US20150013929A1 - Die-casting mold structure for thin-walled zinc alloy shells for electrical connectors - Google Patents

Die-casting mold structure for thin-walled zinc alloy shells for electrical connectors Download PDF

Info

Publication number
US20150013929A1
US20150013929A1 US14/329,541 US201414329541A US2015013929A1 US 20150013929 A1 US20150013929 A1 US 20150013929A1 US 201414329541 A US201414329541 A US 201414329541A US 2015013929 A1 US2015013929 A1 US 2015013929A1
Authority
US
United States
Prior art keywords
runner
gate
casting
liquid metal
mold cavity
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US14/329,541
Other languages
English (en)
Inventor
Zhi Wei LAI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson Components & Equipments Co Ltd
Original Assignee
Johnson Components & Equipments Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Components & Equipments Co Ltd filed Critical Johnson Components & Equipments Co Ltd
Assigned to JOHNSON COMPONENTS & EQUIPMENTS CO., LTD. reassignment JOHNSON COMPONENTS & EQUIPMENTS CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LAI, ZHI WEI
Publication of US20150013929A1 publication Critical patent/US20150013929A1/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/2272—Sprue channels
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C18/00—Alloys based on zinc
    • C22C18/04—Alloys based on zinc with aluminium as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art

Definitions

  • the present invention relates to a casting technology for thin-walled mini castings and, in particular, to a die-casting mold structure for thin-walled zinc alloy shells used in electrical connectors.
  • thin-walled mini zinc alloy shells refer to a zinc alloy product that has a wall thickness about 0.1-0.5 mm.
  • the filling speed for the zinc alloy is about 40 m/s.
  • the molten or liquid metal will enter the mold cavity in the form of jet flow to fill the cavity.
  • the liquid metal may encounter collision, friction and resistance, causing the liquid metal to become a pressurized fluid that exhibits a filling characteristic inferior to that of a jet flow.
  • the pressurized fluid may introduce defects, such as entrapping air bubbles, which may lead to porous castings.
  • the thin-walled zinc alloy shells may be prone to entrap bubbles and may have an incomplete filling. Therefore, a well-designed casting process and mold design has an important influence on molding the shells.
  • Other common defects in the zinc alloy shells are surface bubbles and loose structure, which may reduce the tensile strength and the electrical conductivity of the shells. The result is that the shells may fail to meet quality standards, lowering product yield, and causing a serious impact on normal production of the shells. Even more seriously, it may be difficult for some defects to be detected in the semi-finished products in the casting process. The latent defects may not be found until at a later stage in the process; for example, the defects may not become visible until the electroplating process. Such a late detection of defects would cause an even more severe loss in product yield and greater economic loss.
  • the end runner which is the channel through which the liquid metal flows into the mold cavity, is oriented perpendicular to the mold cavity.
  • the vertical orientation of the runner to the mold cavity is intended to allow the flow vector of the liquid metal to be free of any speed component horizontal to the mold cavity so as to reduce the speed loss when the liquid metal enters the mold cavity, resulting in an improved filling effect.
  • the results have been less than satisfactory. As such, there is a need for an improved die-casting mold structure.
  • An object of the present invention is to provide a simple, inexpensive die-casting mold structure for thin-walled zinc alloy shells used in electrical connectors such as USB connectors to overcome the shortcomings of the conventional technology. Another object is to reduce the vortexes and the entrapped gases in the filling processing for a complete filling so as to reduce surface bubbles and surface flow mark, improve surface smoothness and strength, and increase yield of the die casting process.
  • a die-casting mold structure for thin-walled zinc alloy shells for connectors such as USB connectors is disclosed.
  • the die-casting mold structure includes a longitudinal runner, a transverse runner, an end runner, and a mold cavity, all of which are connected serially to provide a path for the flow of molten or liquid metal.
  • the end runner and the mold cavity are connected through an in-gate.
  • the cross-sectional areas of the longitudinal runner, the transverse runner, the end runner, and the in-gate are progressively smaller in the direction of the flow of the liquid metal.
  • the liquid metal flows through the in-gate and enters the mold cavity at an incidence angle of approximately 30 to 45 degrees. The incidence angle is subtended by the end runner and the plane of the in-gate.
  • the liquid metal enters the mold cavity from the in-gate near the rear end surface of the mold cavity.
  • the incidence angle of the liquid metal jet flow subtended by the end runner and the plane of the in-gate may be set at approximately 30 to 40 degrees.
  • connection between the transverse runner and the end runner forms an arc.
  • the arc has an arc radius of approximately 10 mm to 15 mm.
  • the distance between the mid-point of the in-gate and the rear end surface of the mold cavity is approximately 2 to 3 mm.
  • the distance between the mid-point of the in-gate and the rear end surface of the mold cavity is about 2.5 mm.
  • the runners of the mold structure allow the liquid metal to flow through the in-gate and enter the mold cavity at an angle not perpendicular to the mold cavity. Rather, the direction of flow of the liquid metal makes an incidence angle of between 30 and 45 degrees where the incidence angle is subtended by the end runner and the plane of the in-gate.
  • the direction of flow of the liquid metal is controlled as the liquid metal flows through the runners and into the mold cavity so as to reduce the amount of air mixed into the liquid metal. The result is that the liquid metal can fill the mold cavity more effectively, since casting defects such as surface bubbles, surface flow marks, loose structure, low strength, and low electrical conductivity can be reduced, thereby increasing the product yield of the casting process.
  • FIG. 1 show a schematic view of a die-casting mold structure for thin-walled zinc alloy shells for electrical connectors according to one embodiment of the present invention
  • FIG. 2 shows an enlarged view for the “A” portion indicated in FIG. 1 according to one embodiment of the present invention.
  • the die-casting mold structure includes a longitudinal runner 4 , two transverse runners 3 , two end runners 5 , and two mold cavities 1 , all of which are connected in the order shown to provide a path for molten or liquid metal to flow into the mold cavities 1 .
  • Each of the end runners 5 and its associated mold cavity 1 are connected through an in-gate 2 .
  • the cross sectional areas of the longitudinal runner 4 , the transverse runner 3 , the end runner 5 , and the in-gate 2 are progressively smaller in the direction of the flow of the liquid metal.
  • the flow speed of the liquid metal may be increased gradually to achieve sufficient velocity at the in-gate 2 to allow each mold cavity to be filled properly.
  • the liquid metal flows through the in-gate 2 and enters its associated mold cavity at an incidence angle ( ⁇ ) of approximately 30 to 45 degrees where the incidence angle ( ⁇ ) is subtended by the end runner 5 and the plane of the in-gate 2 .
  • the jet flow of liquid metal in the end runner 5 enters the mold cavity 1 near the rear end surface of the mold cavity 1 .
  • the proper incidence angle ( ⁇ ) allows the mold cavity to be filled completely.
  • each transverse runner 3 and its associated end runner 5 forms an arc R.
  • the arc R has an arc radius of approximately 12 mm.
  • the arc R allows the liquid metal to flow smoothly from each transverse runner 3 to its associated end runner 5 .
  • the distance between the mid-point of each in-gate 2 and the rear end surface of the associated mold cavity 1 is about 2.5 mm. This distance may alleviate the impact from the excessively high speed of the liquid metal at the in-gate 2 to prevent the mold cavity 1 from eroding.
  • the incidence angle ( ⁇ ) of the liquid metal flowing through the in-gate 2 and entering the associated mold cavity 1 significantly affects the quality of the casting.
  • the incidence angle ( ⁇ ) may be determined from two sub-vectors of the speed vector of the liquid metal. As shown in FIG. 2 , the horizontal sub-vector (a) represents the horizontal speed component of the liquid metal; the vertical sub-vector (b) represents the vertical speed component of the liquid metal; the speed vector of the liquid metal forms an incidence angle ( ⁇ ) with the plane of the in-gate ( 2 ).
  • the following parameters may be used in molding a front metal shell of an electrical connector for USB 3.0:
  • FIG. 1 shows a whole raw casting where the two castings of the shells for the USB connectors occupy a small portion of the raw casting (the weight of the raw casting is about 8.009 g whereas the two castings of the shells weigh about 0.830 g each).
  • the shapes and dimensions for the longitudinal runner 4 , the transverse runners 3 , the end runners 5 , and the in-gates 2 may be determined according to the weight and shape of the casting.
  • five configurations for the runners of the raw casting may be obtained.
  • the shapes and dimensions of the longitudinal runner 4 , the transverse runners 3 , the end runners 5 , and the in-gates 2 are the same in each configuration.
  • the configuration of the end runner and in-gate 2 such as changing the direction at which the liquid metal enters the mold cavity 1 and the incidence angle ( ⁇ ) subtended by the end runner 5 and the plane of the in-gate 2 , the five configurations may be obtained.
  • the incidence angles ( ⁇ ) of the five configurations are 45, 40, 35, 33 and 30 degrees.
  • Comparisons may also be made of casting samples from sample mold designs. According to the drawings of the castings, corresponding mold designs may be obtained. A die-casting machine made by FRECH is used to produce the casting samples according to the mold designs. The following table shows the results:
  • the incidence angle ( ⁇ ) which is the angle between the end runner 5 and the mold cavity 1 , may be designed to be between 30 and 45 degrees.
  • the incidence angle ( ⁇ ) is about 30 degrees, the filling effect appears to be optimal, and may produce the highest product yield.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US14/329,541 2013-07-12 2014-07-11 Die-casting mold structure for thin-walled zinc alloy shells for electrical connectors Abandoned US20150013929A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN201310292753XA CN103372638A (zh) 2013-07-12 2013-07-12 一种锌合金usb薄壁件压铸模具结构
CN201310292753.X 2013-07-12

Publications (1)

Publication Number Publication Date
US20150013929A1 true US20150013929A1 (en) 2015-01-15

Family

ID=49458825

Family Applications (1)

Application Number Title Priority Date Filing Date
US14/329,541 Abandoned US20150013929A1 (en) 2013-07-12 2014-07-11 Die-casting mold structure for thin-walled zinc alloy shells for electrical connectors

Country Status (2)

Country Link
US (1) US20150013929A1 (zh)
CN (2) CN103372638A (zh)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170215081A1 (en) * 2014-07-11 2017-07-27 Lg Electronics Inc. Method and apparatus for transmitting wi-fi signals in unlicensed spectrum in wireless communication system

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108543924A (zh) * 2018-05-15 2018-09-18 深圳市奥力压铸五金制品有限公司 一种异形光纤模组真空压铸的浇注系统及其压铸工艺
CN111496223B (zh) * 2020-01-19 2021-10-29 宁波海天金属成型设备有限公司 一种压铸机智能压室金属液卷气控制方法及控制系统
CN111390137A (zh) * 2020-05-27 2020-07-10 湛江德利车辆部件有限公司 一种汽车构件压铸模浇注系统

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6648055B1 (en) * 1999-04-16 2003-11-18 Daimlerchrysler Ag Casting tool and method of producing a component
US20120071022A1 (en) * 2010-09-21 2012-03-22 Hon Hai Precision Industry Co., Ltd. Lower profile cable assembly with a metal shell for preventing emi

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6648055B1 (en) * 1999-04-16 2003-11-18 Daimlerchrysler Ag Casting tool and method of producing a component
US20120071022A1 (en) * 2010-09-21 2012-03-22 Hon Hai Precision Industry Co., Ltd. Lower profile cable assembly with a metal shell for preventing emi

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
Universal Serial Bus Specification Revision 2.0, April 7, 2000, p. 98-101; http://www.usb.org/developers/docs/usb20_docs/#usb20spec *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170215081A1 (en) * 2014-07-11 2017-07-27 Lg Electronics Inc. Method and apparatus for transmitting wi-fi signals in unlicensed spectrum in wireless communication system

Also Published As

Publication number Publication date
CN103372638A (zh) 2013-10-30
CN104275462A (zh) 2015-01-14

Similar Documents

Publication Publication Date Title
US20150013929A1 (en) Die-casting mold structure for thin-walled zinc alloy shells for electrical connectors
CN108543924A (zh) 一种异形光纤模组真空压铸的浇注系统及其压铸工艺
CN104084558B (zh) 一种金属超薄壳体的浇注系统
CN101456068B (zh) 用于模铸的模具,制造铸件产品的方法和铸件产品
CN204052844U (zh) 一种防堵塞防尘铝合金金属铸造模具
WO2016181177A3 (en) Casting process and sand mould provided with an inlet system for producing at least partly thin walled aluminium casts with sand moulding technology by means of gravity casting
CN112453345A (zh) 一种用于制备铝合金压铸件的压铸系统及压铸工艺
US20150013930A1 (en) Die-casting mold and method for thin-walled electrical connector shells
CN203751261U (zh) 一种排气管铸造模型
CN207756873U (zh) 一种用于平板电脑内置镁合金支架的流道结构
CN208895146U (zh) 一种异形光纤模组真空压铸的浇注系统
CN202715771U (zh) 树脂砂标准试棒模
CN208895156U (zh) 一种双流道u型锌合金光纤模组薄壁件压铸模具结构
CN204486710U (zh) 一种挡块模具结构
CN206083821U (zh) 一种保证成品成型强度的压铸模具
CN103949607B (zh) 适用于一次成型摄像头支架的压铸模具
CN211328523U (zh) 一种解决工艺孔断裂、疲软结构的空滤器壳盖
CN211965878U (zh) 一种薄壁大面积异型压铸件的铝硅合金模具
Jin et al. Die design optimization of die casting for fabrication of fuel cell aluminum bipolar plate with micro-channel through casting simulation and experimental investigation
CN202571241U (zh) 一种减少压铸件气孔缩孔的模具结构
CN203390182U (zh) 一种锌合金usb薄壁件压铸模具结构
CN106180637B (zh) 一种压铸模具
CN106217699B (zh) 浇注模具
CN204996846U (zh) 一种高挤压精度的挤压机模具
CN209578112U (zh) 一种应用于压铸模具的抽芯流道结构

Legal Events

Date Code Title Description
AS Assignment

Owner name: JOHNSON COMPONENTS & EQUIPMENTS CO., LTD., TAIWAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:LAI, ZHI WEI;REEL/FRAME:033415/0381

Effective date: 20140722

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION