Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D19/00—Casting in, on, or around objects which form part of the product
  • B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
• • 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
  • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
  • B22D17/2218—Cooling or heating equipment for dies
• • 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
  • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
  • B22D17/2236—Equipment for loosening or ejecting castings from dies
• • 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
  • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
  • B22D17/2272—Sprue channels
• • 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
  • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
  • B22D17/24—Accessories for locating and holding cores or inserts
• • 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
  • B22D17/26—Mechanisms or devices for locking or opening dies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D19/00—Casting in, on, or around objects which form part of the product
  • B22D19/0063—Casting in, on, or around objects which form part of the product finned exchangers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
  • F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
  • F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
  • F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
  • F28D1/05308—Assemblies of conduits connected side by side or with individual headers, e.g. section type radiators
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
  • F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
  • F28F21/081—Heat exchange elements made from metals or metal alloys
  • F28F21/082—Heat exchange elements made from metals or metal alloys from steel or ferrous alloys
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
  • F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
  • F28F21/081—Heat exchange elements made from metals or metal alloys
  • F28F21/084—Heat exchange elements made from metals or metal alloys from aluminium or aluminium alloys
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/0035—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for domestic or space heating, e.g. heating radiators
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
  • F28F2255/14—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes molded
  • F28F2255/146—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes molded overmolded

Definitions

• the present invention relates to a mould for modular elements of bimetal radiators, in particular a mould compatible with automated and unmanned production cycles, and claims the priority of the Italian Patent Application n. 102014902318366 (BS2014A000216).
• the radiators are mainly constituted by a plurality of assembled modular elements, i.e. bonded one to another - in series - in order to achieve the desired radiant surface.
• Each radiator element is hollow inside in order to define a duct for the circulation of hot water fed by the system for heating the environment in which the radiator is positioned.
• radiator manufacturers produce the modular elements by the technique of die-casting aluminium in proper moulds.
• the aluminium is injected speedily and pressurized in a closed mould that defines the cast, also named impression, of the modular element of the radiator.
• the mould is constituted by two mould halves of special steel, which material has a melting point higher than the aluminium; a mould half is stationary, i.e. fixed and does not move, the other mould half is movable with respect to the fixed mould half between a closed position and an open position.
• a mould half In the closed position the two mould halves are in abutment one against the other, just to define the cast/impression of the modular element, and in the open position the two mould halves are separated and the workers can move between them, meaning that the area between the two separated mould halves has to be accessible in order to enable the operations provided by the production cycle to take place.
• the mould is closed, the injection pressure of the molten aluminium is maintained for the whole duration of the moulding process until the solidification of the produced element occurs.
• the mould temperature is controlled and adjusted by means of a proper system for circulating a cooling liquid inside the two mould halves.
• the cooling system comprises ducts obtained inside the mould halves; the ducts are connected to a set of outer - computerized - control units controlling the inflow of the cooling liquid depending on whether they have to remove or transfer heat.
• the cooling liquid is pressurized water and/or diathermal oil.
• the moulds used for producing the bimetal modular elements comprise a maximum of two casts, i.e. they are designed for making two modular elements at every moulding cycle.
• US 3,439,732 describes a mould with two impressions, i.e. able to produce two modular elements at a time.
• a similar solution is described also in documents CN-A-1810414 and CN 2880325Y.
• the previously produced steel core is positioned in the mould before the respective closing, so that it its then incorporated in the aluminium.
• the steel core is anchored to the stationary mould half, the latter for this reason comprising pins for temporary retaining the steel core.
• the steel core is constituted by a vertical pipe whose ends are joined to two horizontal bushings, and for this reason it is frequently defined as type H insert.
• moulds with more than two impressions are not available. The reason is due to worker safety and the execution speed in positioning and locking the inserts in the stationary mould half.
• Object of the present invention is therefore to provide a mould for modular elements of bimetal radiators that allows overcoming the limits of the today available solutions, thus resulting usable in automated production cycles, in order to obtain higher productivity without impairing the workers safety.
• the present invention relates therefore to a mould according to claim 1 for producing bimetal modular elements of hot-water radiators.
• the mould comprises a stationary mould half, named by the field technicians fixed mould half, and a movable mould half.
• the movable mould half can be displaced with respect to the fixed mould half between a closed position, at which the two mould halves are in abutment one against the other, and an open position, at which the two mould halves are far one from another.
• the two fixed and movable mould halves negatively define at least one cast or impression of modular element intended to be filled with molten and pressurized aluminium speedily fed by external means.
• the cast or impression is a recess corresponding to the volume to be filled with the molten aluminium.
• each cast is partially excavated in the fixed mould half and partially in the movable mould half.
• At least one of the two mould halves, and preferably the movable mould half comprises means for retaining a metal insert, for example a steel insert, intended to remain included in the aluminium in order to define a duct for the circulation of hot water in the respective modular element.
• the metal insert will constitute the core of the completed radiator, resistant to corrosive waters.
• the mould further comprises ejecting means to eject the moulded bimetal modular elements; the ejecting means are intended to intervene when the mould is open in order to detach the modular elements from one of the mould halves.
• the ejecting means comprise a plurality of ejecting pins to eject the solidified modular elements in the mould.
• the ejecting pins are translatable in corresponding seats in the mould in a direction transverse to the casts, i.e. are retractable; when activated, they cantileverly come out from the mould half thereby pushing out the modular element until then stuck in the mould half, then causing the detachment thereof.
• the seats of the ejecting pins open just near the casts/impressions, so that when the pins are extended the respective ends push the solidified modular elements out of the casts.
• the mould according to the present invention differs because the means for retaining the metal inserts and the ejecting means are on the same mould half, preferably the movable one.
• One of the advantages achieved by this configuration is the possibility of completely automating the moulding cycle also when the mould is provided with several casts or impressions.
• the loading of the metal inserts in the mould and the taking of the moulded modular elements can occur automatically thanks to a robotic loading and unloading system, as an industrial manipulator.
• Retaining the modular elements on the mould half provided with the ejecting means makes unloading the modular elements very easy without the risk of the same modular elements remaining stuck in one of the mould half.
• This feature makes automation possible for the operations with a robotic arm moving in the area between the two open mould halves, in place of the workers conventionally employed in this step of the moulding cycle.
• a robotic arm is therefore programmable in order to speedily carry out the just described operations, without the risk of the arm striking against the ejecting system of the mould, just because such a system is always on the opposite side of the arm with respect to the moulded modular elements.
• the configuration of the mould according to the present invention is advantageous since it ensures that the modular elements remain all constrained to the same mould half when the mould opens, also when the mould is provided with several casts/impressions. For example, if the mould is provided with four casts/impressions for the simultaneous production of as many modular elements, at the mould opening the four modular elements all remain constrained to the same mould half, and not some on a mould half and others on the other mould half, just because the retaining means are on board of the same mould half.
• the mould is provided with a plurality of casts/impressions of modular elements, and more preferably it is provided with four casts and not of only two.
• the problem of worker safety can be solved by using a robotic arm.
• the present invention makes thus possible the use of several casts/impressions, even four, for the benefit of productivity.
• the casts/impressions are side by side and parallel in the mould.
• this configuration proved to be the best as for the bulk minimization and the possibility of effectively adjusting the mould temperature.
• the mould can be produced with the casts arranged radially around the aluminium inlet point, but in this case the mould would have much larger size and its temperature would be more difficult to adjust.
• the after-casting handling would be complex and economically detrimental.
• the two fixed and movable mould halves define a distribution channel of the molten aluminium in the casts of the modular elements.
• the distribution channel in its turn comprises four arms, or branches, each of which distributes the aluminium to a corresponding cast of the four casts in the mould.
• the channels have geometries specifically sized to make the aluminium get to the four casts in the right times, thus obtaining a high quality production.
• two branches extend between a first and a second cast immediately adjacent thereto, and the other two branches extend between the third and the fourth cast adjacent to the fourth cast.
• the casts are pairwise grouped and the branches of the aluminium distribution channel do not extend between the second and the third cast.
• the steel insert can be simply a pipe with folded ends, or more commonly a pipe connected at its ends to two transverse bushings (either threaded or not) that will constitute the holes connecting the modular elements one with another.
• the means to retain the steel insert are pins.
• the pins have to be configured to retain the steel inserts and prevent them from falling before the mould closes and moving in the mould during the injection of the molten aluminium.
• the pins have to retain the moulded modular elements, when the mould opens, and prevent them from falling before the robotic handling system takes them for their delivery to the next work station provided in the production cycle.
• the just described result is preferably obtained by providing the pins with at least one portion cantileverly extending from the respective mould half and with a shape complementary with respect to the corresponding part of the metal inserts with which it has to interact, whether it is a bend or a bushing.
• the pins In practice when an insert is fitted on the pins, the latter penetrate at least partially in the inserts, in the holes obtained in the bushings or bends, until a sufficient interference between the pin and the metal insert is obtained.
• a robotic arm pushes the inserts onto the pins until the bushings become anchored on the same due to the so- created interference. It is just this interference that ensures the inserts and the modular elements not falling incidentally when the mould is open. The pressure applied by the robotic arm can be adjusted in order to obtain such a result. The interference should also allow extracting the modular elements from the mould.
• the portion of the pins with which the interference is created is a cylindrical portion whose outer diameter corresponds to the inner diameter of the insert bushings. More preferably, the pins are provided with a conical end serving for driving the insertion of the metal inserts into the bushings.
• the other mould is provided with pins, the latter will not have the function of retaining the inserts and the modular elements, just because the latter are desired to always remain on the same mould half, but they will rather act as insert countercheck surface when the mould is closed, in order to obtain the correct centering.
• a centre-to-centre comprised in the interval 350-800 mm is defined between the pins.
• the centre-to-centre between the retaining pins of the radiator is selected from:
• a sleeve wraps each pin, so as to be coaxial with the same and telescopically movable.
• the sleeve is a cylindrical element slidingly fitting to the pins.
• the sleeves are movable with respect to the pins between a rearward position and a forward position.
• the actuator is preferably hydraulic and even more preferably it is the same actuator of the ejecting means, such as for example a dedicated hydraulic circuit.
• the sleeves In the rearward position, the sleeves do not interact with the inserts or the modular elements.
• the sleeves When the mould is closed, but before the molten aluminium is injected, the sleeves are pushed towards the forward position to compensate for possible clearances and move in abutment against the bushings or bends of the metal inserts, that de facto are in this way firmly pressed between the same sleeves and corresponding countercheck surfaces of the other mould half, for example other pins with whom they do not interlock.
• This feature also promotes the automation of the loading of the inserts in the mould, since possible small positioning errors made by a robotic arm are compensated by the intervening sleeves that inevitably force the inserts in the correct position.
• the sleeves also work as ejecting means, since as the mould is opened they can be operated together with the ejecting pins, aiding them in ejecting the moulded modular elements from the mould half. In this instance the sleeves push the inserts outwardly, and the whole modular element with them.
• the mould is usefully designed with determined distances among the casts, so that the heat transferred by the molten and pressurized aluminium speedily injected into the mould can be distributed or removed with the highest efficiency.
• the distance between a first and a second cast, and between a third and a fourth cast is preferably comprised in the range 50-100 mm and the distance between the second and the third cast is comprised in the range 100-200 mm.
• the mould comprises a cooling circuit constituted by a plurality of canalizations obtained in the two mould halves in their inside and fed with a cooling liquid, for example water or diathermal oil, circulated by a series of external electronic control unit.
• a cooling liquid for example water or diathermal oil
• canalizations and flow rates of the cooling liquid are configured for:
• start-up - preheating the mould halves before initially starting the die-casting process
• the Applicant points out that the design of the internal circuits used for regulating the temperature of the bimetal mould with four impressions is strictly bound to the step of cold implementation of the centre-to-centre of the mould, the hot operation thereof and the subsequent cooling of the moulded bimetal modular elements that, after their ejection from the mould, being subjected to different shrinkages however have to be equally sized.
• the dimensional accuracy of the bimetal element mostly depends on the size of cold implementation of the centre-to-centre and on the thermal control of the mould.
• the overall flow rate of the cooling liquid circulating in the canalizations is comprised in the range from the minimum of 90 liters per minute to a maximum of 220 liters per minute.
• the present invention in a second aspect thereof, relates to the method according to claim 17 for producing modular elements of radiators.
• FIG. 1 is a perspective view of the movable mould half of a mould according to the present invention.
• FIG. 1 A is a perspective view of a hot-water radiator obtained by assembling aluminium modular elements
• FIG. 1 is an enlarged view of a portion of the movable mould half
• FIG. 1C is a perspective and enlarged view of a steel insert constrainable to the mould according to the present invention to remain included in an aluminium modular element;
• FIG. 2 is a perspective view of the stationary (fixed) mould half of a mould according to the present invention
• FIG. 3 is a cross sectional view of the movable mould half
• FIG. 4 is a cross sectional view of the stationary mould half
• FIG. 5 is a cross sectional view of the movable mould half
• FIG. 6 is a schematic view of the movable mould half, showing the logic of the cooling system
• FIG. 7 and 8 are perspective views of the movable mould half in corresponding configurations
• FIG. 9 is a front view of a detail of the mould according to the present invention and a steel insert;
• FIG. 10 is a perspective and enlarged view of some components of the mould according to the present invention, in a first configuration
• figure 11 is a perspective and enlarged view of the components shown in figure 9, but in a second configuration.
• Figure 1 is a perspective view of the movable mould half 1 of a mould according to the present invention.
• the movable mould half 1 comprises four cast halves or impression halves A, B, C and D, each of which corresponds to a cast/impression half on the fixed mould half 2 shown in figure 2, respectively A', B', C and D'. All the cast halves are recesses excavated in the material of the corresponding mould half 1 or 2.
• the eight cast halves define together four casts A+A', B+B', C+C, D+D', i.e. the sum of volumes.
• Each cast A+A', B+B', C+C and D+D' constitutes the negative of a modular element of the hot water radiator.
• Figure 1A shows an example of radiator and by the referral 101 a modular element thereof is denoted.
• the mould can comprise one, two or more casts, but the variation shown in the figures, provided with four casts A+A', B+B', C+C, D+D', is the preferred one since it constitutes the best trade-off among production and operation costs and the productivity offered.
• the mould is configured for housing steel inserts 200 intended to remain included in the aluminium that will define the modular element 101.
• the steel inserts 200 are each constituted by a pipe 201 extending in longitudinal direction and two transverse bushings 202 connected to the ends of the pipe 201.
• the steel inserts 200 define together what will be the future duct for the circulation of hot water in the radiator 100.
• the inserts 200 are also visible in figure IB, and in particular figure 1C is a perspective and enlarged view of an insert 200.
• the bushings 202 are threaded; in general, however, the bushings can also be not threaded initially if the heater manufacturer prefers to carry out the threading at a later time after the modular elements have been extracted from the mould.
• the four casts A+A', B+B', C+C and D+D' are positioned parallel one to another, each extending in longitudinal direction.
• the casts A+A', B+B', C+C and D+D' are grouped two by two, with the casts A+A', B+B' forming a first group and the casts C+C and D+D' forming a second group.
• the distance, i.e. the centre-to-centre, between the two groups is longer than the distance between the two casts of a same group.
• the distance between the first cast A+A' and the second cast B+B' and the distance between the third cast C+C and the fourth cast D+D' is comprised in the range 50-100 mm; the distance between the second cast B+B' and the third cast C+C is comprised in the range 100- 200 mm.
• This configuration shown to be optimal for the prearrangement of an effective cooling circuit comprising a plurality of canalizations 3 extending in the two movable 1 and fixed 1 mould halves, for the circulation of a cooling liquid, water and/or diathermal oil.
• the canalizations 3 are all connected with six external control units (or three having double circuit), not shown, that adjust the flow rates and the temperatures of the cooling liquid, as it will be explained in the following.
• FIG. 1B Another feature can be well seen in figure IB. It is the configuration of the distribution channel 5 of the molten aluminium in the casts A+A', B+B', C+C and D+D'.
• the channel 5 is split in two from the starting inlet point of the aluminium into the mould and then again in four branches 51-54.
• the branches 51-54 of the distribution channel 5 of the aluminium are also grouped two by two, as the casts.
• the branches 51 and 52 are adjacent one to another and extend between the first and the second casts A+A', B+B', whereas the branches 53 and 54 are adjacent one to another and extend between the third and the fourth casts C+C and D+D' .
• the distribution channel 5 of the aluminium does not extend between the second cast B+B' and the third cast C+C. This configuration is useful in order to hold the molten aluminium for a sufficient time, i.e. to prevent it from cooling too speedily before reaching the distal ends of the casts with respect to the inlet end.
• Figures 3 and 4 are longitudinal transverse sections, respectively of the movable mould half 1 and fixed mould half 2.
• the canalizations 3 of the cooling circuit are clear and extend inside the respective mould half 1 or 2 in order to distribute the cooling liquid where needed.
• the case K also called bolster
• the die-holder element P the male die M.
• These elements are provided in both the fixed mould half 2 and the movable mould half 1.
• the cast halves A-D and A'-D' are obtained in the male die M.
• Figure 5 is a cross section of the movable mould half 1 taken on a plane transverse to the cast halves A-D.
• the ejecting pins of the modular elements 101 solidified in the mould are denoted.
• the ejecting pins 6, also named movable strip-like plugs, are slidable in corresponding seats obtained in the movable mould half 2, transversely to the plane containing the cast halves A-D.
• the mould is opened, i.e. the movable mould half 1 is moved away from the fixed mould half 2, the bimetal modular elements, now solidified, are ejected by pushing the ejecting pins 6 completely into the respective seats, until coming out and biasing the modular elements until separation from the cast halves A-D.
• the ejecting pins 6 are preferably hydraulic, meaning that the thrust making them partially come out from the respective seats is provided by a pressurized liquid, for example pressurized oil in a proper hydraulic circuit.
• Figure 6 shows a top plan view of the mould half 1.
• the areas 7 and 8 inside the dotted lines correspond to a configuration of the cooling circuit partly defined by the canalizations 3, studied for removing heat.
• the cooling circuit is studied for removing heat from the areas 7 and 8 (the cooling liquid removes heat from the two mould halves 1 and 2 in these areas) and redistributing it as much evenly as possible in the remaining areas of the two mould halves 1 and 2.
• each pair of pins 4 and 4' cooperates in order to temporary retain a bushing 202 of the steel insert 200 during the injection of the molten aluminium in the mould.
• IB, 4 and 7 in each cast half A-D of the movable mould half 1 there are two retaining pins 4, one for each bushing 202 of the steel insert 200 and in each cast half A-D' of the fixed mould half 2 there are corresponding pins 4'.
• Figure IB is an enlargement of figure 1, that shows the area of the movable mould half 1 where the casts A-D are provided.
• the pins 4 can be seen well and the respective retaining function of the bushings 202 of the inserts 200 is evident.
• the inserts 200 are retained by the pins 4 on the movable mould half 1.
• the pins 4 and the pins 4' have a different geometry; the differences have been studied by the Applicant in order to obtain the assurance that, even after the solidification of the modular elements 101 and the opening of the mould, the modular elements 101 are still constrained to the movable mould half 1 and not to the fixed mould half 2. Only at a later time, as described afore in reference to figure 5, the ejecting pin 6 operate to separate each modular element 101 from the movable mould half 1.
• Figure 8 shows well this concept.
• the movable mould half 1 is viewed in perspective, with all the ejecting pins 6 projecting from the mould half 1.
• the pins 4' of the fixed mould half 2 are stationary, just screwed to the fixed mould half 2 at a shank 9.
• the portion 10 projecting inwards of a cast/impression is substantially conical. In figure 9 the taper is accentuated for the sake of clarity, but in practice the taper of the portion 10 is to the minimum.
• the maximum diameter of the conical portion 10 of the pins 4' is such that a press fit occurs with the corresponding bushings 202 of the inserts 200 when the mould is closed.
• the insert 200 has to remain anchored to the movable mould half 1 and therefore the interference created among the bushings 200 and the pins 4' should not be excessive and mainly serves to prevent the molten aluminium from penetrating in the inserts 200 at the threads 203. This situation should not occur since otherwise the obtained modular element 101 would result a reject.
• the shank 9 of the pins 4' comprises a portion 9' having larger diameter than the diameter of the bushings 202 of the inserts 200; in this way, when a bushing 202 of an insert 200 is in abutment against the portion 9' of the pins 4', a seal preventing the molten aluminium from penetrating in the inserts 200 is obtained.
• the pins 4 of the movable mould half 1 are fastened to the movable mould half 4 with a shank 11 and, therefore, are integral with the same.
• the shank 11 also acts as limit element for the bushings 202 of the inserts 200, meaning that the shank 11 constitutes a step against whom the bushings 202 move in abutment.
• the pins 4 comprise a cylindrical portion 12 extending between the shank 11 and an almost conical end 13; the latter is the part of the pins 4 visible in the other accompanying figures.
• the end 13 has a nick 14, i.e. a flat portion intended to face the pipe 201 of the insert 200 at the joint with the bushing 202 but defining a gap with the same.
• the conical end of the pins 4 has more or less the same taper as the end 10 of the pins 4', but since the pins 4 are also provided with the cylindrical portion 12 they make a more effective seal with the bushings 202, meaning that when the mould is opened and the two mould halves 1 and 2 are separated, the bushings 202 of all the inserts 200 are still retained on the pins 4 just by the interference generated with the respective cylindrical portions 12.
• the mould comprises a plurality of sleeves 15 that can be partially telescopically extracted from the movable mould half 1, by sliding on the shank 11 of the pins 4.
• the sleeves 15 are thus sliding in proper seats and have an inner diameter corresponding to the outer diameter of the shank 11 of the pins 4 such to move in abutment head to head against a corresponding bushing 202 of an insert 200, clearly at the side of the movable mould half 1.
• the telescopic movement of the sleeves 15 can be better comprised by observing figures 7 and 8 sequentially.
• the sleeves 15 can not be seen since completely recessed in the respective seats; the conical portions 13 of the pins 4 are visible instead.
• the sleeves 15 can be seen completely extracted from the respective seats and cantileverly projecting from the movable mould half 1; in the same figure, also the extracted ejecting pins 6 can be seen.
• the sleeves 15 are two per each of the four casts A+A', B+B', C+C and D+D', i.e. one per each of the pins 4.
• the sleeves 15 are movable between a retracted position, at which the conical portions 12 and the cylindrical portion 12 are free to receive a bushing 202 of an insert 200 so that it fits completely, and a forward position at which the sleeves 15 are in abutment against the bushing 202 and apply on the same a pressure adequate to seal against the penetration of the molten aluminium in the insert 200.
• the movement of the sleeves 15 is actuated by a hydraulic system as the one used for moving the ejecting pins 6. More preferably, the hydraulic system is the same for the ejecting pins 6 and the sleeves 15, meaning that it is shared.
• Figures 10 and 11 show in detail the assembly comprising the pins 4' and the pins 4; for sake of clarity these elements are shown separate, i.e. not inserted in the remaining of the movable mould half 1.
• a hydraulic actuator having the task of moving the sleeves 15 is denoted.
• the group formed by the elements 12, 13, 15 and 16 can be defined "sleeve ejector" in technical language.
• the sleeves 15 are shown in the rearward position; in figure 11 instead, the sleeves 15 are in abutment against the bushings 202 of the corresponding inserts 200.
• a moulding cycle starts with the mould open. Usually in this step the area between the two mould halves 1 and 2 is occupied by a worker manually inserting an insert 200 in the fixed mould half; in the mould according to the present invention instead, the operation of inserting the inserts 200 is completely automated, meaning that industrial manipulators as robotic arms can be used, and it preferably occurs on the movable mould-half 1.
• the mould is opened.
• the four modular elements 101 are certainly still constrained to the movable mould half 1 during the mould opening.
• the four modular elements 101 are extracted from the movable mould half 1 by activating the ejecting pins 6 and simultaneously also the sleeves 15, as shown in figure 8.
• the modular elements 101 are drawn from the same robotic arm that initially inserted them in the mould half 1; it is evident that the moulding cycle can de facto become totally automatic thanks to the ejecting pins 6 and the pins 4 being on the same mould half 1.
• Loading the inserts 200 in the same mould half (in this case the movable one 1) from which the modular elements 101 are extracted allows greatly simplifying the plants, and in particular allows minimizing the intervention of the robotic arm and optimizing the movements thereof.
• the four modular elements 101 are thus sent to the next work station provided for their production cycle and the mould is ready for a new moulding cycle.
• the great advantage provided by the mould according to the present invention is just of allowing the total automation of the moulding cycle, for the benefit of the worker safety. A significant increase of the productivity can thus be obtained, which could not be obtained by using moulds having several impressions, but with labour for loading the inserts 200.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• General Engineering & Computer Science (AREA)
• Injection Moulding Of Plastics Or The Like (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)

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• 2015
  • 2015-12-03 EA EA201791403A patent/EA033255B1/ru not_active IP Right Cessation
  • 2015-12-03 EP EP15820270.5A patent/EP3237130A1/de not_active Withdrawn
  • 2015-12-03 WO PCT/IB2015/059315 patent/WO2016103086A1/en active Application Filing

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