EP1082200A1 - Injection moulding tool and method for the production thereof - Google Patents

Injection moulding tool and method for the production thereof

Info

Publication number
EP1082200A1
EP1082200A1 EP99917736A EP99917736A EP1082200A1 EP 1082200 A1 EP1082200 A1 EP 1082200A1 EP 99917736 A EP99917736 A EP 99917736A EP 99917736 A EP99917736 A EP 99917736A EP 1082200 A1 EP1082200 A1 EP 1082200A1
Authority
EP
European Patent Office
Prior art keywords
injection
production
producing
model
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP99917736A
Other languages
German (de)
French (fr)
Inventor
Jean-Marc Boechat
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP1082200A1 publication Critical patent/EP1082200A1/en
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds

Definitions

  • the invention relates to a method for producing an injection mold made of metal for the limited mass production of injection molded parts with dimensions of typically greater than 1 mm.
  • the term "limited mass production” is used for the purpose of this description for the production of series with quantities in the order of magnitude of preferably 1000 to 100000 injection molded parts.
  • conventional injection molds can produce around ten times larger series, while the so-called rapid tooling or rapid prototyping processes are suitable for around ten times smaller series.
  • provisional tools made of various materials are often used to produce small quantities of prototypes or pre-series and small series.
  • Cast resin tools or even wooden molds in casting or thermoforming technology have been common for a long time.
  • the injection molding process has always brought a short-term end to the use of such provisional materials due to the high pressures in the mold. Recently, the interest in tools that can be produced quickly and inexpensively has increased again.
  • the invention is therefore based on the object of producing an injection molding tool which, on the one hand, can be produced quickly and inexpensively and, on the other hand, the production larger series than tools made of "soft materials" allow.
  • this is achieved by a method of the type mentioned at the outset, which is distinguished by the fact that a model of the injection-molded part to be produced is placed in a standard mold, the mold is poured out with the placed model by means of powder injection molding, the molded part is debindered and then sintered becomes.
  • Fig.l is a schematic representation of the process steps for producing an injection mold for the manufacture of a plastic gear
  • a model 1 of the injection molded part 2 to be produced in the present case a plastic gear wheel, can be produced in various ways.
  • the necessary dimensional additions to compensate for the shrinkage during sintering are known from powder injection molding technology.
  • a shape of the model is produced on the basis of CAD construction documents 3 by means of the known stereolithography 4 and the synthetic resin model 1 is cast in this in a casting process 5 which is also known per se.
  • this model is placed or assembled in a standard mold 6.
  • the mold is then closed and poured out using powder injection molding.
  • the resulting molded part 7 represents a so-called green body and is very easy to machine in this state.
  • the next step is the debinding of the molded part, which can be carried out in various ways, for example by thermal decomposition, solvent extraction, catalytic debinding, etc.
  • sintering follows, ie a pressure-free compression of the molded part, whereby approximately the theoretical density of the metallic material is reached.
  • the result is an injection molding tool 8 made of metal, which permits production on the order of 100,000 injection molded parts.
  • the advantages of this process lie in the relatively short time required from the design drawing to the finished tool. Typically, this doesn't take more than two weeks.
  • the process is extremely inexpensive. A tool that is manufactured using this process costs around 20 to 30% of a conventional production tool.
  • a further advantage lies in the possibility shown in FIG. 2 of producing a plurality of shaped parts 9, 10, 11 of the same type and storing them in the state of green bodies. Because of the simple reworkability in this state, they can be adapted very quickly to necessary changes if necessary. This means that the reworking, changes or repairs of the tool that are feared in conventional injection molding technology are no longer a problem.

Abstract

The inventive method for the production of a metal mould in order to manufacture a limited amount of mass-produced injection moulded parts (2) consists in producing a moulded part (7) by means of injected powder moulding based on a model for said injection moulded part (2) and in producing a tool therefrom by means of debinding and sintering.

Description

Spritzgusswerkzeug und Verfahren zu seiner HerstellungInjection molding tool and process for its manufacture
Die Erfindung betrifft ein Verfahren zur Herstellung eines Spritzgusswerkzeuges aus Metall für die begrenzte Massenfertigung von Spritzgussteilen mit Abmessungen von typischerweise grösser als 1 mm. Der Begriff "begrenzte Massenfertigung" wird für den Zweck dieser Beschreibung für die Fertigung von Serien mit Stückzahlen in der Grössenordnung von vorzugsweise 1000 bis 100000 Spritzgussteilen verwendet. Im Vergleich dazu sind mit herkömmlichen Spritzgusswerkzeugen etwa zehn mal grössere Serien möglich, während die sogenannten Rapid-Tooling- bzw. Rapid-Prototyping-Verfahren für etwa zehn mal kleinere Serien geeignet sind.The invention relates to a method for producing an injection mold made of metal for the limited mass production of injection molded parts with dimensions of typically greater than 1 mm. The term "limited mass production" is used for the purpose of this description for the production of series with quantities in the order of magnitude of preferably 1000 to 100000 injection molded parts. In comparison, conventional injection molds can produce around ten times larger series, while the so-called rapid tooling or rapid prototyping processes are suitable for around ten times smaller series.
Herkömmliche Spritzgusswerkzeuge für die Massenfertigung von Spritzgussteilen sind sehr aufwendig in der Herstellung und daher sehr teuer. Dies gilt vor allem auch für die Nachbearbeitung im Fall von nachträglich erforderlichen Änderungen. Sie sind daher nur für die echte Massenfertigung von Stückzahlen in Millionenhöhe wirtschaftlich.Conventional injection molding tools for the mass production of injection molded parts are very complex to manufacture and therefore very expensive. This applies above all to post-processing in the event of subsequent changes. They are therefore only economical for the real mass production of quantities in the millions.
Zur Herstellung von kleinen Stückzahlen von Prototypen oder auch von Vor- und Kleinserien werden deshalb häufig provisorische Werkzeuge aus diversen Materialien verwendet. So sind z.B. Giessharzwerkzeuge oder sogar Holzformen in der Giess- oder Warmformtechnik bereits seit längerer Zeit üblich.Therefore, provisional tools made of various materials are often used to produce small quantities of prototypes or pre-series and small series. For example, Cast resin tools or even wooden molds in casting or thermoforming technology have been common for a long time.
Der Spritzgiessprozess hat aufgrund der hohen Drücke im Werkzeug dem Einsatz solcher provisorischer Werkstoffe immer ein kurzfristiges Ende bereitet. In jüngerer Zeit wächst das Inter¬ esse an schnell und kostengünstig herstellbaren Werkzeugen wieder stärker. Der Erfindung liegt daher die Aufgabe zugrunde, ein Spritzgusswerkzeug herzustellen, das einerseits schnell und kostengünstig herstellbar ist und andererseits die Herstellung grösserer Serien ermöglicht, als dies Werkzeuge aus "weichen Werkstoffen" zulassen.The injection molding process has always brought a short-term end to the use of such provisional materials due to the high pressures in the mold. Recently, the interest in tools that can be produced quickly and inexpensively has increased again. The invention is therefore based on the object of producing an injection molding tool which, on the one hand, can be produced quickly and inexpensively and, on the other hand, the production larger series than tools made of "soft materials" allow.
Erfindungsgemäss wird dies gelöst durch ein Verfahren der eingangs erwähnten Art, das sich dadurch auszeichnet, dass ein Modell des zu fertigenden Spritzgussteils in einer Standard- Gussform plaziert wird, die Form mit dem plazierten Modell mittels Pulverspritzguss ausgegossen wird, das entstandene Formteil entbindert und anschliessend gesintert wird.According to the invention, this is achieved by a method of the type mentioned at the outset, which is distinguished by the fact that a model of the injection-molded part to be produced is placed in a standard mold, the mold is poured out with the placed model by means of powder injection molding, the molded part is debindered and then sintered becomes.
Im folgenden wird anhand der beiliegenden Zeichnungen ein Ausführungsbeispiel der Erfindung beschrieben. Es zeigen:In the following an embodiment of the invention will be described with reference to the accompanying drawings. Show it:
Fig.l eine schematische Darstellung der Verfahrensschritte zur Herstellung eines Spritzgusswerkzeugs für die Fertigung eines Kunststoffzahnrads undFig.l is a schematic representation of the process steps for producing an injection mold for the manufacture of a plastic gear and
Fig.2 einen speziellen Ausschnitt aus dem Herstellungsverfahren.2 shows a special section of the manufacturing process.
Ein Modell 1 des zu fertigenden Spritzgussteils 2, im vorliegenden Fall eines Kunststoffzahnrads, kann auf verschiedene Weise hergestellt werden. Die notwendigen Masszugaben zum Ausgleich der Schrumpfung beim Sintern sind aus der Pulverspritzgusstechnik bekannt. Im vorliegenden Ausführungsbeispiel wird aufgrund von CAD-Konstruktionsunterlagen 3 mittels der bekannten Stereolithographie 4 eine Form des Modells hergestellt und in dieser in einem ebenfalls an sich bekannten Giessvorgang 5 das Kunstharzmodell 1 gegossen.A model 1 of the injection molded part 2 to be produced, in the present case a plastic gear wheel, can be produced in various ways. The necessary dimensional additions to compensate for the shrinkage during sintering are known from powder injection molding technology. In the present exemplary embodiment, a shape of the model is produced on the basis of CAD construction documents 3 by means of the known stereolithography 4 and the synthetic resin model 1 is cast in this in a casting process 5 which is also known per se.
In einem nächsten Schritt wird dieses Modell in einer Standard- Gussform 6 plaziert bzw. montiert. Anschliessend wird die Form geschlossen und mittels Pulverspritzguss ausgegossen. Das dabei entstehende Formteil 7 stellt einen sog. Grünkörper dar und ist in diesem Zustand sehr einfach zu bearbeiten. Als nächster Schritt folgt das Entbindern (debinding) des Formteils, das in verschiedener Weise erfolgen kann, z.B. durch thermische Zersetzung, Lösungsmittextraktion, katalytische Entbinderung etc. Schliesslich folgt als weiterer Schritt das Sintern (sintering) , d.h. eine drucklose Verdichtung des Formteils, wobei annähernd die theoretische Dichte des metallischen Werkstoffs erreicht wird. Das Ergebnis ist ein Spritzgusswerkzeug 8 aus Metall, das die Fertigung in einer Grössenordnung von 100000 Spritzgussteilen zulässt.In a next step, this model is placed or assembled in a standard mold 6. The mold is then closed and poured out using powder injection molding. The resulting molded part 7 represents a so-called green body and is very easy to machine in this state. The next step is the debinding of the molded part, which can be carried out in various ways, for example by thermal decomposition, solvent extraction, catalytic debinding, etc. Finally, as a further step, sintering follows, ie a pressure-free compression of the molded part, whereby approximately the theoretical density of the metallic material is reached. The result is an injection molding tool 8 made of metal, which permits production on the order of 100,000 injection molded parts.
Die Vorteile dieses Verfahrens liegen zum einen in der relativ kurzen Zeit, die von der Konstruktionszeichnung bis zum fertigen Werkzeug benötigt wird. Typischerweise dauert dies nicht mehr als zwei Wochen. Zum anderen ist das Verfahren ausgesprochen kostengünstig. Ein Werkzeug, das mit diesem Verfahren hergestellt wird, kostet etwa 20 bis 30% eines herkömmlichen Produktionswerkzeuges. Schliesslich liegt ein weiterer Vorteil in der in Fig. 2 gezeigten Möglichkeit, mehrere gleichartige Formteile 9, 10, 11 herzustellen und sie im Zustand von Grünkörpern aufzubewahren. Sie können wegen der einfachen Nachbe- arbeitbarkeit in diesem Zustand bei Bedarf sehr schnell an notwendige Änderungen angepasst werden. Somit sind auch die in der herkömmlichen Spritzgusstechnik gefürchteten Nachbesserungen, Änderungen oder Reparaturen des Werkzeugs kein Problem mehr.On the one hand, the advantages of this process lie in the relatively short time required from the design drawing to the finished tool. Typically, this doesn't take more than two weeks. On the other hand, the process is extremely inexpensive. A tool that is manufactured using this process costs around 20 to 30% of a conventional production tool. Finally, a further advantage lies in the possibility shown in FIG. 2 of producing a plurality of shaped parts 9, 10, 11 of the same type and storing them in the state of green bodies. Because of the simple reworkability in this state, they can be adapted very quickly to necessary changes if necessary. This means that the reworking, changes or repairs of the tool that are feared in conventional injection molding technology are no longer a problem.
Als Werkstoff für das Werkzeug kommt vorzugsweise Stahl in Frage. Es sind aber auch andere Werkstoffe, die im Pulverspritzguss verarbeitet werden können, also auch z.B. Keramik, denkbar. Steel is the preferred material for the tool. But there are also other materials that can be processed in powder injection molding, e.g. Ceramic, conceivable.

Claims

Patentansprüche claims
1. Verfahren zur Herstellung einer Spritzgussform aus Metall für die begrenzte Massenfertigung von Spritzgussteilen mit Abmessungen von typischerweise grösser als 1 mm, dadurch gekennzeichnet dass1. A method for producing an injection mold made of metal for the limited mass production of injection molded parts with dimensions of typically greater than 1 mm, characterized in that
(a) ein Modell des zu fertigenden Spritzgussteils in einer Standard-Gussform plaziert wird,(a) a model of the injection molded part to be manufactured is placed in a standard mold,
(b) die Form mit dem plazierten Modell mittels Pulverspritzguss ausgegossen wird,(b) the mold is poured out with the placed model using powder injection molding,
(c) das entstandenen Formteil entbindert wird und(c) the resulting molded part is debinded and
(d) das entbinderte Formteil gesintert wird.(d) the debindered molding is sintered.
2. Verfahren zur Herstellung einer Spritzgussform nach Anspruch 1, dadurch gekennzeichnet, dass das Formteil vor der Entbinderung nachbearbeitet wird.2. The method for producing an injection mold according to claim 1, characterized in that the molded part is reworked before debinding.
3. Verfahren zur Herstellung einer Spritzgussform nach Anspruch 1, dadurch gekennzeichnet, dass das Modell im sogenannten Rapid-Prototyping-Verfahren, z.B. mittels Stereo-Lithographie, hergestellt wird.3. A method for producing an injection mold according to claim 1, characterized in that the model in the so-called rapid prototyping process, e.g. using stereo lithography.
4. Spritzgussform aus Metall für die begrenzte Massenfertigung von Spritzgussteilen, dadurch gekennzeichnet, dass sie nach einem Verfahren gemass einem der Ansprüche 1 - 3 hergestellt ist.4. Injection mold made of metal for the limited mass production of injection molded parts, characterized in that it is produced according to a method according to one of claims 1-3.
5. Anwendung des Pulverspritzgussverfahrens zur Herstellung einer Spritzgussform aus Metall für die begrenzte Massenfertigung von Spritzgussteilen. 5. Application of the powder injection molding process for the production of an injection mold made of metal for the limited mass production of injection molded parts.
EP99917736A 1998-05-19 1999-05-18 Injection moulding tool and method for the production thereof Ceased EP1082200A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
CH110398 1998-05-19
CH110398 1998-05-19
PCT/CH1999/000211 WO1999059790A1 (en) 1998-05-19 1999-05-18 Injection moulding tool and method for the production thereof

Publications (1)

Publication Number Publication Date
EP1082200A1 true EP1082200A1 (en) 2001-03-14

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EP99917736A Ceased EP1082200A1 (en) 1998-05-19 1999-05-18 Injection moulding tool and method for the production thereof

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EP (1) EP1082200A1 (en)
JP (1) JP2002515359A (en)
CN (1) CN1301211A (en)
AU (1) AU3593299A (en)
BR (1) BR9910562A (en)
CA (1) CA2332798A1 (en)
HU (1) HUP0102028A2 (en)
MX (1) MXPA00011177A (en)
SK (1) SK17252000A3 (en)
WO (1) WO1999059790A1 (en)

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Publication number Priority date Publication date Assignee Title
FR3027840B1 (en) * 2014-11-04 2016-12-23 Microturbo PROCESS FOR MANUFACTURING A CERAMIC TURBINE BLADE

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Publication number Priority date Publication date Assignee Title
CA1266159A (en) * 1983-04-09 1990-02-27 Takeo Nakagawa Composite and durable forming model with permeability
FR2624770B1 (en) * 1987-12-16 1990-12-28 Ebauchesfabrik Eta Ag PROCESS FOR PRODUCING A MOLD FOR THE MANUFACTURE OF PARTS OF VERY SMALL DIMENSIONS
JPH03267302A (en) * 1990-03-16 1991-11-28 Olympus Optical Co Ltd Method for forming compacting powder
JPH05104589A (en) * 1991-10-15 1993-04-27 Takamatsu Kikai Kogyo Kk Forming method of fitment of injection molding die
DE4332971A1 (en) * 1993-09-28 1995-03-30 Fischer Artur Werke Gmbh Process for the production of interlocking parts
JP3240023B2 (en) * 1993-10-08 2001-12-17 新東工業株式会社 Manufacturing method of durable air-permeable type
JPH08150437A (en) * 1994-11-25 1996-06-11 Ube Ind Ltd Production of die with permeability having heating, cooling hole and die with permeability
DK134295A (en) * 1995-11-28 1997-05-29 Formkon Aps Process for making two or multi-part molds

Non-Patent Citations (1)

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Title
See references of WO9959790A1 *

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Publication number Publication date
JP2002515359A (en) 2002-05-28
CN1301211A (en) 2001-06-27
MXPA00011177A (en) 2003-04-22
AU3593299A (en) 1999-12-06
BR9910562A (en) 2001-09-11
WO1999059790A1 (en) 1999-11-25
SK17252000A3 (en) 2001-04-09
HUP0102028A2 (en) 2001-10-28
CA2332798A1 (en) 1999-11-25

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