MXPA00009316A - Apparatus for die casting an internal passageway and a product manufactured therewith - Google Patents

Abstract

A die casting apparatus (30) comprises a pair of mold assemblies (32, 34) which include molding surfaces cooperatingto define a first mold cavity (35) therebetween for casting a first portion of a cast object in the first mold cavity. One of the mold assemblies comprises a fixed mold core (36, 38), and a movable mold core (40) movable with respect to the fixed mold core along a core axis between a closed position and an open position. The mold cores include casting surfaces (36a, 38a) disposed such that in the closed position the casting surfaces cooperate to define a second mold cavity therebetween extending transversely to the core axis and in communication with the first mold cavity for casting a remaining portion of the object integral with the first portion, while in the released position the object is substantially released from the one mold assembly.

Description

APPARATUS TO PRESSURE AN INTERNAL PASSAGE AND A PRODUCT PREPARED BY THE SAME FIELD OF THE INVENTION The present invention relates to an apparatus for die casting an internal passage. In particular, the present invention relates to an apparatus for melting under pressure an object having an internal passage extending transversely to the line of stroke of the mold and an object made with this apparatus.

BACKGROUND OF THE INVENTION Oil tanks for automotive machines are commonly made as a die-cast aluminum part. The die casting process is preferred over other melting methods, such as sand casting or lost wax casting, because die casting generally has a higher production rate and the process can be further automated . Four-wheel drive vehicles such as sport utility vehicles and off-road vehicles are becoming increasingly popular. With a R3F .: 123396 growing demand for these vehicles, there has been a desire on the part of the vehicle manufacturers to increase the power and functionality of the vehicles without significantly increasing the size of the machine and the vehicle. As a result, the designers of the machines have specified that the transmission shaft extends through the oil reservoir without affecting the capacity of the oil reservoir, thus requiring an internal passage. A skewed cut structure extending transverse to the mold trace line can not be made using conventional pressure casting techniques. The biased cut makes it impossible for the molded object to be removed from conventional molds. As a result, the biased structures are generally molded using molding techniques wherein the core of the mold forming the slanting cut is broken after the molded object has been removed from the mold. This technique is described in U.S. Patent Number 4, 961, 458. The additional steps to form a sand-molded part and remove the sand-molded part increases the cycle time which increases the need for manual labor and finally the cost of the molded product, finished.

BRIEF DESCRIPTION OF THE INVENTION According to the present invention, a die casting apparatus is provided which faces the disadvantages of the die casting molds of the prior art. The die casting apparatus, in accordance with the present invention, comprises a pair of mold assemblies including mold surfaces cooperating to define a first mold cavity therebetween for molding or melting a first portion of a molded object in the mold. the same. One of the mold assemblies comprises a fixed mold core, and a movable mold core that can be moved with respect to the core of the mold fixed along a core axis between a closed position and an open position. The mold cores include positioned molding surfaces such that in the closed position the molding or melt surfaces cooperate to define a second mold cavity therebetween which extends transversely to the core axis and in communication with the first mold cavity for molding or melt a remaining portion of the integral object with the first portion. While in the released position the object is substantially released from the mold assembly. In a preferred embodiment of the invention, the mold assemblies can move relative to each other, along a mold axis, between an open position and a closed mold position. The mold assemblies comprise a male mold assembly and a female mold assembly for receiving the male mold assembly therein, with the first mold cavity defined therebetween which is formed to mold a side wall and an integrally molded base or fused with the side wall. The second mold cavity is formed to mold or fuse a tubular passage integrally molded with the side wall. Preferably, the die casting apparatus also includes a transversely movable core that moves within the second mold cavity to mold the tubular passage between the molten molding surfaces and the transversely moving core. The male mold assembly includes the fixed mold core and the movable mold core. The movable mold core moves relative to the fixed mold core between the closed molding position and the open removal position. The molding or cast surface of the movable mold core is positioned at the end of the movable mold core and oriented such that when the movable mold core is in the molding position, the molding surface of the movable mold core matches the molding surface of the fixed mold core. In addition, the molding surface of the movable core is positioned at a distance from the end of the molten molding surface of the movable core. Once the object has been molded or fused, the male mold assembly and the female mold assembly are opened and moved to the open mold position, and the transversely moving core is removed from the second mold cavity. The molding surface of the movable mold core is then moved relative to the molten molding surface of the fixed mold core by pushing the tubular passage away from the molding surface of the fixed mold core while also pushing the side wall and the base away from the molding surface of the fixed core. Once in the removal position, the molded or molten object is dislodged from the movable core by moving the molded object transversely with respect to the mold cores. The moving core is then returned to the molten molding position and the cycle is repeated.

BRIEF DESCRIPTION OF THE DRAWINGS The preferred embodiment of the invention will now be described, by way of example, with reference to the drawings, in which: Figure 1 is a perspective view of an oil reservoir manufactured by the present invention; Figure 2 is a sectional view of the oil reservoir of Figure 1; Figure 3 is a sectional view of the die casting or molding apparatus, according to the present invention, for molding the oil reservoir of Figure 1, showing the mold assemblies in the closed mold position; Figure 4 is a sectional plan view of the upper part of the die casting apparatus of Figure 3, showing the mold assembly in the closed mold position; Figure 5 is a sectional, side view of the die casting apparatus of Figure 3, showing the mold assemblies in the mold, open position; Figure 6 is a sectional, side view of the die casting apparatus of Figure 3, showing the mold assemblies in the open mold position and the movable core moving to the open position; Figure 7 is a sectional, side view of the die casting apparatus of Figure 3, showing the movable core in the open position; and Figure 8 is a sectional, side view of the die casting apparatus of Figure 3, showing the molded part that is removed from the mold assemblies.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An oil reservoir 10 having a tubular passage structure 12 of the present invention is illustrated in Figures 1 and 2. With the exception of the tubular passage structure 12, the oil reservoir 10 is otherwise of a conventional die-cast fabrication. In this way, the design of the oil reservoir 10 is governed by techniques well known in the art.

The passage structure 12 extends transversely from the opposite side walls 14 of the oil reservoir 10 to present a passage opening 20. The passage structure 12 rises with respect to the oil reservoir bottom 18. In this way, the passage structure 12 does not interfere with the free movement of the oil retained in the oil reservoir 10. The wall 22 of the tubular passage structure 12 has a generally uniform thickness except for a sharp lobe 24 that is formed as a result of the assemblies of mold so that the molded oil reservoir 10 can be removed from the die casting apparatus, as will be apparent from the following discussion. With reference to Figures 3 and 4, a die casting apparatus 30, according to the present invention, is shown mounted on a conventional press-fused press. The die casting apparatus 30 comprises a female mold assembly 32 and a male mold assembly 34 which are mounted 'in a drive unit suitable for reciprocating movement between one open mold position and one position of closed mold. The mounting 32 of the female mold includes conventional holes for receiving and transferring molten material into a mold cavity defined between the female mold assembly 32 and the male mold assembly 32, as is conventional in the art. The female mold assembly 32 has a molding surface 32a that is complementary to the outer surface of the oil reservoir 10. The male mold assembly 34 has a molding surface that is complementary to the inner surface of the oil reservoir 10. molding surface 32a of mounting 32 of the female mold and the molding surface of mounting 34 of the male assembly cooperate to define a mold cavity 35 therebetween to integrally mold or melt bottom 18 of oil tank 10 with side walls 14. The male mold assembly 34 comprises first and second fixed mold cores 36, 38, and a movable mold core 40 that can be moved with respect to the cores 36., 38 of mold, fixed. The core 40 of the movable mold is mounted on a drive unit 42 which moves the core 40 of the movable mold in a reciprocating manner between a "closed" or "molding" position and an "open" or "part removal" position. " Preferably, the core 40 of the movable mold moves along an axis that is parallel to the axis of motion of the mold assemblies 32, 3. The molding surface of the male mold assembly 34 is comprised of molding surfaces 36a, 38a, 40a formed at the respective ends of the mold cores 36, 38, 40. In the molten molding position, shown in Figure 3, the movable mold core 40 sits between the fixed mold cores 36, 38 such that the molding surface 40a coincides with the mold surfaces 34a, 3ßa of the mold cores 36, 38, fixed to form the interior surface of the container of oil 10. in the part removal position, shown in Figure 6, the molding surface 40a of the movable core extends beyond the fixed core molding surfaces 36a, 38a. The fixed mold core 36 and the movable mold core 40 have respective, cooperating sliding surfaces, denoted together as 46a. Similarly, sliding, co-operating surfaces 46b are provided between the movable mold core 40 and the fixed mold core 38 '. Preferably, the sliding surfaces 46a, 46b are tapered from the axis of movement of the core 40 of the moving mold, from the molten molding position to the open position, to allow the movable mold core 40 to easily extend beyond the fixed mold cores 36, 38 to allow the molded object to be removed from the male mold assembly 34. The movable mold core 40 has a melt or molding surface 44, which comprises an arcuate cut portion and a substantially planar portion, positioned at a distance from the molding surface 40a to form part of the passage structure 12. The fixed mold core 36 has a molding surface 45 which is complementary to the molding surface 44 of the movable mold to form the movable passage. When the movable mold core 40 is in the molten or molding position, the molding surface 44 of the movable core and the molding surface 45 of the fixed core cooperate to form a transverse cavity 47 that is in communication with the mold cavity 35. and extending transversely to the axis of movement of the movable mold core 40. In addition, the flat portions of the molten molding surfaces 44, 45 intersect to form the lobe 24. However, when the movable core 40 is in the part removal position, the molding surface 44 of the movable core is placed at a distance away from the casting surface 45 of the fixed core. The die casting apparatus 30 also includes an array of cores 48 and 50 that move transversely. The cores 48, 50 move in drive units suitable for the reciprocating movement in a direction transverse to the axis of movement of the movable core 40, between an "inserted" or "molding" position and a "withdrawal" or "retracted" position. retracted. " In the molten molding position, the cores 48, 50 extend through the transverse cavity 47 defined by the molten molding surfaces 44, 45 of the movable core 40 and the fixed mold core 36. In this position, the cores 48, 50 abut in an end-to-end manner, and separate inward from the molding or casting surfaces 44, 45 to form the wall 22 of the tubular passage structure 12 between them. . The tips of eof the cores 48, 50 taper slightly to improve removal of the cores 48, 50 after molding or melting. Optionally, a tapered, individual core extending from one side of the mold could be used with satisfactory results. Referring now to Figures 3 to 8, the method of operation of the die casting apparatus 30 will now be described. The molding and casting surfaces of the die casting apparatus 30 are cleaned and treated as is conventional in the art. The assemblies 3234 of the mold are then closed as illustrated in Figure 3 and the cores 48, 50 are moved to the cast position. Molten material is then injected under pressure into the mold cavity 35 and the transverse cavity 47 to form a molded part 52 (in this case the oil in the reservoir 10) having a bottom 18, side walls 14 integrally molded with the bottom 18, and a tubular passage 12 integrally molded with the side walls 14. Preferably, the molten material comprises a metal alloy of molten aluminum. However, if desired other materials may be used. Once the molded part 52 has sufficiently solidified, the female mold assembly 32 opens and retracts to the part removal portion, as illustrated in Figure 5. Simultaneously or sequentially, the cores 48 , 50 are removed from the transverse cavity. 47 to allow the molded portion 52 to be subsequently removed from the die casting apparatus 30. The molded part 52 remains attached to the fixed mold cores 36, 38 and the movable mold core 40. The drive unit 42 is activated to extend the movable mold application 40 from the melt position to the part removal position, shown in Figure 6, to slide the flat portion of the tubular passage 12 (formed from the melt surface). 45) along the sliding surface 46a. As a consequence, the tubular passage 12 is pushed out of the transverse cavity 47 and the molded part 52 is pushed out of the male mold assembly 34. Depending on the size and configuration of the molded part 52, lifting apparatuses and ejector pins may be required to aid in the removal of the molded part 52 from the fixed mold cores 36, 38. The movable mold core 40 then extends fully, as illustrated in Figure 7, such that the passage structure 12 is capable of free movement with respect to the fixed mold core 36. The molded part 52 is then manipulated to be released from the movable mold core 40. Subsequently, the molded part 52 moves transversely with respect to the axis of movement of core 40 of the movable mold to extract the molded part 52 from the die casting apparatus 30, as illustrated in Figure 8. As will be appreciated, the geometry of the movable core 40 is avoided by the position of the passage structure 12 and the bottom 18 of the oil reservoir 10. Specifically, the molded part 52 must be able to slide relative to the core 40 of the movable mold so that the part molded 52 can be removed from the die casting apparatus 30. Accordingly, as illustrated in Figure 8, the flat portion of the tubular passage 12 (formed of the melt surface 44) is somewhat lowered with respect to the bottom 18, and the bottom 18 is substantially free of obstructions that would otherwise interfere with the transverse movement of the molded part 52. Once the molded part 52 of the movable core 40 is removed, the movable mold core 40 retracts back towards the molten position. The melting or molding cycle is then repeated.

The embodiment of the invention described above is proposed to be an example of the present invention and alterations and modifications may be made thereto by those skilled in the art, without departing from the scope of the invention as defined by the claims. annexes. It is noted that in relation to this date, the best method known by the applicant to carry out the present invention is that which is clear from the present description of the invention. Having described the invention as above, the content of the following is claimed as property:

Claims (20)

1. A die casting apparatus for molding or melting a container including a base and a side extending from the base, base and side defining an interior of the container therebetween, the die casting apparatus is characterized in that it comprises : a first mold assembly including a first molding surface; and a second mold assembly including a second molding surface, the first and second molding surfaces that are configured to define a first mold cavity therebetween, the first mold cavity including a base portion for molding or melting the mold. phase therein and a side portion for melting or molding the side in the mima integrally with the base, the second mold assembly comprising a first mold core and a second mold core, the mold cores each including a respective melt surface configured to define a second mold cavity therebetween, the second mold cavity which is in communication with the side portion to melt or mold a remaining portion of the container integral with the side, the second mold cavity which is oriented to place the remaining portion inside the interior of the container that separates from the base portion in the lateral portion to mold or melt the portion re stante away from the base at least on the side, the second core of the mold moving relative to the first mold core to facilitate the release of the molded container from the second mold assembly.

2. The pressure casting apparatus according to claim 1, characterized in that the side 'comprises a pair of container sides, the lateral portion is configured to mold the sides of the container, and the molten or mold surfaces. for molding or melting the remaining portion integrally with the sides of the container.

3. The die casting apparatus according to claim 1 or 2, characterized in that the remaining portion * comprises a remaining tubular portion, and the die casting apparatus includes a movable core, the moving core that can be moved within the second mold cavity for molding or melting the remaining tubular portion between the movable core and the melt surface and for facilitating the release.

4. The die casting apparatus according to claim 2 or 3, characterized in that the second mold core can be moved along a core axis, and the melt surfaces are configured to orient the second mold cavity in a manner transversal in relation to the core axis.

5. The die casting apparatus according to claim 4, characterized in that the first and second mold assemblies can be moved relative to one another along a mold axis parallel to the axis of the core.

6. The die casting apparatus according to claim 4 or 5, characterized in that the core axis is positioned transversely to the base portion.

7. The die casting apparatus according to claim 4, 5 or 6, characterized in that the second molding surface is separated from the melting surface of the second mold core.

8. The die casting apparatus according to claim 4, 5 or 6, characterized in that the molding surfaces include a sliding surface to facilitate movement of the second core of the mold relative to the first mold core with the sliding surface that they are configured to facilitate the release.

9. The die casting apparatus according to claim 8, characterized in that the sliding surface is used from the axis of the core.

10. A container molded part using the die casting apparatus according to claims 1 to 9.

11. A molded container characterized in that it comprises: a base and an integrally molded side with the base, base and side defining a container interior therebetween; and a member integrally molded and separating from the base at least on the side, the member including an outer member surface comprising an arcuate surface portion and an upper portion extending from the arcuate surface apex portion

12. The molded container according to claim 11, characterized in that the flat portion comprises a first flat surface portion and a second flat surface portion, the flat surface portions extending from the arcuate surface portion and terminating at the apex. .

13. The molded container according to claim 11 or 12, characterized in that the member comprises a tubular member.

14. The molded container according to claims 11, 12 or 13, characterized in that the member is oriented parallel to the base.

15. The molded container according to claims 11, 12 or 13 14, characterized in that the side comprises at least two side members extending from the base, the member extends between the two side members.

16. A method for molding a container including a base and a side extending from the base, the base and the side defining an interior of the container therebetween, the method is characterized in that it comprises the steps of: providing a first mold assembly which includes a first molding surface; providing a second mold assembly including a second molding surface, the first and second molding surfaces being configured to define a first mold cavity therebetween, the first mold cavity including a base portion for molding the base in the mold same and a side portion for molding or melting the side therein integrally with the base, the second mold assembly comprising a first mold core and a second mold core, the mold cores each including a melt surface respective configured to define a second mold cavity between these, the second mold cavity that is in communication with the side portion for molding a remaining portion of the container integral with the side; driving one of the mold assemblies towards the other of the mold assemblies and driving one of the melt surfaces of the mold core towards the other of the melt surfaces of the mold core to form the first and second mold cavities; molding or fusing the side integrally with the base, and molding or melting the remaining portion integrally with the side, the remaining portion that is placed inside the interior of the container and that is separated from the base; separate the mold assemblies from each other; moving the melt surface of the mold core from the other melt surface of the mold core to separate the molded container from the other melt surface of the mold core; and removing the molded container from the second mold assembly.

17. The melting method according to claim 16, characterized in that the driving step comprises driving a mold assembly along a mold axis, and the moving step comprises moving the mold core including the melting surface of the mold. mold core along a core parallel to the mold axis.

18. The melting method according to claim 17, characterized in that the melting step of the remaining portion comprises melting or molding the remaining portion transversely with respect to the core axis.

19. The melting method according to claim 16, characterized in that the step of melting or molding comprises the step of inserting a moving mold core into the second mold cavity, injecting a molten material into the first and second mold cavities. , allow the molten material to solidify, by removing the moving mold core from the second mold cavity.

20. A container characterized in that it is molded according to the method of claim 16, 17, 18 or 19.