimensionally stable, in particular in all radial directions and thus enables a particularly accurate and precise execution of the case, for example in the context of a die-casting process. In addition, the cavity is then opened so that this part of at least one channel, which extends towards at least one housing opening. In other words, this means that the cavity is subsequently also used to guide the water during operation of the sanitary fitting. The channel may in particular extend directly to the housing opening, but it is also possible that this ends at a distance from the housing opening and the water is then discharged, for example via additional lines or other sections of the casting core.

It is also considered to be advantageous in particular that the casting core is provided with at least one receptacle into which, at least at times during step B), a movable slide of the casting tool penetrates. This has the particular advantage that on the recordings and the movable slide can be performed accurately and also a precise training of housing wall sections is possible. In this case, housing openings can be formed directly. It can be provided that at least two receptacles are provided for two movable slides of the casting mold at the casting core.

Furthermore, it is possible that a channel is formed by a cavity of the casting core, which opens towards at least one receptacle. In particular, this can be done in such a way that a separating wall located between the receptacle and the cavity is removed or pierced. Thus, the cavity or the channel is also accessible via the access of the housing or the casting core, which was initially formed with a receptacle.

Next, a sanitary fitting is proposed, comprising at least one metallic housing with an interior space which is accessible via at least two housing openings, wherein in the interior of a casting core of a Plastic material is positioned, which comprises at least one channel, via which the at least two housing openings are fluidically connectable and wherein the casting core is produced by means of internal pressure injection molding.

The production method of the casting core can be subsequently easily recognized by a person skilled in the art. In particular, it can be easily ascertained that this was produced by means of an internal pressure injection molding process. In this case, of course, different process variants come into consideration, such as a gas injection technique (GIT) or an internal gas pressure injection molding (GID) and / or internal pressure injection molding (WID).

In addition, the use of a casting core produced by means of an internal pressure injection molding method for shaping a metallic housing and forming a channel as a section of a water path in a sanitary fitting is proposed.

It should be noted that the facts explained with reference to the individual process can be transferred to the explanations concerning the casting core or the sanitary fitting and vice versa. The same applies to the characterization of the use.

• 1: einen Ablauf eines Herstellungsverfahrens für einen Gießkern,
• 2: eine Ausführungsform eines Gießkerns,
• 3: eine Gießform, eingelegt in ein Gießwerkzeug, und
• 4: eine Ausführungsform einer Sanitärarmatur.

The invention and the technical environment are explained below with reference to figures. It should be understood that the figures may show specific embodiments of the invention, which, however, are not intended to limit the overall disclosure of the invention in any way. It should also be pointed out that the features shown in combination in the figures can be extracted individually and / or combined with other features of the description and / or other figures, as far as this is not explicitly excluded or recognizable to those skilled in the art technical problems. They show schematically:

• 1 : a sequence of a manufacturing method for a casting core,
• 2 an embodiment of a casting core,
• 3 : a mold, inserted in a casting tool, and
• 4 : an embodiment of a sanitary fitting.

1 illustrates a possible process flow for the production of a casting core 1 , First shown above is that a flowable plastic material 3 in a mold 4 is injected. At a given time, additionally or alternatively, a filling medium 5 in the partially with flowable plastic material 3 filled template 4 added so that the plastic material 3 towards the matrix 4 is pressed and the filling medium 5 preferably completely from the plastic material 3 is surrounded. Has the filling medium 5 within the plastic material 3 or the die 4 assumed a desired position, solidifies the plastic material 3 to a casting core 1 , Subsequently, the filling medium 5 removed again, leaving at least the cavity 6 in the casting core 1 is trained. Subsequently, the casting core 1 from the matrix 4 are removed and used for a casting process for the production of the sanitary fitting.

2 shows an example of a variant of the casting core 1 for a sanitary fitting, which has a one-piece, a closed cavity 6 having body 7 having formed with a plastic material. In the present case, the casting core 1 with an outer receptacle 8th formed a recording volume 9 that has at least 30% of the room volume 10 of the closed cavity 6 Has. In the case shown, there is the casting core 1 exclusively from a single plastic material 3 , Between the (single) recording 8th and the adjacently disposed closed cavity 6 is a partition 21 educated.

3 now illustrates how the casting core 1 in a casting tool 17 can be inserted. After insertion of the casting core 1 in the casting tool 17 can, for example, slide 16 in the recording 8th and / or to the casting core 1 be introduced. In particular, the casting tool forms 17 and the (only) casting core 1 Column then made of the metallic material 14 to be cast, after solidification of the metallic material 14 then the case 11 is formed. In the present case it is shown that practically the entire interior 12 inside the case 11 from the casting core 1 is filled. At the same time, the Scheiber 16 or a corresponding extension of the casting core 1 several housing openings 13 provided immediately during the casting process.

The thus produced composite of metallic housing 11 and therein remaining plastic core 1 can now be post-processed or subjected to further completion or assembly for further process steps.

4 illustrated in the left area, for example, that initially through a hole and an opening to the cavity 6 was generated, where in the housing opening 13 an additional mousseur 18 can be positioned. In order to now forms the former cavity 6 a channel 15 which can be traversed by water, with the desired water jet then over the mousseur 18 the sanitary fitting 2 leaves. Right in 4 is shown that in the lower part of a housing opening 13 is provided, for example, the water supply lines in the inner regions of the housing 11 can be installed or where the housing can be attached to a vanity. In the area where previously the recording 8th and / or the cavity 6 was now, for example, a so-called cartridge adapter 19 positioned in which a cartridge 20 is attached. About the cartridge adapter 19 For example, water supplies and / or the position of the cartridge 20 relative to an actuating mechanism (above indicated single lever mixer) are aligned. The cartridge contains, for example, actuators with which the water temperature and / or the amount of water are regulated, which then the channel 15 is fed and thus also on the mousseur 18 is delivered.

• - Erstellen des Hohlraums durch ein Gasinnendruckverfahren oder ein Wasserinnendruckverfahren,
• - Einspritzpunkt des Füllmediums im Bereich der Stelle, an der später der Mousseur beziehungsweise der Wasserauslauf positioniert ist,
• - Bereitstellen von Aufnahmen beziehungsweise Schiebern am Gießwerkzeug, über die ein Kartuschenadapter positionsgenau platziert werden kann,
• - Einbringen einer Bohrung in den Gießkern an der Stelle, an der schließlich der Wasserauslauf beziehungsweise der Mousseur vorgesehen ist, wobei ein Zugang von außen zu dem vorherigen Hohlraum gebildet ist,
• - Aufbohren der Trennwand im Bereich zwischen Aufnahme und Hohlraum, so dass dort gegebenenfalls ein Absatz gebildet ist, über den der Kartuschenadapter und/oder die Kartusche ortsgenau positionierbar ist,
• - Aufbohren einer äußeren Wand des Körpers des Gießkerns für eine passive Anschlussgeometrie für Schläuche der Wasserzuführleitung.

In particular, the following variants result for the production process of the casting core and / or the sanitary fitting:

• Creation of the cavity by an internal gas pressure method or an internal water pressure method,
• - Injection point of the filling medium in the area where the mousseur or the water outlet is later positioned,
• Providing shots or slides on the casting tool, via which a cartridge adapter can be placed with exact position,
• Introduction of a bore into the casting core at the point where the water outlet or mousseur is finally provided, an access from the outside to the previous cavity being formed,
• Drilling the dividing wall in the area between the receptacle and the cavity so that, if appropriate, a shoulder is formed through which the cartridge adapter and / or the cartridge can be positioned in a location-specific manner,
• - Drilling an outer wall of the body of the casting core for a passive connection geometry for hoses of the water supply pipe.

With the concepts proposed here it is achieved in particular that no further sealing connections are to be provided in the case of a plurality of casting cores. In particular, this also includes the step of connecting several casting cores to one another. Likewise, it is easy and without a particular risk of damaging the housing possible to make after the surface treatment of the housing nor a processing of the plastic core, for example in the region of the cartridge seat and / or a jet regulator seat.

LIST OF REFERENCE NUMBERS

1

casting core

2

plumbing fixture

3

Plastic material

4

die

5

filling medium

6

cavity

7

body

8th

admission

9

receiving volume

10

volume

11

casing

12

inner space

13

housing opening

14

metallic material

15

channel

16

pusher

17

casting tool

18

mousseur

19

cartridge adapter

20

cartridge

21

partition wall

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 2662163 [0004]

Claims (9)

Method for producing a casting core (1) for a sanitary fitting (2), comprising at least the following steps: a) injecting a flowable plastic material (3) into a die (4), b) adding a filling medium (5) in the partially filled with flowable plastic material (3) die (4), so that the plastic material (3) on the die (4) and the filling medium (5) is surrounded by the plastic material (3) . c) solidification of the plastic material (3) to a casting core (1), d) removing the filling medium (5), so that at least one cavity (6) in the casting core (1) is formed. Method according to Claim 1 in which at least one gas or one liquid is added as the filling medium (5). Casting core (1) for a sanitary fitting (2) with at least one one-piece, a closed cavity (6) having body (7) which is formed with a plastic material (3). Casting core (1) after Claim 3 wherein it has at least one outer receptacle (8) having a receiving volume (9) of at least 30% of the volume (10) of the closed cavity (6). Method for producing a sanitary fitting (2) which has at least one metallic housing (11) with an interior (12) accessible via at least two housing openings (13), the method comprising at least the following steps: A) inserting a casting core (1) produced by a method according to any one of Claims 1 or 2 or trained according to Claim 3 or 4 , in a casting tool (17), B) casting around the casting core (1) with a metallic material (14), C) solidifying the metallic material (14) to the housing (11), D) forming at least one channel (15) a cavity (6) of the casting core (1), wherein the at least one channel (15) opens towards at least one housing opening (13). Method according to Claim 5 in which the casting core (1) is provided with at least one receptacle (8) into which, at least temporarily during step B), a movable slide (16) of the casting tool (17) penetrates. Method according to Claim 6 in which a channel (15) is formed through a cavity (6) of the casting core (1), which opens towards at least one receptacle (8). Sanitary fitting (2), comprising at least one metallic housing (11) with an interior space (12) accessible via at least two housing openings (13), wherein a casting core (1) of a plastic material (3) is positioned in the interior space (12) is, which comprises at least one channel (15) through which the at least two housing openings (13) are fluidically connectable and wherein the casting core (1) is made by means of internal pressure injection molding. Use of a casting core (1) produced by means of an internal pressure injection molding method for shaping a metallic housing (11) and forming a channel (15) as a section of a waterway in a sanitary fitting (2).

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