JP2000314399A - Propeller fan, molten metal forming method for the propeller fan, and molten metal forming device for the propeller fan - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simply change a shaft length and a shaft diameter by forming a shaft part formed integrally by melting metal with a blade part, as either one part of a die gate part formed as a metal passage to the blade part at formation of, or a housing part for housing a solidified metal. SOLUTION: A blade part is rotated by the rotation of a motor which is directly connected to a rotary shaft hole 7. In a shaft part for supporting and rotating the blade part, removing a die gate part 2 which is injection molded, a boss part 8 is completed. When an outer diameter dimension of the boss part 8 of the shaft part is formed with the same dimension as that of the gate part 2 at die design, a tip of a housing part 4 for housing solidified metal by which a nozzle outlet of an injection molder is blocked, or an injection side of the gate part 2 is cut out by means of machining work, and the rotary shaft hole 7 is formed by only machining. The conical gate part 2 is as a center of a hub part 6, and thereby molten metal can be filled uniformly from the center of a shaft into the circumference where multiple blades are formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a technique for forming a propeller fan by molding a metal such as a low melting point alloy, for example, a magnesium (Mg) alloy, by injection molding or the like.

[0002]

BACKGROUND OF THE INVENTION Propeller fans are generally made of plastic materials. In addition, when used in a place where a fire is used, such as a kitchen use, or a place with a high temperature, it is made of metal. The manufacturing method of a product made of metal uses a thin steel plate, a thin aluminum plate, or the like, configures the blade portion with an integral drawing, and connects and fixes a rotating shaft portion formed of a separate part. For this reason, the blade formed from a thin steel plate by integral drawing has a problem in terms of strength because the hub portion of the blade is rapidly reduced and the drawn portion may be cracked. In addition, the blade shape also had poor dimensional accuracy due to a phenomenon that a once-squeezed shape called springback returned to its original shape. In addition, when the material of the blade is a thin aluminum plate, it is thin and light, but the material cost is high and the hub part of the blade cannot be narrowed down more rapidly than the steel plate. Without
Characteristics were bad. In addition, since the rotating shaft portion is a separate component, it takes time to manufacture.

[0003] In a large-sized propeller fan, a blade portion and a rotary shaft portion are formed as separate parts, but the blade portions are not integrated, and a plurality of metal blades are used.
A component called a spider formed of a steel plate or the like thicker than the blade portion fixes the blade to the rotating shaft. For this reason, if the material of the blade is made of inexpensive steel plate, the parts will be heavy, the balance of the blade will be poor, and a balancing work will be required, and the manufactured propeller fan will have a natural frequency of the blade of It was low and did not go for high-speed rotation. In addition, since the rotating shaft portion is a separate component, it takes time to manufacture.

Also, products such as fans made of plastics, especially special plastics mixed with glass fiber to increase the strength, are difficult to reuse, and due to the problem of recycling as a measure against the global environment, the use of mixed materials is limited to metal parts. A review has been made. In addition, for metal parts, it is desired to use a metal having a lower melting point than a combination of dissimilar metals that are difficult to separate or a metal such as a steel plate or aluminum that requires a lot of energy for production. Regarding the thixomolding method of injection-molding a magnesium alloy, which is a typical example of a metal having a low melting point, Nikkei Mechanical 1996.
No. 2.9,495, Nikkei Mechanical 1998.
No. 2, Industrial Materials May 1998 (Vol. 46 No. 5) and Industrial Materials October 1998 (Vol. 46 No. 10). The thixomolding method is a coined word made up of chixolopy and injection molding, and refers to a semi-solid injection molding method of a low melting point alloy developed in the United States. Using a granular rice chip made from a magnesium alloy ingot as a raw material, it is injected into a product mold at high speed and removed as a molded product, as in plastic injection molding. Can be carried out by changing according to the use such as a state containing a solid.

FIG. 16 is a structural view of a thixomolding apparatus which is an injection molding apparatus. 151 is a feeder 155
Hopper for feeding raw materials into the machine, 152 is a screw 153
Are rotated inside and heated by an electric heater 157, a backflow prevention ring 154, an inert atmosphere,
109 is a product mold; 112 is a storage unit 1 from the injection molding machine.
A nozzle for injecting the molten metal accumulated in 22 by a high-speed shot system, and 121 is a rotary drive. In FIG. 16, a magnesium alloy pellet is charged from a hopper 151, and an amount measured by a feeder 155 is charged into a cylinder 152. Since the outer periphery of the cylinder 152 is heated by the electric heater 157 to be a semi-molten magnesium alloy, it is separated from the feeder 155 by the inert atmosphere 156. In order to properly control the amount of the semi-molten magnesium alloy, only the injected amount is measured and supplied by the feeder, but the injected amount does not completely match the supply amount unlike resin molding. The magnesium alloy charged into the cylinder 152 is conveyed forward by the rotation of the screw 153, formed into a slurry, and injected by the screw. Thixomolding utilizes the thixotropic properties of magnesium alloys. Magnesium alloys exist in a solid-liquid coexistence state in which solid-state dendrites are connected in branches. Therefore, in this state, the viscosity is high. When a shearing force is continuously applied by the rotating screw 153, the dendrite is cut and finely granulated. Therefore, the fluidity is increased.

FIG. 17 shows a structural view of a nozzle portion of a molding machine. Reference numeral 110 denotes a solidification plug for preventing the semi-molten magnesium alloy 111 from flowing out of the tip nozzle 112, and reference numeral 113 denotes a gate in the mold 109. Tip nozzle 1 of molding machine
Reference numeral 12 denotes a semispherical convex gate 1 of the mold 109.
The inlet 13 has a slightly larger hemispherical concave shape, and both are contact-connected by a spherical surface. If the contact connection is not tight, the semi-molten magnesium alloy 111 may blow out into the air and burn, and care must be taken in adjusting the contact connection. Semi-solid magnesium alloy 1
At the tip of 11, there is a lump of solidified metal called a solidification plug 110. When the metal is injected, the solidification plug jumps out, and the injection is completed in a very short time of several hundredths to several tens of seconds. FIG. 18 is an explanatory view showing a state where the injection molding machine and the mold are separated after the injection is completed. The metal piece is clogged in the gate portion 113, and the solidified plug 110 remains in the separated portion.

The following are examples of the shape of the propeller fan. Japanese Patent Application Laid-Open No. 10-4729 discloses a resin blade having a hollow portion for reducing noise.
No. 8, JP-A-7-18991, there is a problem that the blades of the blade are deformed during high-temperature operation because the material of the fan is a resin.

[0008] A thin steel plate or a thin aluminum plate is used, and the blade portion is formed by integral drawing. For example, a rotating shaft portion made of aluminum die-casting (a flange of a boss portion is connected).
Japanese Patent Publication No. 3-54337 discloses a fan that is formed by caulking and coupling with separate parts (for example, rivets). Since the hub portion is rapidly squeezed, a crack may be formed in the squeezed portion, and there is a problem in strength. Further, the material of the blade portion is the same, and those using a spider are described in Japanese Utility Model Publication No. 5-45838 and Japanese Utility Model Publication No. 7-23600.

[0009] Japanese Patent No. 1577205 discloses a blade having a wing shape in which the velocity boundary layer is controlled by using centrifugal force and the centrifugal force is used to reduce noise. However, there is a problem that the shape is very disadvantageous in terms of stress.

Japanese Patent Application Laid-Open No. 9-228995 discloses a method in which an airflow separation suppressing rib is provided on the negative pressure side of a blade to reduce noise.
And Japanese Patent No. 2566183.

The shape and manufacturing method of a propeller fan using a magnesium alloy are described in, for example, Japanese Patent Application Laid-Open No. 10-2054.
No. 93 is described. Also, about the axial flow fan using a magnesium alloy, it is described in “Magnesium Yomimoto Shotaro Morozumi Karos Publishing” that the cooling tower fan (impeller) was put into practical use around 1950. However, automobile-related products have been put into practical use as cooling fans, and many devices using aluminum die casting have been put into practical use.

[0012]

SUMMARY OF THE INVENTION A thin steel plate or a thin aluminum plate or the like is used, and the blade portion is formed by an integral drawing.
The rotating shaft part is caulked with another part to constitute the fan, the weight is increased and balancing work is required, the unevenness of the caulking increases, the wind noise and noise when the fan rotates There was a problem that it became large. Also, when aluminum or plastic is used, there is a problem that it is not desirable from the viewpoint of the global environment. On the other hand, the thixomolding method of injection-molding a magnesium alloy, which is a typical example of a metal having a low melting point, has a low reactivity with the iron of the mold material of the magnesium alloy, but has a very small shrinkage ratio as compared with plastic, so that the magnesium alloy has a small shrinkage. Due to the problem of release of magnesium alloy, it is common to apply a release agent, which is not usually used in plastic molding, to a mold. In addition, since the injection is completed in a short time, it is difficult to uniformly fill the thin and many blades with the magnesium alloy, and there is a problem that practicality is difficult. That is,
In the thixomolding method, when a molten metal is filled in a complicated shape such as a fan, it is not practical, and there is a problem with mold measures such as mold release. In addition, there was a similar problem in the magnesium die casting method.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a propeller fan manufactured by metal molding such as injection molding of a low melting point alloy such as magnesium. It is another object of the present invention to obtain a propeller fan melt injection molding method and a propeller fan melt injection molding apparatus which have a simple structure and are inexpensive and highly reliable. Another object of the present invention is to provide a product that is easy to recycle and that uses low-energy, low-cost devices to manufacture products and that enhances recyclability and that is environmentally friendly. Another object of the present invention is to provide a technique for easily and inexpensively manufacturing a complicated thin plate structure such as a wing.

[0014]

A propeller fan according to the present invention is provided with a blade portion in which a number of blades are integrally formed on an outer peripheral portion of a cylindrical or conical hub portion, and a blade provided at a central portion of the hub portion. A shaft portion supporting the blade portion and being rotationally driven by a motor, wherein the shaft portion is formed by melting a metal together with the blade portion, and the shaft portion is formed by molding the blade portion when forming. At least one of a gate portion of a mold to be formed and a storage portion for storing solidified solidified metal.

Further, in the propeller fan of the present invention, the shaft portion is obtained by removing the tip of the portion where the solidified metal exists in the injection side of the gate portion or the storage portion for storing the solidified metal.

Further, in the propeller fan according to the present invention, the thickness of the inner peripheral portion of the blade adjacent to the joint portion with the hub portion is made larger than the thickness of the outer peripheral portion of the blade and smaller than twice.

Also, a propeller fan according to the present invention is provided with a spider provided at a central portion and having a shaft portion that supports a blade portion and is driven to rotate by a motor, and a blade coupled with the spider and having a thickness smaller than the spider. And
The shaft portion is a gate portion of a mold to be a metal flow path to the blade portion at the time of molding or at least a part of a storage portion for storing solidified solidified metal, and the spider The gate portion or the storage portion is provided on the suction side, and the storage portion or the gate portion is provided on the discharge side, and the shaft portion is formed by processing the gate portion and the storage portion.

Further, in the propeller fan of the present invention, the metal to be melted and integrally formed is a magnesium alloy.

Also, the propeller fan of the present invention has a blade portion formed by integrally forming a large number of blades on an outer peripheral portion of a cylindrical or conical hub portion, and a blade portion provided at a central portion of the hub portion to support the blade portion. And a shaft portion that is rotated and driven by a motor, the shaft portion being formed integrally by melting a metal together with the blade portion, and the shaft portion is formed of metal to the blade portion during molding. A gate portion of a mold to be formed as a flow path or at least a part of a storage portion for storing solidified solidified metal, and a suction side of the hub portion includes a plurality of pin gates of the gate portion. A recess for gate processing is provided.

Further, in the propeller fan of the present invention, the number of recesses is equal to or greater than the number of blades of the blade portion.

In the propeller fan of the present invention, the diameter of the gate portion connected to the hub portion, the diameter of the plug catcher, and the diameter of the solidified plug are reduced in this order.

Further, the propeller fan of the present invention is provided with an airflow separation suppressing rib protruding toward the suction side of the blade portion and provided integrally with the blade portion.

Further, in the propeller fan of the present invention, the blades at the blades have a uniform thickness.

Further, in the method for forming a molten metal of a propeller fan according to the present invention, at least a part of the metal is melted from a metal forming machine and blown out from a nozzle, and the metal blown out from the nozzle is formed into a molded product of a propeller fan by a mold. In a method for forming a molten metal of a propeller fan to be formed, a shaft portion provided at a center portion of a hub portion, supporting a blade portion, and being rotationally driven by a motor. Injecting molten metal from a part, and removing the solidified metal solidified and blown out to the nozzle of the metal molding machine from the gate portion after injecting the molten metal into a molded product to form a shaft portion It is a thing.

Further, a method for forming a molten metal of a propeller fan according to the present invention is a method for forming a molten metal of a propeller fan using a mold having a shaft hole shape. In a propeller fan molten metal forming method of melting and blowing out from a nozzle and forming the metal blown out from the nozzle into a molded product of a propeller fan by a mold, the blade is provided at a central portion of a hub portion and supports a motor. A step of injecting molten metal from a shaft part which is driven to rotate and melts the metal together with the wing part and integrally molds; and, after injecting the molten metal into a molded product, a part of a gate portion is formed. And removing the shaft hole.

Further, according to the method for forming molten metal of a propeller fan according to the present invention, in a propeller fan provided with a blade portion integrally formed with a large number of blades on an outer peripheral portion of a hub portion, a metal is provided at a central axial position of the hub portion. Connecting a nozzle of a molding machine and injecting at least a part of the molten metal into a molded product; and filling the injected metal into an overflow portion connected to the blade portion and an outer peripheral portion of a blade of the blade portion. And removing the overflow section.

The apparatus for forming a molten metal of a propeller fan according to the present invention includes a metal forming machine for melting at least a part of a metal and blowing the same from a nozzle, and a mold for forming a propeller fan using the metal blown from the nozzle. And a shaft part which is provided at the center of the hub part of the propeller fan, supports the blade part and is driven to rotate by a motor. A gate part of a mold to be molded or a storage part for storing solidified metal, which serves as a metal flow path to the blade part provided at the position of the shank part to be molded, and a molded part on the gate part side with respect to the molded product. It has a movable mold on the opposite side of the fixed mold.

[0028]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 Hereinafter, a first embodiment of the present invention will be described with reference to the drawings. 1 to 3
FIG. 1 shows an explanatory view in the case of manufacturing a propeller fan according to an embodiment of the present invention. 1 is a cross-sectional view in a gate processing state, FIG. 2 is a cross-sectional view before gate processing, and FIG. 3 is a perspective view before gate processing. In the figure, reference numeral 6 denotes a cylindrical or conical (including frustoconical) hub portion, 5 denotes a wing provided with a large number of blades 33 integrally formed with the hub portion 6, and 8 denotes a shape after forming. A boss having a rotary shaft hole 7 to be machined;
Reference numeral 2 denotes a gate, which is an entrance of a mold into which molten metal injected from the injection molding machine flows from the boss 8 to the blade 33, and 3 denotes a solidified plug (gate) torn at the nozzle of the injection molding machine. Plug part connected to the end of part 2),
Reference numeral 4 denotes a storage section (plug catcher section connected to the end of the gate section 2) for storing the solidified metal that has blocked the nozzle outlet of the injection molding machine. Reference numeral 9 denotes an airflow separation suppressing rib provided integrally on the suction side (negative pressure surface side) of the blade portion 33. Reference numeral 30 denotes an overflow section.

In the structure shown in FIGS.
The blade 33 is rotated by the rotation of the motor directly connected to the motor. The boss portion 8 is completed by removing the gate portion 2 of the mold to be injection-molded from the shaft portion for supporting and rotating the blade portion 33 as shown by the dotted line in FIG. Here, if the outer diameter of the boss portion 8 of the shaft portion is set to be the same as the outer diameter of the gate portion 2 when designing the mold, the tip of the plug catcher 4 or the injection side of the gate portion 2 is cut off by machining. It is only necessary to machine the rotary shaft hole 7. When the shaft length is to be increased or the shaft diameter is to be changed, the design can be freely performed by selecting the gate dimensions of the mold.

As described above, by setting the position of the conical gate portion 2 at the center of the hub portion 6 and making good use of the shape of the gate portion injected from the injection molding machine, the die design of the propeller fan can be improved. Materials can be saved while effectively utilizing the structure, and a structure with less processing can be obtained. In addition, the amount of magnesium processing waste is reduced, and the safety of the processing operation can be improved. As described above, since the gate portion 2 is not provided at a deviated portion of the hub portion 6, the magnesium alloy can be uniformly filled from the center of the shaft to the periphery where a large number of blades 5 are formed. For example, when a metal fan is integrally formed using a magnesium alloy by metal forming such as thixo molding, the molten metal can be uniformly filled from the center of the shaft to the periphery where a large number of blades are formed, and It can be easily handled when the length is increased or when the shaft diameter needs to be changed.

A blade integrally formed of a magnesium alloy is extremely excellent in strength, and is suitable for, for example, high-speed rotation. When the number of rotations is doubled with the same blade, the air volume is doubled and the pressure is 4
Times and the shaft power becomes 8 times. Although the output of the motor is the same as the shaft power, the size of the motor shaft, that is, the size of the rotary shaft hole 7 generally differs as the output increases. That is, according to this patent, it is possible to easily manufacture blades having the same shape but different outputs, that is, different rotary shaft holes 7.

In FIG. 3, reference numeral 30 denotes an overflow section. The overflow portion 30 is evacuated when the molten metal in the mold fills the molded product (fan), and the evacuated portion is provided on the blade 5 as the overflow portion 30. By providing such an overflow portion 30, it is possible to prevent the occurrence of the so-called underfill or nest, which is caused by the drawback that the injection amount and the supply amount of the thixomolding method do not completely match, is not partially filled, The quality of molded products can be improved. Usually, since the overflow part 30 is a thin connection part, it can be easily removed from the wing 5.

In FIG. 1, the thickness of the root portion of the blade 5 connected to the hub portion 6 is smaller than twice the thickness of the outer peripheral portion of the blade. The effect of changing the blade root thickness from 1.0 mm to 1.5 mm was found to be reduced by 38% in stress value and 46% in blade deformation amount when calculated by the structural analysis program. At the same time, the blade thickness has a distribution, that is, if the thickness of the root portion of the blade is within 1.5 times the thickness of the outer peripheral portion of the blade, the noise characteristics will not deteriorate and if it is smaller than twice, it will be practically acceptable. Has also been clarified experimentally. Also, noise can be reduced compared to conventional plastic fans,
Compared to a thin-blade fan with a constant blade thickness that can minimize noise, noise is less aggravated, stress can be reduced, and a fan with good formability can be obtained. As described above, a blade excellent in strength can be produced without deteriorating the noise characteristics, and the material cost is not much changed, so that the production cost can be almost the same.

The propeller fan shown in FIGS. 1 to 3 is made of a magnesium alloy. In the figure, the blade outer diameter X is Φ
260, the blade inner diameter (hub diameter) Y is Φ92. Regarding the thickness of each wing of the wing portion 33, the thickness of the root of the wing made of ordinary plastic is required to be 3.5 mm in order to maintain strength, and is very thick. The thickness Z (where r at the place where the wing 5 is joined to the hub portion 6 is eliminated) is made of a magnesium alloy, and is 1.5 mm because it is stronger than plastic. Further, in order to make the blade 5 capable of withstanding the high-speed rotation of the fan, the blade root thickness Z is set to 1.5 mm. Accordingly, the thickness of the hub portion 6 is 1.5 mm of the blade root thickness (the inner peripheral portion thickness of the blade) Z.
The thickness was 1.75 mm, which was slightly thicker. The blade root thickness Z is 1.0 mm
From 1.5 mm, the stress value decreases by about 38% and the deformation amount decreases by about 46% when calculated by the structural analysis program. In addition, if the whole blade | wing part 33 is made into the same thickness, performance will improve.

FIG. 7 is a table showing the relationship between noise characteristics, strength and formability of the blade outer diameter Φ260 and four blades. The case where the blade tip thickness is changed while the blade tip thickness is 1.0 mm is shown. The horizontal axis is the blade root thickness, and the vertical axis is the noise value and the stress value. In FIG. 7, the solid line indicates the stress value, and the stress increases as the root thickness of the blade is smaller. The dotted line indicates the noise value, and the lower the root thickness, the lower the noise. Therefore, the noise characteristics are good, the molding is easy, and the strength is advantageous. The root thickness of the blade is preferably around 1.5 mm, but the noise characteristics show that if the root thickness is smaller than 2 mm, the noise will not deteriorate. Since it is about 0.3 dB, which is practically insignificant, it can be seen that it is better to make it smaller than twice.
Also, compared to conventional plastic blades, the root thickness of the blades is 3.5 mm, so the noise is about 2 dB higher, and the rigidity is weak and the dimensional accuracy is poor, so the noise is even higher. Therefore, the blade of the present invention is lower by about 3 dB.

In FIG. 3, reference numeral 9 denotes an airflow separation suppressing rib provided integrally on the suction side (negative pressure side) of the blade 5. According to the present embodiment, since the blades are integrally formed of a magnesium alloy, the airflow separation suppressing ribs 9 can be provided very easily, like a plastic blade, despite being made of metal, Noise is reduced with little increase in manufacturing costs. On the other hand, when the blade is made of a thin steel plate or a thin aluminum plate like a conventional metal blade, it is difficult to provide the airflow separation suppressing rib 9 accurately and at low cost. For example, in the case of drawing by a metal mold, there is a problem that the outer peripheral portion at the tip of the rib is rounded and the effect of suppressing airflow separation cannot be sufficiently exhibited.

A method of manufacturing the direct gate system employed in the present invention, that is, a method of manufacturing a cross sectional view before processing the gate portion 2 shown in FIG. 3 will be described below. 4 to 6
The mold structure and the releasing operation will be described below. 4 to 6
FIG. 3 is a sectional view of a mold structure for producing a propeller fan.
In the figure, 1 is a molding part of a product which is a blade part, 2 is a gate part, 101 is a tip nozzle of an injection molding machine (chikso molding apparatus) in which a solidification plug 3 is clogged at an outlet for injection, and 102 is a mold. Fixed mold (cavity)
Then, it is fixed to the molding machine with bolts or the like by the fixed side mounting plate 103. A movable mold (core) 104 is fixed to a molding machine by bolts or the like by a movable mounting plate 105. The cavity 102 includes a mold base 102a and a fixed-side mounting plate 103. The mold base 102a
The shape of one side of the product to be die cut is dug into the right side. In some cases, one-sided shape of the product is engraved in a part called an insert, and the insert is incorporated into the mold base 102a. Cavity 10
The core 104 opposite to 2 includes a mold base 104a, a movable-side mounting plate 105, an ejector 104b, and a spacer block 104c. In the mold base 104a, the shape of one side of the product to be die-cut is dug into the left side. The ejector 104b is for extruding a molded product from a mold by obtaining the force of the extruder 106, and the spacer block 104c is for ejecting the ejector 10b.
4b determines the left and right sliding range. A stopper plate 104d is attached to the tip of the ejector 104b, whereby the molded part 1 is released from the movable mold base 104a, and the molded product is smoothly taken out.

Next, the molding process will be described. First, a magnesium alloy 107 which is a material of the molded part (product) 1 is in a molten state in the tip nozzle 101. Magnesium alloy 1 in molten state injected from tip nozzle 101
Reference numeral 07 denotes a mold base 102a of the fixed mold 102 and a mold base 104 of the core 104 which is the movable mold.
In the product shape dug in a, it is filled in a very short time (several hundredths to several tens of seconds in the case of a molding machine with a clamping force of 450 t), and then cooled in a mold for about a few seconds. The molded article 1 is in a fixed state in the insides 102a and 104a. At this time, a portion connecting the molded product 1 and the tip nozzle 101 is called a gate portion, and the gate portion 2, a plug catcher 4 provided on the molding portion side forming the gate portion, and a solidified plug provided on the metal injection side. It consists of three. Here, in order to securely store the solidified plug 3 in the plug catcher 4, it is preferable to set the outer diameter so that it does not move after a collision. By decreasing the diameter of the gate portion 2 in contact with the hub 6, the diameter of the plug catcher 4, and the diameter of the solidified plug 3 in this order, the solidified plug can be securely stored in the plug catcher during molding. However, there is no problem that the flow of the molten metal in the gate portion is hindered to deteriorate the formability. For example, the diameter of the gate 2 intersecting with the hub 6 is 30 mm, the diameter of the plug catcher 4 is 18 mm, and the diameter of the solidified plug 3 is 14 mm.

Next, as shown in FIG.
1 moves back (moves rightward) in the direction of arrow 1 from the fixed mold 102, and is sheared by the solidification plug 3 at the tip of the gate 2, and the molded article 1 and the tip nozzle 101 are separated.

Next, the movable mold 104 is separated from the fixed mold 102 by the operation of the molding machine in the direction of arrow 2. At this time, the molded product 1 is the mold base 1 of the movable mold 104.
The release resistance between the mold 04a and the molded product 1 must be smaller on the fixed side than on the movable side.

Finally, as shown in FIG. 6, the stopper plate 1 attached to the tip of the ejector 104b
04d obtains the force of the extruder 106, and the fixed mold 1
02, the molded article 1 is taken out from the mold base 104a of the movable mold 104. With the above-described molding machine, for example, a propeller fan having a large number of blades formed from the center of the shaft can be integrally molded in a short time and with high precision using a magnesium alloy.

Although the method of injection molding mainly by the thixomolding method has been described above, there is also a die casting method as a metal molding method of integrally forming a propeller fan using a magnesium alloy. The die casting method is described in the aforementioned “Magnesium Reader Shotaro Morozumi, Karos Publishing”. The die casting method includes a cold chamber method and a hot chamber method. Hereinafter, a brief description will be given with reference to the drawings. FIG. 12 is an explanatory diagram of a molding process of the cold chamber method, and FIG. 13 is an explanatory diagram of a molding process of the hot chamber method. In the figure, 109 is a mold, 109a is a fixed mold, 109b is a movable mold, 109c is a mold space, 13
0 is molten metal, 132 is a pressurized chamber (shot sleeve), 13
3 is an automatic water heater, 134 is a piston, 135 is molten metal 13
0 is a molded product (product), 136 is a gate, 1
37 and 138 are ejector pins, 139 is a tip nozzle, and 140 is a crucible. FIG. 12 illustrates the cold chamber method. The method comprises the following steps (s
12), and the molten metal 13 as shown in FIG.
Step 1 for pouring 0 into the pressurizing chamber 132, Step 2 for injecting the melt 130 into the mold 109 as shown in FIG. 12B, and opening the movable mold 109b of the mold 109 as shown in FIG. 12C.
Step 3 is to extrude a molded product (product) 135 formed by molding the molten metal 130 as shown in FIG.

In the cold chamber method, the pressurizing chamber 132
Is not in the molten metal 130 which is a molten magnesium alloy,
Not heated. The molten metal 130 is poured into the pressurizing chamber 132 for each cycle by hand or by an automatic water heater 133 from a heat retaining furnace (not shown) (step 1). Next, piston 1
As the 34 slides inside the pressurizing chamber 132 to the left, the molten metal 130 is injected into the mold space 109c carved in the mold 109 (step 2). Next, the movable mold 109b of the mold 109 is moved to the left side in the figure to open the mold 109 (step 3). Finally, the ejector pin 13 serving as a means for pushing out the product 135 from the fixed mold 109b.
Extrude using 7, 138 (step 4). At this time, since the product 135 has the gate portion 136 formed at the time of molding, it is removed by post-processing. The cold chamber method requires a longer molding time than a hot chamber machine, but since the pressurizing chamber 132 is not in the molten metal 130, casting of a high melting point metal becomes possible.

On the other hand, the hot chamber method is shown in FIG.
This will be described below. The method includes the following steps (step
p) and a pressurizing chamber 132 as shown in FIG.
Step 1 'into which the molten metal 130 flows, a step for injecting the molten metal 130 into the mold 109 as shown in FIG.
2 ′, movable mold 109b of mold 109 as shown in FIG.
Step 3 ′, and a molded product (product) 135 formed by molding the molten metal 130 as shown in FIG.
09 from step 09 '.

A pressurizing chamber 132 is located in the melt 130 and is heated. The molding method is just like a water gun. First, a molten metal 130 is heated in a crucible 140 at a high temperature of about 600 ° C. The pressurizing chamber 132 has a pressurizing chamber gate 1
Hot water is supplied in a state where the piston 134 is raised from 41 (step 1 ′). Next, the piston 134 is
By sliding the inside downward, the molten metal 130 is engraved in the mold 109 from the tip nozzle 139 into the mold space 109c.
(Step 2 '). At this time, if the joining surface between the tip nozzle 139 and the mold 109 is not tight, the magnesium alloy in a molten state may blow out into the air and burn, so care must be taken in adjusting this contact connection. . Further, the crucible 140 is sealed with, for example, a lid (not shown) or the like. When adding a magnesium alloy ingot serving as the material of the molten metal 130, the lid is opened, but at this time, the molten magnesium alloy reacts with air. The space between the lid and the melt 130 is always SF6 + A
It is filled with ir and is sealed to keep the quality of the molten metal 130 at all times. Next, the movable side mold 109 of the mold 109
b is moved to the left side of the drawing to open the mold 109 and the piston 1
34 is raised (step 3 '). Finally, the product 135 is ejected from the movable mold 109b by the ejector pin 137,
Extrude using 138 (step 4 '). At this time, since the product 135 has the gate portion 136 formed at the same time when the product 135 is formed, it is removed by post-processing. In this state, the pressurizing chamber 132 and the piston 134 are ready for the next injection.

As described above, in the hot chamber method, since it is not necessary to supply hot water to the pressurizing chamber 132 every cycle, the molding time can be shortened. However, since the pressurizing chamber 132 is in the molten metal 130, a material having excellent heat resistance and low reactivity with molten magnesium is used for the material of the pressurizing chamber 132 and the piston 134. Here, since magnesium has low reactivity with iron, heat-resistant steel having a high melting point can be used,
Since the piston 134 moves up and down at a high speed in the pressurizing chamber 132 to inject the molten metal into the molten metal 130 at a high temperature of about 600 ° C., it is necessary to overhaul the piston 134 and the pressurizing chamber 132 every 100,000 shots, for example. This causes an increase in molding cost. Here, a major difference from aluminum die casting is that magnesium has a low reactivity with iron, so that a hot chamber method can be used, and continuous molding can be performed in the same manner as thixomolding, but attention must be paid to safety. Since aluminum has high reactivity with iron, the hot chamber method has not been put to practical use.

Each of the features is mechanically large in the cold chamber machine, but is limited to the small components in the hot chamber machine. However, a hot chamber machine is superior in terms of prevention of molten metal oxidation, casting pressure, productivity, and the like.
In other words, small parts that need to be mass-produced can be continuously molded and have a shorter molding time than cold chamber machines. Extra mold is required. The die casting method enables molding with a small molding machine because the mold clamping force of the molding machine can be reduced to about half compared to the thixomolding method, but the injection speed is low, so for example, thin blades like a sirocco fan Not suitable for long products. Further, since it is necessary to increase the draft of the mold, the trailing edge of the root of the blade 5 and the leading edge of the next blade are connected to the outer periphery of the hub 6 in FIG. In the case of thixomolding, a step of 0.3 mm occurs, which is 0.3 mm. However, it is possible to form the mold by the die casting method without any problem in terms of function. It is not necessary to provide the part 4, but the gate part has a similar shape.

In the cold chamber method, if the working procedure is correct and the accuracy of the mold is secured, no abnormalities will occur suddenly. However, in the hot chamber method, abnormalities may occur at unexpected times. Particularly, similar to thixomolding, semi-solid magnesium alloy 1 caused by poor contact between tip nozzle 139 and mold 109.
Eleven blowout combustion. In addition, in the hot chamber method, the ingot of the material placed on the pallet usually needs to be placed in a drying oven and dried to completely remove the water in the ingot. The molten metal scattered when put into a certain crucible. The moisture and magnesium remaining in the cavity due to the double blow of the release agent reacted inside the cavity and caused abnormal combustion.
As we did not heat shot sleeve enough before work,
There have been reports of cases in which condensation has occurred in the shot sleeve and the moisture has reacted with magnesium to cause abnormalities, and automation has been performed to address this.

FIG. 14 shows the overflow section 3 shown in FIG.
An example of a method for removing 0 is shown. FIG. 14A is a perspective view of the upper trimming die, and FIG. 14B is a perspective view of the lower trimming die. There are a method of processing manually and a method of cutting with a press using a trimming mold as in the present embodiment. Reference numeral 141 denotes a trimming upper die, and 142 denotes a trimming lower die, which is mounted on a press machine, and a product having the overflow section 30 mounted thereon, for example, as shown in FIG. 3, is placed on the trimming lower die, and the trimming upper die 141 is placed from above. The blade is lowered, and the outer periphery of the blade is removed by pressing.

This trimming mold can be manufactured relatively inexpensively if it is a flat plate, but it is expensive if it has a three-dimensional shape such as the outer peripheral portion of a blade of a propeller fan. In other words, if the trimming dies can be amortized in mass production, this method, which requires extra trimming dies but can reduce the processing cost, is suitable. It is better to process by hand without manufacturing.

Embodiment 2 Hereinafter, a second embodiment of the present invention will be described with reference to the drawings. 8 and 9 show a method of manufacturing a propeller fan using a pin gate method.

The propeller fan can be manufactured by using a direct gate method or a pin gate method. The direct gate method directly fills the magnesium alloy, which is the material of the blade, from the center of the rotating shaft (the center of the hub 6), and the pin gate method, the magnesium alloy, which is the material of the blade from several places of the hub 6 Is directly charged. There is a side gate method as the gate method. However, this method has difficulty in filling a plurality of thin blades evenly, and the outer diameter of the blade has a three-dimensional shape so that gate processing and mold manufacturing are possible. However, not only the projected area of the product, but also the projected area of the whole molded part including the gate part becomes large, and as a result, the mold becomes large and the molding machine becomes large. Think. In the description of the first embodiment, the case where the gate for injecting the molten metal from the nozzle is from one position is shown. However, it is also possible to branch the metal injected from one nozzle into a plurality at the gate portion and fill the molded product through the pin gate 2 from a plurality of small inlets. In this case, the pin gate 2 may be provided between the nozzle of the injection molding machine and the molded product of the mold. FIG.
FIG. 3 is a perspective view of a propeller fan. In the figure, 5 is a blade, 6 is a hub portion, 8 is a boss portion, 9 is an airflow separation suppressing rib provided integrally on the suction side (suction side) of the blade 5.
Reference numeral 0 denotes a recess provided in the hub 6. FIG. 9 is a sectional view of FIG.

According to this method, the fan can be manufactured more easily without requiring post-processing of the boss portion 8 in the portion of the rotary shaft hole 7. As a shape for carrying out this, the outer peripheral portion of the hub portion on the blowing side (pressure surface side) of the blade is set to be at least 1.5 times the thickness of the other hub portion, and the suction side of the blade 5 of the hub portion 6 (the suction side). In (), the recess 10 is formed as many or as many as the number of blades in order to gate a plurality of pin gates in a gate portion filled with a magnesium alloy. Compared to the case where the number of the concave portions is smaller than the number of blades, the plurality of blades can be evenly filled with the molten metal, and the formability is good. In order to perform the gate processing, the shape of the concave portion 10 was set such that the outer diameter was φ6 and the depth was 1 mm with respect to the outer diameter φ4 of the pin gate portion. The number of pin gates was four at four blades. In this case, the gate processing was also good, and, for example, in the case of cleaning or the like, a rag or the like did not catch on this portion. However, according to this manufacturing method, the rotation shaft hole 9 cannot be arbitrarily changed. As described above, the fan can be more easily manufactured without requiring post-processing of the boss portion of the rotary shaft hole portion. In addition, the gate processing is good, and for example, in the case of cleaning or the like, it is possible to provide a fan that does not catch a rag or the like in this portion.

Embodiment 3 FIG. Figure 10 shows the actual fairness 3-54
No. 337, when the material of the blade 5 is made of an aluminum plate, the plate thickness is 1.2 mm, and the outer diameter of the blade is Φ260, and in the first embodiment (FIGS. 3 is a performance comparison table when the device is manufactured with the above. The horizontal axis of FIG. 10 (a) is the air volume Q [m ³ / h] of the fan, the vertical axis is the rotation speed N [min ⁻¹ ], and FIG.
(B) the horizontal axis of the fan air volume Q [m ³ / h], the vertical axis represents the noise level _{SPL A [dB (A)]} , the horizontal axis represents the fan air volume Q [m ³ / h shown in FIG. 10 (c) ], The vertical axis is the static pressure Ps [Pa].

In FIG. 10, the solid line is a magnesium alloy impeller, and the broken line is an aluminum plate impeller. In the figure, in the large air volume region, the noise of the magnesium alloy impeller is low by about 3 dB. This is largely due to the provision of the airflow separation suppressing ribs 9 integrally. Further, noise is low by about 4 dB even in the middle air volume region. This is because a fan made of an aluminum plate with an integrated throttle cannot perform a rapid drawing process, so that the wing shape of the hub cannot be ideally manufactured, and the noise of the wind flowing in the medium air volume region is generated. . Therefore, the magnesium alloy impeller can reduce noise in the entire air volume range.

In the case of thixomolding, the solidification plug 3 is provided at the tip of the tip nozzle, prevents the molten metal from flowing out, and is injected to store the solidified plug 3 in the storage portion 4 and the molten metal flows into the gate portion 2. Configuration. The hot runner is a mechanism for supplying a molten metal in a molten state to a mold cavity, and is a mechanism commonly used in an injection molding machine of engineering plastic (engineering plastic; special plastic). In the case of injection molding of magnesium alloy, the melting temperature is 600 ° C., which is much higher than around 200 ° C. for engineering plastics. Therefore, the hot runner manifold and hot tip are made of special heat-resistant steel. In the molding up to the above, FIGS.
As described in the above, the direct gate portion 2 of the passage for flowing the molten metal to the mold was necessary, and was removed thereafter, so that the material yield was low. Furthermore, it is reported that the molding cycle time can be reduced by about 30%, and the amount of molten metal to be actually injection-molded is reduced, so that there are cases where molding can be performed by an injection molding machine having a small clamping force. The hot runner mechanism is a heating and cooling mechanism that has been improved by improving the heat resistance of the electromagnetic induction heating coil. If this technology is improved, the overflow circuit required for the mismatch between the injection amount and the filling amount, which is a drawback of thixomolding, becomes smaller and the work to remove this part becomes easier, reducing manufacturing costs and reducing this part. Recycling has also become easier.

Embodiment 4 FIG. FIG. 11 is a diagram of a propeller fan showing another embodiment of the present invention. FIG. 11 (a)
Is a side view, and FIG. 11B is a front view. In the figure,
5 is a blade, 7 is a rotary shaft hole, 8 is a boss, and 13 is a spider. The blade 5 having a small thickness and the spider 13 having a thickness greater than the blade portion are integrally formed, and a rotary shaft hole 7 provided in the spider 13 on the suction side (negative pressure side) of the blade 5.
Having a gate portion 2 for filling a portion with a magnesium alloy,
A plug catcher 4 for accommodating the solidified plug 3 of thixomolding is provided on the blowout side (pressure surface side) of the blade on the opposite side, and the gate portion 2 and the plug catcher 4 are processed by post-processing to have a rotary shaft hole 7. The boss 8 is formed. According to the present embodiment, since the propeller fan can be integrally formed of a magnesium alloy, for example, the thickness of the joint between the blade and the spider can be freely designed, the strength is excellent, the noise is low, and the recycling is excellent. A relatively large metal fan can be easily manufactured by integral molding.

If the blades of the blades of the propeller fan are all made uniform, a fan with the lowest noise, light weight and low material cost can be provided if there is no problem in strength and formability. The magnesium alloy described above is, for example, AZ91
D. Magnesium not only has a low melting point, but also has a lower density than other metals (2/3 of aluminum, 1 /
4) A light propeller fan can be made, which is the most suitable for the rotating body. In addition, specific strength, specific proof stress, vibration absorption power,
Shows excellent characteristics such as heat dissipation, dimensional stability, and electromagnetic wave shielding. It should be noted that a component manufactured using a magnesium alloy is marked with a mark made of the magnesium alloy, for example, AZ91D, thereby increasing the recycling rate.

Embodiment 5 FIG. FIG. 15 is a cross-sectional view of a gate processing state of a propeller fan according to Embodiment 5 of the present invention, and the same reference numerals as in FIGS. 1 and 4 indicate the same parts. In the figure, 2 is a gate portion, 5 is a wing, 6 is a hub portion, 7 is a rotary shaft hole, 8 is a boss portion, 102a is a mold base in which one side shape of a product to be die-cut is dug to the right, 14
Reference numeral 3 denotes a rotating shaft mold pin. In FIG. 15, the present embodiment has a solidification plug 3 and a solidification plug 3 for preventing the molten metal shown in FIG. 1 from flowing out in a shape applied to the case of the hot runner method of the magnesium die casting method or the thixo molding method described above. The storage section 4 for storing is unnecessary. Since the storage section 4 becomes unnecessary, it is not necessary to remove this portion by post-processing as shown in FIG. In addition, if a rotating shaft mold pin 143 having the same shape as the shaft hole is provided in a portion constituting the inner surface side of the hub portion 6 on the movable side of the mold, the rotating shaft hole 7 can be formed simultaneously with molding.
Can be formed, and the post-processing is only a process of cutting the tip of the gate portion 2, which is very easy. In particular, when the shaft hole processing is formed by post-processing, the center of the shaft with respect to the hub portion 6 is 0.1 to 0.1 to
The processing jig requires accuracy because there is a risk of imbalance due to a displacement of about 0.2 mm. However, in the present embodiment, since the rotary shaft hole 7 is formed by integral molding, very high accuracy is achieved. As shown in FIG.
If you make the tip of 3 (right side in the figure) bullet-shaped or hemispherical,
When the molten metal flows from the gate portion 2 to the hub portion 6, the flow of the molten metal is prevented from being hindered by the rotating shaft mold pin 143. When the diameter of the rotary shaft hole 7 is increased, the outer diameter of the boss 8 must be naturally increased in order to secure the flow area of the molten metal in the gate portion 2. If the outer diameter of the shaft cannot be increased, the size of the rotating shaft hole formed by the rotating shaft mold pin 143 may be increased by post-processing. In this case, the shaft hole is not formed from the beginning, but is formed in advance. Is easy to open, and it is also possible to cope with a case where the power of the drive motor increases as described above and the shaft diameter of the drive motor increases accordingly. The rotating shaft mold pin 143 may be provided with a pin having the same shape as the rotating shaft hole 7 on the mold movable mold side opposite to the injection side of the gate portion 2.

As described above, the mold is provided with the rotating shaft mold pin 143 having the same shape as the rotating shaft hole 7, and is provided at the center of the hub to support the blades and to be driven to rotate by the motor. A step of injecting the molten metal from a shaft part which is formed by melting the metal together with the blade part and integrally forming; and a step of forming a rotary shaft hole 7 by removing a part of a gate portion after injecting the molten metal into a molded product. It is equipped with. Therefore, the rotary shaft hole 7 can be configured only by removing an extra gate portion after molding. Also, the rotary shaft hole 7 of the shaft portion
This eliminates the need for machining and provides high precision, and provides a highly accurate propeller fan with little post-molding processing.

[0061]

Since the present invention is configured as described above, it has the following effects.

The propeller fan according to the present invention has a blade portion in which a large number of blades are integrally formed on an outer peripheral portion of a cylindrical or conical hub portion, a blade portion provided at a center portion of the hub portion, supports the blade portion, and includes a motor. A shaft portion that is rotatably driven and is integrally formed by melting metal together with the blade portion, and the shaft portion is formed as a metal flow path to the blade portion when forming. Since it is at least a part of the gate part of the mold or the storage part for storing the solidified solidified metal, the length and diameter of the shaft can be easily changed by changing the processing dimensions of the gate part.

Further, in the propeller fan of the present invention, the shaft portion is formed by removing the tip of the injection side of the gate portion or the tip of the portion where the solidified metal is present in the storage portion for storing the solidified metal. it can.

Further, in the propeller fan of the present invention, the thickness of the inner peripheral portion of the blade adjacent to the joint with the hub portion is made larger than the outer peripheral portion of the blade and smaller than twice, so that noise is reduced. Got lower.

A propeller fan according to the present invention includes a spider provided at a central portion and supporting a blade portion and having a shaft portion driven and rotated by a motor; a wing connected to the spider and having a thickness smaller than the spider; A shaft portion is a gate portion of a mold to be a metal flow path to a blade portion during molding or at least a part of a storage portion for storing solidified solidified metal, and a spider The suction side has a gate part or storage part, and the discharge side has a storage part or gate part.The gate part and storage part are processed to form the shaft part, so that the thickness of the joint part between the blade part and the spider is reduced. Can be freely designed.

Further, the propeller fan of the present invention is excellent in recyclability, light weight and strength as compared with a metal fan combined with plastic or dissimilar metal, because the metal to be integrally formed by melting is a magnesium alloy. Excellent and low-noise fans can be provided at low cost.

Further, the propeller fan of the present invention has a blade portion formed by integrally forming a large number of blades on an outer peripheral portion of a cylindrical or conical hub portion, and a blade portion provided at a central portion of the hub portion to support the blade portion. A shaft part that is driven to rotate by a motor, the shaft part being formed integrally by melting metal together with the blade part, and the shaft part serves as a metal flow path to the blade part during molding. A recess portion for performing gate processing of a plurality of pin gates of the gate portion, which is at least a part of a gate portion of a mold to be formed or a storage portion for storing solidified solidified metal. , The gate processing is good without requiring post-processing of the boss portion of the rotary shaft hole.

Further, in the propeller fan of the present invention, since the number of concave portions is equal to or greater than the number of blades of the blade portion, a plurality of blades can be uniformly filled with molten metal, and the formability is good.

In the propeller fan of the present invention, the diameter of the gate portion connected to the hub portion, the diameter of the plug catcher, and the diameter of the solidified plug are reduced in this order, so that the flow of the molten metal in the gate portion is improved.

In the propeller fan of the present invention, the airflow separation suppressing rib protruding toward the suction side of the blade is provided integrally with the blade, so that a low-noise fan can be provided with almost no increase in manufacturing cost.

Further, the propeller fan of the present invention has a blade with a uniform blade thickness, so that if there is no problem in terms of strength and formability, a fan with the lowest noise, light weight and low material cost is provided. it can.

Further, in the method for forming a molten metal of a propeller fan according to the present invention, at least a part of the metal is melted from a metal forming machine and blown out from a nozzle, and the metal blown out from the nozzle is formed into a molded product of a propeller fan by a mold. In the method for forming a molten metal of a propeller fan, a shaft portion provided at a central portion of a hub portion, supporting a blade portion and rotating and driven by a motor, wherein the shaft portion that melts the metal together with the blade portion and integrally forms the same. Injecting molten metal;
Removing the solidified metal that has been solidified and blown out from the gate portion into the nozzle of the metal forming machine after forming the molded product by injecting the molten metal to form a shaft portion, so that the processing dimensions of the gate portion are changed. This makes it possible to establish a manufacturing method in which the shaft length and the shaft diameter can be easily changed.

The molten metal forming method of a propeller fan according to the present invention is a method of forming a molten metal of a propeller fan by using a mold having a shaft hole shape. In a propeller fan molten metal molding method in which a metal blown from a nozzle is melted and blown out from a nozzle and formed into a molded product of a propeller fan by a mold, a blade is provided at a center portion of a hub portion and a motor is used. A step of injecting molten metal from a shaft part which is driven to rotate and which melts the metal together with the wing part and integrally molds; and a step of removing a part of the gate part after injecting the molten metal to form a molded product. With the step of forming a hole, the machining of the rotating shaft hole in the shaft is unnecessary and the precision is high. Emissions can be obtained.

Further, according to the method for forming a molten metal of a propeller fan of the present invention, in a propeller fan having a blade portion integrally formed with a large number of blades on an outer peripheral portion of a hub portion, a metal forming process is performed at a central axial position of the hub portion. Connecting the nozzle of the machine and injecting at least a part of the molten metal into the molded article; filling the injected metal into an overflow portion connected to the blades and the outer periphery of the blades of the blades; The step of removing the part prevents the so-called underfill or nest that is partially filled, which is caused by the drawback that the injection amount and the supply amount do not completely match, and improves the quality of the molded product. A method can be established.

The molten metal forming apparatus for a propeller fan according to the present invention comprises: a metal forming machine that melts at least a part of a metal and blows out from a nozzle; and a mold that forms a propeller fan with the metal blown out from the nozzle. In the molten metal forming apparatus provided with, a shaft portion provided at the center of the hub portion of the propeller fan, supporting the blade portion, and rotating and driven by a motor, and melting the metal together with the blade portion to form the metal integrally. A gate portion of a mold to be formed, which serves as a metal flow path to the blade portion provided at the position of the shaft portion, or a storage portion for storing solidified metal, and a fixed side mold on the gate portion side with respect to the molded product. Since the movable side mold is provided on the opposite side, the propeller fan can be integrally formed in a short time with high accuracy.

[Brief description of the drawings]

FIG. 1 is a sectional view of a propeller fan according to Embodiment 1 of the present invention in a gate processing state.

FIG. 2 is a sectional view of the propeller fan according to Embodiment 1 of the present invention before gate processing.

FIG. 3 is a perspective view of the propeller fan according to the first embodiment of the present invention before gate processing.

FIG. 4 is a sectional view of a mold structure of the propeller fan according to the first embodiment of the present invention.

FIG. 5 is a sectional view of a mold structure of the propeller fan according to the first embodiment of the present invention.

FIG. 6 is a sectional view of a mold structure of the propeller fan according to Embodiment 1 of the present invention.

FIG. 7 is a relationship diagram of noise characteristics, strength, and formability of the propeller fan according to Embodiment 1 of the present invention.

FIG. 8 is a perspective view of a propeller fan according to Embodiment 2 of the present invention in a gate processing state.

FIG. 9 is a sectional view of a propeller fan according to a second embodiment of the present invention before gate processing.

FIG. 10 is a performance comparison diagram of the propeller fan according to the third embodiment of the present invention.

FIG. 11 is a side view and a front view of a propeller fan according to a fourth embodiment of the present invention.

FIG. 12 is an explanatory diagram of a molding process of the cold chamber method.

FIG. 13 is an explanatory diagram of a molding process of the hot chamber method.

FIG. 14 is a perspective view of a trimming mold.

FIG. 15 is a sectional view of a propeller fan according to Embodiment 5 of the present invention in a gate processing state.

FIG. 16 is a sectional view of a conventional injection molding machine.

FIG. 17 is a partial sectional view of a conventional injection molding machine.

FIG. 18 is a partial sectional view of a conventional injection molding machine.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Molding part, 2 gate parts, 3 solidification plugs, 4 plug catchers, 5 blades, 6 hub parts, 7 rotary shaft holes, 8
Boss part, 33 blade part, 130 molten metal, 132 pressurized chamber, 133 automatic water heater, 134 piston, 135
Products, 136 gates, 137 ejector pins,
138 Ejector pin, 139 tip nozzle, 140
Crucible, 141 upper trimming die, 142 lower trimming die, 143 rotary shaft mold pin.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Jiro Fukuyama 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Mitsui Electric Co., Ltd. (72) Inventor Akio Endo 2-3-2 Marunouchi 3-chome, Chiyoda-ku, Tokyo Inside Rishi Electric Co., Ltd. (72) Inventor Yasu Makino 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Sanbishi Electric Co., Ltd. (72) Inventor Hitoshi Kikuchi 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Mitsubishi Electric F term in the company (reference) 3H033 AA02 BB02 BB08 CC01 DD25 DD26 EE06 EE11

Claims (14)

[Claims] 1. A blade having a plurality of blades integrally formed on an outer peripheral portion of a cylindrical or conical hub, and a blade provided at a center of the hub to support the blade and to be rotationally driven by a motor. A shaft formed by melting a metal together with the blade and integrally forming the shaft, wherein the shaft is formed as a metal flow path to the blade at the time of molding. A propeller fan, which is at least a part of a gate portion of a mold or a storage portion for storing solidified solidified metal. 2. The propeller fan according to claim 1, wherein the shaft portion is formed by removing a tip of a portion where the solidified metal is present from an injection side of the gate portion or a storage portion for storing the solidified metal. 3. The thickness of the inner peripheral portion of the wing adjacent to the coupling portion with the hub portion is made larger than the outer peripheral portion of the wing and smaller than twice. 2. The propeller fan according to any one of 2. 4. A spider provided at a central portion and having a shaft portion that supports a blade portion and is rotationally driven by a motor, and a wing coupled with the spider and having a thickness smaller than the spider. The portion is at least a part of a gate portion of a mold to be a metal flow path to the blade portion at the time of molding, or at least a part of a storage portion for storing solidified solidified metal. The propeller fan has the gate portion or the storage portion on the side, and the storage portion or the gate portion on the blowout side, and the shaft portion is formed by processing the gate portion and the storage portion. 5. The propeller fan according to claim 1, wherein the metal to be integrally formed by melting is a magnesium alloy. 6. A blade portion formed by integrally forming a large number of blades on an outer peripheral portion of a cylindrical or conical hub portion, and a blade portion provided at a center portion of the hub portion for supporting the blade portion and rotating by a motor. A shaft formed by melting a metal together with the blade and integrally forming the shaft, wherein the shaft is formed as a metal flow path to the blade at the time of molding. A gate portion of the mold or at least a part of a storage portion for storing solidified solidified metal,
A propeller fan, characterized in that a recess is formed on the suction side of the hub portion for performing gate processing on a plurality of pin gates of the gate portion. 7. The propeller fan according to claim 6, wherein the number of recesses is equal to or greater than the number of blades of the blade portion. 8. The propeller fan according to claim 1, wherein the diameter of the gate portion connected to the hub portion, the diameter of the plug catcher, and the diameter of the solidified plug are reduced in this order. 9. The propeller fan according to claim 1, wherein an airflow separation suppressing rib protruding toward the suction side of the blade is provided integrally with the blade. 10. The propeller fan according to claim 1, wherein the blades of the blade portion have a uniform thickness. 11. A method for forming a molten metal of a propeller fan, wherein at least a part of the metal is melted from a metal forming machine and blown out from a nozzle, and the metal blown out from the nozzle is formed into a propeller fan molded product by a mold. Injecting molten metal from a shaft portion provided at a central portion of the portion and supporting the blade portion and rotationally driven by a motor, wherein the shaft portion melts the metal together with the blade portion and integrally forms the shaft portion; Forming a shaft by removing the solidified metal that has been solidified and blown out from the gate portion to the nozzle of the metal forming machine after injecting the metal into a molded product, thereby forming a shaft portion. Method. 12. A method for forming a molten metal of a propeller fan, wherein at least a part of the metal is melted from a metal forming machine and blown out from a nozzle, and the metal blown out from the nozzle is formed into a propeller fan molded product by a mold. Injecting molten metal from a shaft portion provided at a central portion of the portion and supporting the blade portion and rotationally driven by a motor, wherein the shaft portion melts the metal together with the blade portion and integrally forms the shaft portion; Forming a shaft hole by removing a part of the gate portion after injecting the metal into a molded product, and forming the shaft hole using a mold having a shaft hole shape. Method. 13. A propeller fan having a blade portion integrally formed with a large number of blades on an outer peripheral portion of a hub portion, wherein a nozzle of a metal forming machine is connected to a central axial position of the hub portion and at least a part of the nozzle is melted. Injecting the injected metal into a molded product, filling the injected metal into an overflow portion connected to the blade portion and the outer peripheral portion of the blade of the blade portion, and removing the overflow portion. A method for forming a molten metal of a propeller fan. 14. A molten metal forming apparatus comprising: a metal forming machine that melts at least a part of metal and blows out from a nozzle; and a mold that forms a propeller fan using the metal blown out from the nozzle. A shaft portion that is provided at the center of the hub portion of the fan and that supports the blade portion and is rotationally driven by a motor, and is provided at the position of the shaft portion that melts metal together with the blade portion and integrally molds the metal. A gate portion of a mold to be formed as a metal flow path to the blade portion or a storage portion for storing solidified metal; and a movable mold at a side opposite to the fixed mold at the gate portion side with respect to the molded product. And a molten metal forming apparatus for a propeller fan.