JP2024039255A - Die-cast product production method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a die-cast product production method which can produce a die-cast product having a complicated internal space and can suppress the remaining of unintentional gaps.

SOLUTION: A die-cast product production method of the invention has: a first step of forming plural members 10, 20 for insert member formation to be joined so as to form into an insert member 30 having an internal space by die casting; a second step of forming the insert member 30 by joining the plural members 10, 20 for insert member formation; and a third step of forming a die-cast product in which the insert member 30 is wrapped in a cast-in member by die casting.

SELECTED DRAWING: Figure 6

COPYRIGHT: (C)2024,JPO&INPIT

Description

The present invention relates to a method of manufacturing a die-cast product having an internal space.

Die casting is one of the metal forming methods currently widely used. According to die casting, metal members with high dimensional accuracy can be manufactured in a short time (high cycle) by press-fitting molten metal into a mold.

Metal products manufactured by die-casting (hereinafter referred to as die-cast products) take advantage of their high dimensional accuracy and are often treated as final products as they are or after being subjected to simple processing and treatment. On the other hand, since die casting is also one of the metal mold casting methods, there are restrictions on the shapes of die-cast products that can be manufactured. For example, die cast products with complex interior spaces (eg, tortuous heat exchange medium channels) are difficult or impossible to manufacture with conventional die casting.

As a technique for manufacturing a die-cast product having an internal space, for example, the product is divided into a plurality of parts, and a member with a shape that can be die-casted is inro-fitted (with a convex shape) on the joint side of each member. A component casting process in which parts are cast into a shape that can be fitted (fitting with a concave shape), and each component is made into a base by inro fitting at each joint, and the opposing surfaces of the base are surrounded at a predetermined interval to form a predetermined external shape. A die-casting manufacturing method is known which includes a bonding step of inserting a substrate into a bonding mold provided with a cavity to enable the bonding, filling the cavity with molten metal, and forming a product by integrally solidifying the molten metal on the substrate. (See Patent Document 1.)

According to the conventional method for manufacturing die-cast castings (hereinafter simply referred to as the "conventional method"), die-cast products with complex internal spaces are manufactured by providing an internal space inside a base body into which each member is inro-fitted. It becomes possible to do so.

Japanese Patent Application Publication No. 2002-346720

However, when a die-cast product is actually manufactured using the conventional method, there is a problem in that unintended gaps remain between the members constituting the base body. For example, when the internal space is used as a heat exchange medium flow path, the gap causes serious problems such as leakage of the heat exchange medium (for example, water) and damage to the die-cast product.

The present invention has been made to solve the above problems, and provides a die-casting product that can manufacture die-cast products having complex internal spaces and can suppress the unintended gaps from remaining. The purpose is to provide a method for manufacturing products.

The manufacturing method of the die-cast product of the present invention is characterized by including a first step of forming, by die casting, a plurality of insert member forming members which become an insert member having an internal space when joined together, a second step of forming the insert member by joining the plurality of insert member forming members, and a third step of forming, by die casting, a die-cast product in which the insert member is cast-in with a cast-in member.

According to the method for manufacturing a die-cast product of the present invention, since it includes the third step of forming a die-cast product by die-casting, in which an insert member having an internal space is cast in a cast-in member, the method for manufacturing a die-cast product has a complicated internal space as in the conventional method. It becomes possible to manufacture die-cast products with

Furthermore, since the method for manufacturing a die-cast product of the present invention includes the second step of forming an insert member by joining a plurality of insert member forming members, the plurality of insert member forming members are joined to form a single insert. Becomes a member. Therefore, according to the method for manufacturing a die-cast product of the present invention, it is possible to prevent unintended gaps from remaining.

Therefore, the method for manufacturing a die-cast product of the present invention is capable of manufacturing a die-cast product having a complicated internal space, and is capable of suppressing the unintended gap from remaining. becomes.

In addition, in the conventional method, each cast member is formed into a base body (corresponding to the insert member of the present invention) by inro-fitting each joint part. For this reason, even after fitting and subsequent product manufacturing, unintended gaps remain between the members constituting the base body.

It is a flowchart of the manufacturing method of the die-cast product concerning an embodiment. It is a figure shown in order to demonstrate the member 10 for insert member formation formed in 1st process S10 of embodiment. It is a figure shown in order to demonstrate the member 20 for insert member formation formed in 1st process S10 of embodiment. It is a sectional view which expands and shows a part of joining planned surfaces 16 and 26 of members 10 and 20 for insert member formation after carrying out the 4th process S20 of an embodiment. It is a figure shown in order to explain application of residual stress and lattice defect. It is a figure which shows how the insert member 30 is formed in 2nd process S30 of embodiment. It is a figure shown in order to demonstrate the product mold 100 used in 3rd process S40 of embodiment. It is a figure shown in order to demonstrate the product mold 200 used in 3rd process S40 of embodiment. It is a sectional view showing how product molds 100 and 200 used in the third step S40 of the embodiment are combined. It is a figure which shows how the die-cast product 40 is formed in 3rd process S40 of embodiment. It is a figure shown in order to demonstrate the die-cast product 40 formed in 3rd process S40 of embodiment.

EMBODIMENT OF THE INVENTION Hereinafter, the manufacturing method of the die-cast product of this invention is demonstrated based on embodiment shown in a figure. Each drawing is a schematic diagram and does not necessarily strictly reflect the actual structure, composition, ratio, etc. The embodiments described below do not limit the claimed invention. Furthermore, not all of the elements and combinations thereof described in the embodiments are essential to the present invention.

[Embodiment]
FIG. 1 is a flowchart of a method for manufacturing a die-cast product according to an embodiment.
As shown in FIG. 1, the method for manufacturing a die-cast product according to the embodiment includes a first step S10, a fourth step S20, a second step S30, and a third step S40. Each step will be explained below.

1. First step S10
FIG. 2 is a diagram shown to explain the insert member forming member 10 formed in the first step S10 of the embodiment. FIG. 2(a) is a plan view of the insert member forming member 10, and FIG. 2(b) is a sectional view taken along line A1-A1 in FIG. 2(a).
FIG. 3 is a diagram shown to explain the insert member forming member 20 formed in the first step S10 of the embodiment. FIG. 3(a) is a plan view of the insert member forming member 20, and FIG. 3(b) is a sectional view taken along line A2-A2 in FIG. 3(a).

The first step S10 is a step of forming a plurality of insert member forming members by die-casting, which become an insert member 30 (described later) having an internal space 32 by joining. Therefore, the first step S10 can also be expressed as a "insert member forming member forming step." In the embodiment, as a plurality of insert member forming members, an insert member forming member 10 (see FIG. 2) and an insert member forming member 20 (see FIG. 3) are formed.

As shown in FIG. 2, the insert member forming member 10 is formed with a recess 12 that becomes an internal space 32 together with a recess 22, which will be described later, when the insert member 30 is formed. The recess 12 has a meandering groove shape. Furthermore, communication ports 14 are formed at both ends of the recess 12, respectively. The surface indicated by the reference numeral 16 in FIG. 2 is a surface to be joined, which is a surface to be joined in the second step S30.

As shown in FIG. 3, the insert member forming member 20 is formed with a recess 22 that becomes an internal space 32 together with the recess 12 when an insert member 30 is formed. The recess 22 has a meandering groove shape. Note that the insert member forming member 20 does not have the communication port 14 formed therein. The surface indicated by the reference numeral 26 in FIG. 3 is a surface to be joined which is a surface to be joined in the second step S30.

The insert member forming members 10 and 20 described above have shapes that can be easily formed by general die casting. Therefore, detailed explanation regarding the formation itself of the insert member forming members 10 and 20 will be omitted. Note that part or all of the recesses 12 and 22 and the communication port 14 may be formed by post-processing (cutting or drilling) after die-casting.

The material used to form the plurality of insert member forming members (insert member forming members 10, 20) in the first step S10 is the same as the material used to form the die cast product 40 (described later) in the third step S40. It's the same. The identity of materials as used herein refers to the degree of identity that conforms to the classification according to Japanese Industrial Standards (JIS).

The material used to form the plurality of insert member forming members (insert member forming members 10, 20) in the first step S10 and the material used to form the die cast product 40 in the third step S40 are aluminum-based materials. It is. The term "aluminum-based material" as used herein refers to a material made of aluminum or an aluminum alloy. As the aluminum-based material, an ADC-based material (ADC12, etc.), which is an alloy for die casting, can be suitably used.

2. Fourth step S20
FIG. 4 is an enlarged sectional view showing a part of the joining surfaces 16 and 26 of the insert member forming members 10 and 20 after carrying out the fourth step S20 of the embodiment. FIG. 4(a) is an enlarged sectional view of a part of the surface to be joined 16, and FIG. 4(b) is an enlarged sectional view of a part of the surface to be joined 26.
FIG. 5 is a diagram shown for explaining the application of residual stress and lattice defects. FIG. 5(a) is a diagram schematically showing the arrangement of atoms before applying residual stress to the joining surface 16 of the insert member forming member 10, and FIG. FIG. 5(c) is a schematic diagram showing the arrangement of atoms after adding lattice defects, FIG. It is a schematic diagram shown in order to explain a hole. 5(a) and 5(b) are oblique projection diagrams, and the round objects arranged in a cubic shape are atoms. FIG. 5(c) is a perspective view, and FIG. 5(d) is a plan view. In FIGS. 5(c) and 5(d), atoms are indicated by white circles. FIG. 5 is only a schematic diagram and does not show the specific crystal structure, etc. of the surface 16 to be joined. Although the atoms in FIG. 5 are illustrated as having a simple cubic lattice structure, this is for convenience to make the diagram easier to understand, and the atoms in the insert member forming member 10 are actually This does not indicate that it has such a structure. In FIGS. 5(a) and 5(b), reference numeral 10 indicates a part of the insert member forming member 10. In FIG.

The fourth step S20 is a step of applying residual stress to at least the joining surfaces 16, 26 of the insert member forming members 10, 20 while leaving a chill layer on the surface. Therefore, the fourth step S20 can also be expressed as a "residual stress applying step." The fourth step S20 is performed between the first step S10 and the second step S30.

The term "chill layer" as used herein refers to a characteristic structure of a die-cast member (hereinafter referred to as a die-cast member), and a relatively high-strength structure formed near the surface of the die-cast member. means. Die-cast parts are formed by injecting molten metal into a mold at high pressure, but the surface part of the die-cast part is cooled more rapidly than the inner part of the die-cast part due to contact with the mold, etc. be done. Therefore, a chill layer is formed on the surface of the die-cast member, which has a structure with higher density (fewer voids) than the inside. Although the chill layer does not have clear boundaries, for example, in die-cast members formed using aluminum-based materials, it is considered appropriate to treat the range of about 0.3 mm from the surface as the chill layer. There is.

"Residual stress" as used herein refers to stress that exists (remains) within an object. Since stress remains in a die-cast member even if it is manufactured by die-casting, "applying residual stress" in this specification can also be referred to as "increasing residual stress."

In the fourth step S20, residual stress is applied by plastically deforming the surface of the target surface (at least the surfaces to be joined 16, 26). Specifically, in the fourth step S20, residual stress is applied by shot blasting. The shot blasting process refers to a process in which a projecting material (granules) collides with the surface of an object. Conditions such as the material of the shot material, the particle size, and the speed at which the shot material is made to collide can be arbitrarily determined depending on the type of material constituting the insert member forming members 10, 20, etc. However, when setting the conditions, care must be taken to ensure that the surfaces of the surfaces 16 and 26 to be joined are not scraped and the chill layer is not lost. Regarding the material of the shot material, for example, aluminum-based materials and steel materials can be suitably used. When the shot blasting process is performed, fine irregularities are formed on the surfaces of the surfaces 16 and 26 to be joined due to the collision of the blast materials (see FIG. 4). Note that since FIG. 4 is a schematic diagram, the size, ratio, shape, etc. of the surface irregularities are not limited to those shown.

In addition, in the fourth step S20, residual stress may be applied to surfaces other than the joining surfaces 16 and 26 of the insert member forming members 10 and 20.

Here, the application of residual stress will be explained using the insert member forming member 10 as an example. By applying residual stress to the intended joining surface 16, the atomic level structure (particularly the metal crystal structure) in the intended joining surface 16 can be affected (see Figures 5(a) and 5(b)), and the generation of lattice defects, which are disturbances in the atomic arrangement, can be promoted. In particular, by applying residual stress to the intended joining surface 16 by plastically deforming the surface of the intended joining surface 16, it is possible to generate a large number of dislocations d1 (Figure 5(c)), which are linear lattice defects in which the atomic arrangement is shifted by rows. In addition, the application of residual stress can also generate vacancies d2 (see Figure 5(d)), which are point-like lattice defects, and planar lattice defects. The above matters are also the same for the insert member forming member 20.

Note that it is preferable that the surfaces 16 and 26 to be joined each have a predetermined surface roughness. In this specification, "predetermined surface roughness" refers to surface fine structure such as deformation of unevenness, destruction, slippage, etc. on the surface to be joined when pressure is applied to the surface to be joined for joining in the second step. Roughness that tends to cause changes. Although the preferable value for the predetermined surface roughness varies depending on the type of material, the required bonding strength, etc., it is generally considered preferable that Ra=0.05 μm or more. Note that the "surface microstructure" in this specification refers to a surface structure on an atomic scale.

3. Second step S30
FIG. 6 is a diagram showing how the insert member 30 is formed in the second step S30 of the embodiment. FIG. 6(a) is a sectional view showing a state in which the insert member forming member 10 and the insert member forming member 20 are pressed relative to each other, and FIG. 6(b) is a sectional view showing the bonding surface 16, 26, FIG. 6(c) is a sectional view showing the insert member 30 formed by diffusion bonding, and FIG. 6(d) is an enlarged sectional view showing the state of the bonding interface after bonding. It is a diagram. The symbol P and thick arrows in FIG. 6A indicate that the insert member forming member 10 and the insert member forming member 20 are pressed relative to each other.

The second step S30 is a step of forming the insert member 30 by joining a plurality of insert member forming members (insert member forming members 10, 20). Therefore, the second step S30 can also be expressed as a "bonding step." In the second step S30, the insert member 30 is formed by diffusion bonding a plurality of insert member forming members (insert member forming members 10, 20).

In the second step S30, the insert member forming members 10 and 20 are relatively pressed so that pressure is applied to the joining surfaces 16 and 26 while the joining surfaces 16 and 26 are in contact with each other. (See FIG. 6(a).) The insert member forming members 10 and 20 are diffusion bonded. As a result, the insert member 30 is formed (see FIGS. 6(c) and 6(d)). In addition, in FIG. 6(c) etc., the part indicated by the reference numeral 10a is the part of the insert member 30 that was the insert member forming member 10, and the part indicated by the reference numeral 20a is the part of the insert member forming member 20 of the insert member 30. This is the part that was. Although the two-dot chain line in FIG. 6(c) indicates the bonding interface, the two-dot chain line does not indicate that the bonding interface remains, but rather that the illustrated object is formed from multiple members. This is to clearly show that. This also applies to FIGS. 10 and 11, which will be described later.

In the second step S30, the insert member forming members 10 and 20 are pressed relative to each other, thereby causing a change in the surface microstructure on the joining surfaces 16 and 26. The insert member 30 is formed by diffusion bonding. Changes in the surface microstructure include deformation of unevenness, destruction, slippage, etc. (see FIG. 6(b)), and the combination of these and the residual stress applied to the surfaces 16 and 26 to be bonded promotes diffusion bonding. Ru.

The principle by which diffusion bonding is promoted between the surfaces to be joined to which residual stress has been applied is believed to be as follows. By applying residual stress to each surface to be joined, it is possible to promote the occurrence of lattice defects in each surface to be joined, as described above. As the number of lattice defects increases, each surface to be joined becomes in a state in which atoms can easily move. As a result, it is possible to activate the diffusion of atoms and the establishment of metallic bonds between the surfaces to be joined (the joint interface).

In this specification, "relatively pressing the insert member forming members 10 and 20" means fixing a certain insert member forming member (for example, insert member forming member 20) and pressing another insert member forming member. This does not mean only pressing by applying a moving force to the insert member forming member 10 (for example, the insert member forming member 10). The insert member forming member to which the moving force is applied may be the opposite of the above. Moreover, you may press by applying a moving force to both the insert member forming members 10 and 20. In addition, in FIG. 6(a), pressure is expressed by a thick arrow P, but this is a schematic expression and does not indicate that pressure is concentrated on a specific point of the insert member forming member. do not have.

In the second step S30, the insert member forming members 10 and 20 are heated in order to promote diffusion bonding, and the process is carried out while maintaining the insert member forming members 10 and 20 at a certain temperature (however, the temperature is below the melting point). It is preferable to do so. That is, in the second step S30, the insert member forming members 10, 20 are bonded under temperature conditions that allow diffusion bonding (preferably under temperature conditions suitable for diffusion bonding). It is preferable to press them relatively.

Temperature conditions suitable for diffusion bonding differ mainly depending on the type of material constituting the insert member forming members 10 and 20. For example, if the material is the ADC 12 made of aluminum-based material, the temperature can be about 500 to 550°C. In addition, as for the pressure to be applied, the optimum value varies greatly depending on the type of material composing the insert member forming members 10 and 20, the shape of the insert member forming members 10 and 20, the bonding temperature, etc., so it is necessary to select an appropriate value. Although it is difficult to specify, it is thought that a pressure on the order of approximately MPa is required.

When the insert member forming members 10 and 20 are diffusion bonded, it is necessary to maintain the temperature and pressure to a certain extent in order to obtain high bonding force. The time varies depending on the type of material constituting the insert member forming members 10, 20, the shape of the insert member forming members 10, 20, bonding temperature, pressure, etc., but is, for example, about 10 minutes to 3 hours. be able to.

The second step S30 is preferably carried out in vacuum or in an inert gas. Note that it is considered that the second step S30 can also be performed in the presence of air.

In the second step S30, an insert member 30 is formed in which the internal space 32 communicates with the outside through the two communication ports 14 (see FIG. 6(c)).

4. Third step S40
FIG. 7 is a diagram shown to explain the product mold 100 used in the third step S40 of the embodiment. 7(a) is a plan view of the product mold 100, and FIG. 7(b) is a sectional view taken along A3-A3 in FIG. 7(a).
FIG. 8 is a diagram shown to explain the product mold 200 used in the third step S40 of the embodiment. FIG. 8(a) is a plan view of the product mold 200, and FIG. 8(b) is a sectional view taken along A4-A4 in FIG. 8(a).
FIG. 9 is a cross-sectional view showing how the product molds 100 and 200 used in the third step S40 of the embodiment are combined.
FIG. 10 is a diagram showing how a die-cast product 40 is formed in the third step S40 of the embodiment. FIGS. 10(a) to 10(d) are process diagrams.
FIG. 11 is a diagram shown to explain the die-cast product 40 formed in the third step S40 of the embodiment. FIG. 11(a) is a plan view of the die-cast product 40, and FIG. 11(b) is a sectional view taken along line A5-A5 in FIG. 11(a).

The third step S40 is a step of forming, by die-casting, a die-cast product 40 in which the insert member 30 is cast-in with the cast-in member 42a. Therefore, the third step S40 can also be expressed as a "die-cast product forming step." "A die-cast product in which an insert member is cast-in with a cast-in member" can also be expressed as "a die-cast product having a structure in which part or all of the insert member is covered with a cast-in member."

First, the product molds 100 and 200 used in the third step S40 will be described. Note that which of the product molds 100 and 200 is a movable mold and which is a fixed mold is not related to the essence of the present invention, and therefore a description thereof will be omitted. Moreover, what is shown in FIGS. 7 to 10 is a part of the structure of the product mold 100, 200, and the product mold 100, 200 may have a structure other than that shown or explained. . Examples of the structure include screw holes for fixing, holes for passing various pins, heat exchange medium channels, and spaces or holes for degassing.

The product mold 100 has a product corresponding part 102 corresponding to a part of the shape of the die-cast product 40, as shown in FIG. The product corresponding portion 102 is formed with an insert member holding portion 104 that corresponds to the shape of a portion of the insert member 30 (a portion near the communication port 14) and is used to hold the insert member 30 during mold clamping. Moreover, a runner 106 (runner) is formed in the product mold 100.

The product mold 200 has a product corresponding part 202 corresponding to a part of the shape of the die-cast product 40, as shown in FIG. The product corresponding portion 202 is formed with an insert member holding portion 204 that corresponds to the shape of a portion of the insert member 30 (a portion near the communication port 14) and is used to hold the insert member 30 during mold clamping. Furthermore, a runner 206 (gate) is formed in the product mold 200. By combining (clamping) the product mold 100 and the product mold 200, a cavity C corresponding to the shape of the die-cast product 40 is formed (see FIG. 9).

Next, the formation of the die-cast product 40 using the product molds 100 and 200 will be described. In addition to the mold, molding by die casting requires an opening/closing device to open and close the mold, an injection device to inject molten metal into the mold, etc., but since these are common types, they are not shown in the diagram. and the explanation will be omitted.

First, the insert member 30 is placed at a predetermined position in the product corresponding part 202 of the product mold 200 (see FIG. 10(a)). In the embodiment, the insert member 30 is arranged so that a portion of the insert member 30 near the communication port 14 contacts the insert member holding portion 104 (numerals are not shown in FIG. 10).

Next, the product mold 200 and the product mold 100 are combined (clamped) to form a cavity C (see FIG. 10(b)). At this time, a portion of the insert member 30 near the communication port 14 is sandwiched between the insert member holding portion 104 and the insert member holding portion 204 (numerals are not shown in FIG. 10). By doing so, the insert member 30 can be arranged so that at least a portion (in the embodiment, a portion other than the portion near the communication port 14) is in contact with the cavity C of the product mold 100, 200. . Further, the communication port 14 is temporarily closed by the product molds 100 and 200 (specifically, by the insert member holding section 204).

Next, the cast-in molten metal 42 is introduced into the cavity C via the runners 106, 206 (not shown in FIG. 10) (see FIG. 10(c)). In the embodiment, the die-cast product 40 is formed with the communication port 14 temporarily closed by the product molds 100 and 200 (specifically, by the insert member holding part 204). In this specification, "a state in which the communication port is temporarily closed" refers to a state in which the communication port is closed so that the communication port can be unblocked after forming a die-cast product.

Thereafter, the die-cast product 40 is formed by solidifying the cast-in molten metal 42 to form a cast-in member 42a (see FIG. 10(d)). In die casting, the cast-in molten metal 42 is cooled in a relatively short time, so the insert member 30 does not melt. On the other hand, since the cast-in molten metal 42 contracts during the solidification process, it is thought that diffusion bonding or a similar phenomenon occurs between the insert member 30 and the cast-in molten metal 42 due to heat and pressure. Therefore, the insert member 30 is integrated with the cast-in member 42a. Note that in FIG. 10(d) and the like, the part indicated by the reference numeral 30a is the part that was the insert member 30 in the die-cast product 40.

Although explanations using illustrations are omitted, the die-cast product 40 can be taken out by opening the product molds 100, 200. After the die-cast product 40 is taken out, processing commonly performed in the die-casting field, such as removing the metal material solidified in the runners 106 and 206 and deburring, can be performed.

Through the above steps, a die-cast product 40 having a complicated internal space 32 can be manufactured (see FIG. 11). Note that the internal space 32 in the die-cast product 40 is a heat exchange medium flow path. By circulating a heat exchange medium (for example, a liquid such as water or oil, or a gas such as air or inert gas) into the internal space 32 through the communication port 14, it is brought into contact with the die-cast product 40 or the die-cast product 40. It is possible to cool or heat things.

A die-cast product manufactured by the method for manufacturing a die-cast product of the present invention, such as the die-cast product 40 (in which the internal space can be used as a heat exchange medium flow path), can be used, for example, as a power generator (engine, motor, etc.), a power exchanger, etc.・Transmission devices (robot joints, transmissions, bearings, etc.), electronic components/modules (integrated circuits, semiconductor devices, these modules, etc.), lighting devices (vehicle headlights, taillights, etc.) or power storage devices (batteries) , a capacitor, etc.).

If the die-cast product is a temperature regulating member for regulating the temperature of a power generating device (engine, motor, etc.), the heat generated during use can be rapidly removed through the flow of a heat exchange medium. It becomes possible to exhibit good performance over a long period of time.
In addition, if the die-cast product is a temperature regulating member for regulating the temperature of power exchange/transmission devices (robot joints, transmissions, bearings, etc.), the heat generated during use can be rapidly absorbed by the circulation of a heat exchange medium. By removing these particles, it becomes possible to allow the power exchange/transmission device to perform precise operations over a long period of time.
In addition, if the die-cast product is a temperature regulating member for regulating the temperature of electronic parts/modules (integrated circuits, semiconductor devices, these modules, etc.), the heat generated during use can be rapidly absorbed by the circulation of a heat exchange medium. By removing these particles, it is possible to maintain the performance of electronic components and modules for a long time.
In addition, if the die-cast product is a temperature regulating member for regulating the temperature of a lighting device (headlights, taillights, etc. of vehicles, etc.), the heat generated during use is rapidly removed by the circulation of a heat exchange medium. This allows the illumination device to exhibit good performance over a long period of time.
In addition, if the die-cast product is a temperature control member for regulating the temperature of a power storage device (battery, capacitor, etc.), the heat generated during use (during charging or discharging) can be rapidly absorbed by the circulation of a heat exchange medium. By removing these particles, it is possible to maintain the performance of the power storage device over a long period of time. Furthermore, if the temperature of the power storage device becomes too low in cold regions, etc., it is possible to prevent the performance of the power storage device from deteriorating due to low temperatures by circulating a warm heat exchange medium inside the die-cast product to heat it. It becomes possible.

Note that the temperature control member, which is a die-cast product manufactured by the method of manufacturing a die-cast product of the present invention, adjusts the temperature by circulating a heat exchange medium, so unlike existing heat sinks, it does not have a bulky heat dissipation structure in the form of fins or crests. There is no need to install it near the temperature control target. Therefore, the temperature control member can be suitably used when a large space cannot be secured near the temperature control target or when it is desired to downsize the temperature control target. Note that the temperature adjustment member may be built into the object to be temperature adjusted, or may be attached externally.

Moreover, the die-cast product manufactured by the method for manufacturing a die-cast product of the present invention can be used as a heat exchange member for realizing heat exchange between a region with a high temperature and a region with a low temperature by circulating a heat exchange medium. I can do it. A heat sink can only dissipate the absorbed heat to the surroundings, but in such a heat exchange member, the circulation of the heat exchange medium allows the absorbed heat to be transferred to a region that requires heating. For example, in a hybrid car used in a cold region, the heat exchanger described above is used to transfer the heat absorbed from the engine to the power storage device and air conditioner, thereby reducing energy waste and regulating the temperature of each device. becomes possible. The above heat exchange member can also be said to be part of a heat exchange system combined with a device for circulating a heat exchange medium. It is thought that the heat exchange member can be applied to vehicles, factories, houses, etc.

5. Effects of the method for manufacturing a die-cast product according to the embodiment

The method for manufacturing a die-cast product according to the embodiment includes a third step S40 of forming a die-cast product 40 by die-casting, in which an insert member 30 having an internal space 32 is cast-in with a cast-in member 42a, and therefore is different from the conventional method. It is likewise possible to produce die-cast products 40 with complex interior spaces 32.

Furthermore, since the method for manufacturing a die-cast product according to the embodiment includes a second step S30 of forming the insert member 30 by joining a plurality of insert member forming members (insert member forming members 10, 20), The plurality of insert member forming members (insert member forming members 10 and 20) become an integrated insert member 30 by joining. Therefore, according to the method for manufacturing a die-cast product according to the embodiment, it is possible to prevent unintended gaps from remaining.

Therefore, the method for manufacturing a die-cast product according to the embodiment makes it possible to manufacture a die-cast product 40 having a complicated internal space 32, and also to suppress the remaining unintended gaps. This is the manufacturing method.

Furthermore, according to the method for manufacturing a die-cast product according to the embodiment, the second step S30 includes forming the insert member 30 by joining a plurality of insert member forming members (insert member forming members 10 and 20). , there is no need to form a structure (for example, a stepped labyrinth structure or an unnecessary internal space) to prevent the molten metal 42 from entering the internal space 32 when forming the die-cast product 40 by die-casting, and it is possible to It becomes possible to form the insert member 30 with a much thinner profile compared to the conventional method using a joint.

Further, according to the method for manufacturing a die-cast product according to the embodiment, in the third step S40, the insert member 30 is inserted so that at least a part thereof contacts the cavity C of the product mold 100, 200 in which the cavity C can be formed. After placement, the insert member 30 is reliably cast in order to form the die-cast product 40 by introducing the cast-in molten metal 42 into the cavity C and solidifying the cast-in molten metal 42 to form the cast-in member 42a. becomes possible.

Further, according to the method for manufacturing a die-cast product according to the embodiment, the material used to form the plurality of insert member forming members (insert member forming members 10, 20) in the first step S10 is used in the third step S40. Since the material is the same as that used to form the die-cast product 40 in , it reduces the stress (especially thermal stress) generated between the part 30a that was the insert member 30 and the cast-in member 42a, and prevents temperature changes. It becomes possible to manufacture a die-cast product 40 in which the part 30a that was the insert member 30 and the cast-in member 42a are difficult to separate.

Further, according to the method for manufacturing a die-cast product according to the embodiment, the material used to form the plurality of insert member forming members (insert member forming members 10, 20) in the first step S10 and the material used in the third step S40. Since the material used to form the die-cast product 40 is an aluminum-based material, it is possible to manufacture the die-cast product 40 that can be used in various fields by taking advantage of the strength and light weight of the aluminum-based material.

Further, according to the method for manufacturing a die-cast product according to the embodiment, the fourth step S20 is performed in which residual stress is applied to at least the joining surfaces 16 and 26 of the insert member forming members 10 and 20 while leaving a chill layer on the surface. , is included between the first step S10 and the second step S30, and in the second step S30, the insert member 30 is formed by diffusion bonding a plurality of insert member forming members (insert member forming members 10, 20). Because of this, it is possible to join multiple insert member forming members (insert member forming members 10 and 20) formed by die casting, which is generally considered difficult to obtain high bonding strength, with high bonding strength. becomes.

Furthermore, according to the method for manufacturing a die-cast product according to the embodiment, in the fourth step S20, residual stress is applied by shot blasting, so that residual stress is applied while forming fine irregularities using a simple method. It becomes possible to do so.

Further, according to the method for manufacturing a die-cast product according to the embodiment, in the second step S30, an insert member 30 in which the internal space 32 communicates with the outside through the two communication ports 14 is formed, and a third In step S40, the die-cast product 40 is formed with the communication port 14 closed, so the internal space 32 can be used as a space (for example, a heat exchange medium channel) that can exchange fluid with the outside. .

Although the present invention has been described above based on the above embodiments, the present invention is not limited to the above embodiments. It is possible to implement the present invention in various ways without departing from the spirit thereof, and for example, the following modifications are also possible.

(1) The shapes of the insert member forming members 10, 20, the insert member 30, and the die-cast product 40 in the above embodiments are merely examples, and can be made into any shape without departing from the scope of the present invention.

(2) In the above embodiment, the plurality of insert member forming members are two insert member forming members 10 and 20, but the present invention is not limited to this. The plurality of insert member forming members may be three or more insert member forming members. In addition, when the plurality of insert member forming members are composed of three or more insert member forming members, all the insert member forming members may be joined at once in the second step, or two insert member forming members may be joined at once. It is also possible to join them one by one.

(3) In the above embodiment, the material used to form the plurality of insert member forming members (insert member forming members 10, 20) in the first step S10 is used to form the die cast product 40 in the third step S40. However, the present invention is not limited thereto. The material used to form the plurality of insert member forming members in the first step may be different from the material used to form the die cast product in the third step.

(4) In the above embodiment, the material used to form a plurality of insert member forming members (insert member forming members 10, 20) in the first step S10 and the material used to form the die cast product 40 in the third step S40 Although the material used for this purpose was an aluminum-based material, the present invention is not limited thereto. Any metal material that can be die-cast can be applied to the present invention.

(5) In the above embodiment, residual stress is applied by plastically deforming the surface of the target surface, but the present invention is not limited to this. Residual stress may be applied to the target surface by means other than plastic deformation (for example, heat treatment such as rapid cooling).

(6) In the above embodiment, residual stress is imparted by shot blasting, but the present invention is not limited to this. Residual stress may be imparted by a treatment other than shot blasting.

(7) In the above embodiment, the insert member 30 in which the internal space 32 communicates with the outside through at least two communication ports 14 is formed in the second step S30, but the present invention is not limited to this. It's not something you can do. The number of communication ports can be changed depending on the purpose and the shape of the internal space, and may be one or three or more. Further, when the internal space is formed for purposes such as heat insulation or weight reduction, the communication port may not be present.

(8) The present invention may further include a fifth step of forming a protective layer on the wall surface constituting the internal space after the third step. Examples of the protective layer include a resin layer and an oxide film layer. The resin layer can be formed by dipping or the like. The oxide film layer can be formed by alumite treatment or the like.

DESCRIPTION OF SYMBOLS 10, 20... Member for forming an insert member, 10a, 20a... Portion of the insert member that was a member for forming an insert member, 12, 22... Recessed portion, 14... Communication port, 16, 26... Surface to be joined, 30... Insert member , 30a... Portion that was an insert member in a die-cast product, 32... Internal space, 40... Die-cast product, 42... Molten metal for cast-in, 42a... Cast-in member, 100, 200... Mold for product, 102, 202... Product Corresponding part, 104, 204... Insert member holding part, 106, 206... Runway, C... Cavity

Claims (10)

A first step of forming by die-casting a plurality of insert member forming members that become an insert member having an internal space by joining;
a second step of forming the insert member by joining the plurality of insert member forming members;
A method for manufacturing a die-cast product, comprising a third step of forming a die-cast product by die-casting, in which the insert member is cast into a cast-in member. In the third step, after arranging the insert member so that at least a portion of the insert member is in contact with the cavity of a product mold capable of forming a cavity, a molten metal for cast-in is introduced into the cavity, and the molten metal for cast-in is introduced into the cavity. 2. The method for manufacturing a die-cast product according to claim 1, wherein the die-cast product is formed by solidifying a molten metal to form the cast-in member. 2. The method according to claim 1, wherein the material used to form the plurality of insert member forming members in the first step is the same as the material used to form the die cast product in the third step. 2. The method for manufacturing a die-cast product according to 2. Claim characterized in that the material used to form the plurality of insert member forming members in the first step and the material used to form the die cast product in the third step are aluminum-based materials. 3. The method for manufacturing a die-cast product according to 3. In each insert member forming member constituting the plurality of insert member forming members, when the surface to be joined in the second step is the planned joining surface,
a fourth step of applying residual stress to at least the surface to be joined of the insert member forming member while leaving a chilled layer on the surface between the first step and the second step;
3. The method for manufacturing a die-cast product according to claim 1, wherein in the second step, the insert member is formed by diffusion bonding the plurality of insert member forming members. 6. The method for manufacturing a die-cast product according to claim 5, wherein in the fourth step, the residual stress is applied by shot blasting. In the second step, forming the insert member in which the internal space communicates with the outside through at least one communication port,
3. The method for manufacturing a die-cast product according to claim 1, wherein in the third step, the die-cast product is formed with the communication port temporarily closed. 8. The method of manufacturing a die-cast product according to claim 7, further comprising a fifth step of forming a protective layer on a wall surface constituting the internal space after the third step. The die-cast product according to claim 7, wherein the die-cast product is a temperature regulating member for regulating the temperature of a power generation device, a power exchange/transmission device, an electronic component/module, a lighting device, or a power storage device. manufacturing method. The die-cast product according to claim 7, wherein the die-cast product is a heat exchange member for realizing heat exchange between a high-temperature region and a low-temperature region by circulating a heat exchange medium. manufacturing method.

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