WO2011160508A1 - Die cast product and process of preparing the same - Google Patents

Die cast product and process of preparing the same Download PDF

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Publication number
WO2011160508A1
WO2011160508A1 PCT/CN2011/074107 CN2011074107W WO2011160508A1 WO 2011160508 A1 WO2011160508 A1 WO 2011160508A1 CN 2011074107 W CN2011074107 W CN 2011074107W WO 2011160508 A1 WO2011160508 A1 WO 2011160508A1
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WO
WIPO (PCT)
Prior art keywords
metal plate
die cast
cast product
process according
raw material
Prior art date
Application number
PCT/CN2011/074107
Other languages
French (fr)
Inventor
Zhiyuan Fan
Chunzhang Li
Jianghui Li
Mingzhu Chang
Jiaxin Zhang
Original Assignee
Byd Company Limited
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 Byd Company Limited filed Critical Byd Company Limited
Publication of WO2011160508A1 publication Critical patent/WO2011160508A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
    • 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

Definitions

  • the present disclosure relates to a die cast product, and a process of preparing the same.
  • Die casting process is one of the most important methods for preparing shaped structural part of nonferrous metal.
  • Products formed by die casting may have good properties such as high size precision, high density, high strength, high hardness, high recycling rate, and high production rate.
  • die cast products not only have advantages such as complex shapes, clear outlines, deep chambers and thin walls, but also may be produced mechanically and automatically.
  • die cast products have some disadvantages. Because of short filling time and fast cooling speed of molten alloys, gases in the mold chamber may not be discharged in time. Moreover, the feeding is very difficult, which may cause pores, concavities, and shrinkages on the surface of the die cast products.
  • conventional die cast products may have rough surfaces, and surface treatment for the die cast products is quite limited and not mature at present.
  • the present disclosure is directed to solve at least one of the problems existing in the prior art. Accordingly, a process of preparing a die cast product and a die cast product prepared by the process are provided.
  • a process of preparing a die cast product may comprise the steps of: disposing a metal plate in a predetermined position within a mold; disposing a raw material of the die cast product onto the metal plate; and die casting the metal plate and the raw material integrally to form the die cast product.
  • a die cast product obtainable through the method described above is provided.
  • the metal plate and the raw material are placed in corresponding locations of the mold, and integrally die cast to form the die cast product. Because the outer surface of the die cast product has been subjected to treatment, surface treatment for the final die cast product may be avoided, thus shortening the production cycle of forming the die cast product and reducing the production cost. Further, the die cast product is formed by integrally die casting the metal plate and the raw material, which may have advantages of both the metal plate and the raw material and may have rich and colorful appearance.
  • a process of preparing a die cast product may comprise the steps of: disposing a metal plate in a predetermined position within a mold; disposing a raw material of the die cast product onto the metal plate; and die casting the metal plate and the raw material integrally to form the die cast product.
  • the process further comprises a step of coating an adhesive on a surface of the metal plate to be contacted with the raw material prior to the die casting step.
  • the adhesive may be any known one commercially available on the market.
  • the adhesive may form a layer having a thickness of about 0.03-0.05 mm, thus preventing adhesive leakages caused by high speed and high pressure during the die casting step, and consequently preventing the bad influence on the appearance of the die cat product.
  • the process may further comprise a step of polishing the outer surface of the die cast product.
  • the polishing step may be performed by using abrasive paper with suitable meshes, such as fine abrasive paper with about 1200-1500 meshes. In this way, the quality of the die cast product may be further improved to meet the requirements of different customers.
  • the die cast product made of metal alloys such as zinc alloys may be blackened due to surface oxidation when directly exposed to the air without surface treatment.
  • the outer surface of the metal plate was previously subjected to at least one treatment selected from the group consisting of spray painting, electroplating, etching, and laser engraving.
  • electroplating may offer fine appearance to the die cast product and improve the density and the wear resistance of the die cast product.
  • Spray painting may be used for decoration protecting and mark painting, and may also offer various colors to the die cast product.
  • Etching may offer embossed stereoscopic effects to the die cast product by forming textures with different thickness on the outer surface of the die cast product.
  • Laser engraving may carve various letters, signals, and patterns, and the size of the letters may range from millimeters to microns, which may play a special role in anti-counterfeiting.
  • the outer surface of an aluminum plate is subjected to anodic oxidation to form an oxidation film on the outer surface of the die cast product.
  • the oxidation film may be a protective layer which may protect the surface of the die cast product from environmental corrosion, and may improve the wear resistance, electric conductivity, thermal conductivity, and optical properties of the die cast product.
  • electroplating metals may be any known metal in the art, such as nickel, stannum, copper, silver, gold, or any combination thereof.
  • the metal plate may be made of aluminum, stainless steel, and/or any combination thereof. In one embodiment, the metal plate may have a thickness of about 0.1 -0.3 mm. In this way, deformations of the die cast product caused by high pressure and high temperature during the die casting step may be prevented.
  • a whole or a part of the outer surface of the die cast product may be treated by spray painting, electroplating, etching, or laser engraving according to the structure of the die cast product and the design of the casting mold.
  • the connecting portion of the die cast product may not be treated, and only the remaining portion of the die cast product may be treated, thus reducing the production cost.
  • the die casting step may be performed under conditions of: a mold temperature of about 180-280 ° C , an injection pressure of about 4-50 MPa, and a cooling time of about 2.0-6.0 s.
  • the injection pressure may be about 4.06-46.80MPa.
  • the mold may comprise a movable mold part and a fixed mold part. The temperature of the movable mold part may be higher than that of the fixed mold part. In one embodiment, the temperature of the movable mold part is 210-250 ° C , and the temperature of the fixed mold part is 190-230 ° C .
  • the raw material may be any known metal and/or metal alloy used in die cast products, such as zinc alloy, magnesium alloy, aluminum alloy, copper alloy, or tin-lead alloy.
  • a die cast product is also provided.
  • the die cast product may be formed by die casting a raw material and a metal plate integrally through the process described above.
  • the outer surface of the metal plate is previously subjected to at least one treatment selected from the group consisting of spray painting, electroplating, etching, and laser engraving. In this way, the die cast product may have rich and colorful appearance.
  • a process of preparing a die cast product using zinc alloy as a raw material comprises the following steps.
  • a structural drawing of the die cast product was designed, in which the location of a metal plate was determined.
  • a mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
  • An aluminum plate with a thickness of 0.1 -0.3 mm was stamped and machined. During the process, the dimensional tolerance of the aluminum plate was strictly controlled to ensure the machining precision.
  • a surface (also called decorated surface) of the aluminum plate was subjected to electroplating using the aluminum plate as a cathode and a plating metal as an anode, the aluminum plate was placed into a plating solution containing the plating metal, and a metal film was plated on the decorated surface of the aluminum plate through electrolysis.
  • the other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material.
  • the adhesive forms a layer with a thickness of about 0.05 mm.
  • the metal plate and zinc alloy were placed in corresponding locations of the mold and integrally die cast.
  • the die casting was performed under conditions of: a zinc alloy temperature of about 420-43CTC , a mold temperature of about 180-22CTC , an injection pressure of 4.06-9.61 MPa, and a cooling time of 2.0-3.0 s.
  • the temperature of the movable mold part was 210 ° C , which was higher than that of the fixed mold part, i.e., 190 ° C .
  • Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1200 meshes to meet the requirements of different customers.
  • a process of preparing a die cast product using zinc alloy as a raw material comprises the following steps.
  • a structural drawing of the die cast product was designed, in which the location of a metal plate was determined.
  • a mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
  • a stainless steel plate with a thickness of 0.1 -0.3 mm was stamped and machined.
  • a surface (also called decorated surface) of the stainless steel plate was subjected to electroplating using the stainless steel plate as a cathode and a plating metal as an anode, the stainless steel plate was placed into a plating solution containing the plating metal, and a metal film was plated on the decorated surface of the stainless steel plate through electrolysis.
  • the other surface of metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material.
  • the adhesive forms a layer with a thickness of about 0.05 mm.
  • the metal plate and zinc alloy were placed in corresponding locations of the mold and integrally die cast.
  • the die casting was performed under conditions of: a zinc alloy temperature of about 420-43CTC , a mold temperature of about 180-22CTC , an injection pressure of 4.06-9.61 MPa, and a cooling time of 2.0-3.0 s.
  • the temperature of the movable mold part was 210 ° C , which was higher than that of the fixed mold part, i.e., 190 ° C .
  • Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1500 meshes to meet the requirements of different customers.
  • a process for preparing a die cast product using magnesium alloy as a raw material comprises the following steps.
  • a structural drawing of the die cast product was designed, in which the location of a metal plate was determined.
  • a mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
  • a surface (also called decorated surface) of the aluminum plate was subjected to anodic oxidation to form an oxide film on the decorated surface of the aluminum plate, thus forming a metal plate with colorful appearance, improved density, good thermal resistance, and good wear resistance.
  • the other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material.
  • the adhesive forms a layer with a thickness of about 0.03 mm, thus preventing the influence on the appearance of the metal plate caused by the leakage of the adhesive during the die casting step.
  • the metal plate and magnesium alloy were placed in corresponding locations of the mold and integrally die cast to form the die cast product. During the die casting process, the parameters were well controlled to ensure fine appearance of the die cast product.
  • the die casting was performed under conditions of: a magnesium alloy temperature of about 600-65CTC , a mold temperature of about 210-27CTC , an injection pressure of 34.34-46.80MPa, and a cooling time of 3.0-5.0 s.
  • the temperature of the movable mold part was 250 ° C , which was higher than that of the fixed mold part, i.e. , 210 ° C .
  • Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1200 meshes to meet the requirements of different customers.
  • a process for preparing a die cast product using magnesium alloy as a raw material comprises the following steps.
  • a structural drawing of the die cast product was designed, in which the location of a metal plate was determined.
  • a mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
  • a stainless steel plate with a thickness of about 0.1 -0.3 mm was stamped and machined. During the process, the dimensional tolerance of the stainless steel plate was strictly controlled to ensure the machining precision.
  • a surface (also called decorated surface) of the stainless steel plate was subjected to anodic oxidation to form an oxide film on the decorated surface of the stainless steel plate, thus forming a metal plate with colorful appearance, improved density, good thermal resistance, and good wear resistance.
  • the other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material.
  • the adhesive forms a layer with a thickness of about 0.03 mm, thus preventing the influence on the appearance of the metal plate caused by the leakage of the adhesive during the die casting step.
  • the metal plate and magnesium alloy were placed in corresponding locations of the mold and integrally die cast to form the die cast product. During the die casting process, the parameters were well controlled to ensure fine appearance of the die cast product.
  • the die casting was performed under conditions of: a magnesium alloy temperature of about 600-650 ° C , a mold temperature of about 210-270 ° C , an injection pressure of 34.34-46.80MPa, and a cooling time of 3.0-5.0 s.
  • the temperature of the movable mold part was 250 ° C , which was higher than that of the fixed mold part, i.e. , 210 ° C .
  • a process for preparing a die cast product using aluminum alloy as a raw material comprises the following steps.
  • a structural drawing of the die cast product was designed, in which the location of a metal plate was determined.
  • a mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
  • An aluminum plate with a thickness of about 0.1 -0.3 mm was stamped and machined. During the process, the dimensional tolerance of the aluminum plate was strictly controlled to ensure the machining precision.
  • a surface (also called decorated surface) of the aluminum plate was sprayed with various kinds of paints to form a metal plate with rich and colorful visual effects.
  • the other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material.
  • the adhesive forms a layer with a thickness of about 0.04 mm, thus preventing the influence on the appearance of the metal plate caused by the leakage of the adhesive during the die casting step.
  • the metal plate and aluminum alloy were placed in corresponding locations of the mold and integrally die cast to form the die cast product. During the die casting process, the parameters were well controlled to ensure fine appearance of the die cast product.
  • the die casting was performed under conditions of: an aluminum alloy temperature of about 700-730 ° C , a mold temperature of about 220-260 ° C , an injection pressure of 34.34-46.80MPa, and a cooling time of 4.0-6.0 s.
  • the temperature of the movable mold part was 240 ° C , which was higher than that of the fixed mold part, i.e. , 230 ° C .
  • a process for preparing a die cast product using aluminum alloy as a raw material for die cast product comprises the following steps.
  • a structural drawing of the die cast product was designed, in which the location of a metal plate was determined.
  • a mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
  • a stainless steel plate with a thickness of about 0.1 -0.3 mm was stamped and machined. During the process, the dimensional tolerance of the stainless steel plate was strictly controlled to ensure the machining precision.
  • a surface (also called decorated surface) of the stainless steel plate was sprayed with various kinds of paints to form a metal plate with rich and colorful visual effects.
  • the other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material.
  • the adhesive forms a thickness of about 0.04 mm, thus preventing the influence on the appearance of the metal plate caused by the leakage of the adhesive during the die casting step.
  • the metal plate and aluminum alloy were placed in corresponding locations of the mold and integrally die cast to form the die cast product. During the die casting process, the parameters were well controlled to ensure fine appearance of the die cast product.
  • the die casting was performed under conditions of: an aluminum alloy temperature of about 700-730 ° C , a mold temperature of about 220-260 ° C , an injection pressure of 34.34-46.80MPa, and a cooling time of 4.0-6.0 s.
  • the temperature of the movable mold part was 240 ° C , which was higher than that of the fixed mold part, i.e., 230 ° C .
  • Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1500 meshes to meet the requirements of different customers.
  • the metal plate and the raw material are placed in corresponding locations of the mold, and integrally die cast to form the die cast product. Because the outer surface of the die cast product has been subjected to treatment, surface treatment for the final die cast product may be avoided, thus shortening the production cycle of forming the die cast product and reducing the production cost. Further, the die cast product is formed by integrally die casting the metal plate and the raw material, which may have advantages of both the metal plate and the raw material and may have rich and colorful appearance. The die cast product may be directly used as the shell of electronic products such as cell phones, MP3s or notebooks without surface treatment.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

A process of preparing a die cast product is provided. The process comprises the steps as follows: disposing a metal plate in a predetermined position within a mold; disposing a raw material of the die cast product onto the metal plate; and die casting the metal plate and the raw material integrally to form the die cast product. A die cast product prepared by the process is also provided. The product has advantages of the metal plate and the raw material. The process shortens the production cycle of forming the die cast product and reduces the production cost.

Description

DIE CAST PRODUCT AND PROCESS OF PREPARING THE SAME
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to, and benefits of Chinese Patent Application No. 201010214514.9 filed with State Intellectual Property Office, P. R. C. on June 25, 2010, the entire content of which is incorporated herein by reference.
FIELD
The present disclosure relates to a die cast product, and a process of preparing the same.
BACKGROUND
Die casting process is one of the most important methods for preparing shaped structural part of nonferrous metal. Products formed by die casting may have good properties such as high size precision, high density, high strength, high hardness, high recycling rate, and high production rate. Further, die cast products not only have advantages such as complex shapes, clear outlines, deep chambers and thin walls, but also may be produced mechanically and automatically.
However, die cast products have some disadvantages. Because of short filling time and fast cooling speed of molten alloys, gases in the mold chamber may not be discharged in time. Moreover, the feeding is very difficult, which may cause pores, concavities, and shrinkages on the surface of the die cast products.
Roughness caused by pores, concavities, and shrinkages on the surface of the die cast products brings great inconvenience to surface treatment for the die cast products. At present, surface treatment for the die cast products is quite limited, in which spray painting and electroplating are relatively practical until now. Spray painting not only may be complex, but also may cause shrinkages, pores, concaves, etc. on the painted surface of the die cast product. Moreover, as the concaves and pores may be only flatten by a paint layer with high thickness, not only the thickness and the appearance of the die cast products may be significantly influenced, but also the paints may be wasted. Sand holes, pores, and concaves on the surface of the die cast products after electroplating may cause a very low yield rate, which is about 50%.
As described above, conventional die cast products may have rough surfaces, and surface treatment for the die cast products is quite limited and not mature at present.
SUMMARY
In viewing thereof, the present disclosure is directed to solve at least one of the problems existing in the prior art. Accordingly, a process of preparing a die cast product and a die cast product prepared by the process are provided.
According to an aspect of the present disclosure, a process of preparing a die cast product is provided. The process may comprise the steps of: disposing a metal plate in a predetermined position within a mold; disposing a raw material of the die cast product onto the metal plate; and die casting the metal plate and the raw material integrally to form the die cast product.
According to another aspect of the present disclosure, a die cast product obtainable through the method described above is provided.
According to embodiments of the present disclosure, the metal plate and the raw material are placed in corresponding locations of the mold, and integrally die cast to form the die cast product. Because the outer surface of the die cast product has been subjected to treatment, surface treatment for the final die cast product may be avoided, thus shortening the production cycle of forming the die cast product and reducing the production cost. Further, the die cast product is formed by integrally die casting the metal plate and the raw material, which may have advantages of both the metal plate and the raw material and may have rich and colorful appearance.
Additional aspects and advantages of the embodiments of present disclosure will be given in part in the following descriptions, become apparent in part from the following descriptions, or be learned from the practice of the embodiments of the present disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENT
Reference will be made in detail to embodiments of the present disclosure. The embodiments described herein are explanatory, illustrative, and used to generally understand the present disclosure. The embodiments shall not be construed to limit the present disclosure.
According to an aspect of the present disclosure, a process of preparing a die cast product is provided. The process may comprise the steps of: disposing a metal plate in a predetermined position within a mold; disposing a raw material of the die cast product onto the metal plate; and die casting the metal plate and the raw material integrally to form the die cast product.
In one embodiment, the process further comprises a step of coating an adhesive on a surface of the metal plate to be contacted with the raw material prior to the die casting step. By doing this, the adhesion between the metal plate and the raw material may be enhanced. The adhesive may be any known one commercially available on the market. In one embodiment, the adhesive may form a layer having a thickness of about 0.03-0.05 mm, thus preventing adhesive leakages caused by high speed and high pressure during the die casting step, and consequently preventing the bad influence on the appearance of the die cat product.
In one embodiment, the process may further comprise a step of polishing the outer surface of the die cast product. The polishing step may be performed by using abrasive paper with suitable meshes, such as fine abrasive paper with about 1200-1500 meshes. In this way, the quality of the die cast product may be further improved to meet the requirements of different customers.
It has been found by the inventors that, the die cast product made of metal alloys such as zinc alloys may be blackened due to surface oxidation when directly exposed to the air without surface treatment. Accordingly, in one embodiment, the outer surface of the metal plate was previously subjected to at least one treatment selected from the group consisting of spray painting, electroplating, etching, and laser engraving. For example, electroplating may offer fine appearance to the die cast product and improve the density and the wear resistance of the die cast product. Spray painting may be used for decoration protecting and mark painting, and may also offer various colors to the die cast product. Etching may offer embossed stereoscopic effects to the die cast product by forming textures with different thickness on the outer surface of the die cast product. Laser engraving may carve various letters, signals, and patterns, and the size of the letters may range from millimeters to microns, which may play a special role in anti-counterfeiting. In one embodiment, the outer surface of an aluminum plate is subjected to anodic oxidation to form an oxidation film on the outer surface of the die cast product. The oxidation film may be a protective layer which may protect the surface of the die cast product from environmental corrosion, and may improve the wear resistance, electric conductivity, thermal conductivity, and optical properties of the die cast product. The above-mentioned treatments are ordinary in the prior art, and other treatments may also be used here. Different treatments may be adopted according to the requirements of different customers. In one embodiment, electroplating metals may be any known metal in the art, such as nickel, stannum, copper, silver, gold, or any combination thereof.
In one embodiment, the metal plate may be made of aluminum, stainless steel, and/or any combination thereof. In one embodiment, the metal plate may have a thickness of about 0.1 -0.3 mm. In this way, deformations of the die cast product caused by high pressure and high temperature during the die casting step may be prevented.
In one embodiment, a whole or a part of the outer surface of the die cast product may be treated by spray painting, electroplating, etching, or laser engraving according to the structure of the die cast product and the design of the casting mold. As some die cast products may be used as connectors in an assembly, the connecting portion of the die cast product may not be treated, and only the remaining portion of the die cast product may be treated, thus reducing the production cost.
In one embodiment, the die casting step may be performed under conditions of: a mold temperature of about 180-280°C , an injection pressure of about 4-50 MPa, and a cooling time of about 2.0-6.0 s. In one embodiment, the injection pressure may be about 4.06-46.80MPa. In one embodiment, the mold may comprise a movable mold part and a fixed mold part. The temperature of the movable mold part may be higher than that of the fixed mold part. In one embodiment, the temperature of the movable mold part is 210-250°C , and the temperature of the fixed mold part is 190-230°C .
In one embodiment, the raw material may be any known metal and/or metal alloy used in die cast products, such as zinc alloy, magnesium alloy, aluminum alloy, copper alloy, or tin-lead alloy. According to another aspect of the present disclosure, a die cast product is also provided. The die cast product may be formed by die casting a raw material and a metal plate integrally through the process described above. In one embodiment, the outer surface of the metal plate is previously subjected to at least one treatment selected from the group consisting of spray painting, electroplating, etching, and laser engraving. In this way, the die cast product may have rich and colorful appearance.
The present disclosure will be described in detail with reference to the following embodiments. EMBODIMENT 1
A process of preparing a die cast product using zinc alloy as a raw material comprises the following steps.
a) Preparing Casting Mold
A structural drawing of the die cast product was designed, in which the location of a metal plate was determined. A mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
b) Manufacturing Metal Plate
An aluminum plate with a thickness of 0.1 -0.3 mm was stamped and machined. During the process, the dimensional tolerance of the aluminum plate was strictly controlled to ensure the machining precision. A surface (also called decorated surface) of the aluminum plate was subjected to electroplating using the aluminum plate as a cathode and a plating metal as an anode, the aluminum plate was placed into a plating solution containing the plating metal, and a metal film was plated on the decorated surface of the aluminum plate through electrolysis.
c) Coating Adhesive
The other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material. The adhesive forms a layer with a thickness of about 0.05 mm.
d) Die Casting The metal plate and zinc alloy were placed in corresponding locations of the mold and integrally die cast. The die casting was performed under conditions of: a zinc alloy temperature of about 420-43CTC , a mold temperature of about 180-22CTC , an injection pressure of 4.06-9.61 MPa, and a cooling time of 2.0-3.0 s. The temperature of the movable mold part was 210°C , which was higher than that of the fixed mold part, i.e., 190°C .
e) Further Treatment
Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1200 meshes to meet the requirements of different customers.
EMBODIMENT 2
A process of preparing a die cast product using zinc alloy as a raw material comprises the following steps.
a) Preparing Casting Mold
A structural drawing of the die cast product was designed, in which the location of a metal plate was determined. A mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
b) Manufacturing Metal Plate
A stainless steel plate with a thickness of 0.1 -0.3 mm was stamped and machined.
During the process, the dimensional tolerance of the stainless steel plate was strictly controlled to ensure the machining precision. A surface (also called decorated surface) of the stainless steel plate was subjected to electroplating using the stainless steel plate as a cathode and a plating metal as an anode, the stainless steel plate was placed into a plating solution containing the plating metal, and a metal film was plated on the decorated surface of the stainless steel plate through electrolysis.
c) Coating Adhesive
The other surface of metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material. The adhesive forms a layer with a thickness of about 0.05 mm.
d) Die Casting The metal plate and zinc alloy were placed in corresponding locations of the mold and integrally die cast. The die casting was performed under conditions of: a zinc alloy temperature of about 420-43CTC , a mold temperature of about 180-22CTC , an injection pressure of 4.06-9.61 MPa, and a cooling time of 2.0-3.0 s. The temperature of the movable mold part was 210°C , which was higher than that of the fixed mold part, i.e., 190°C .
e) Further Treatment
Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1500 meshes to meet the requirements of different customers.
EMBODIMENT 3
A process for preparing a die cast product using magnesium alloy as a raw material comprises the following steps.
a) Producing Casting Mold
A structural drawing of the die cast product was designed, in which the location of a metal plate was determined. A mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
b) Manufacturing Metal Plate
An aluminum plate with a thickness of about 0.1 -0.3 mm was stamped and machined.
During the process, the dimensional tolerance of the aluminum plate was strictly controlled to ensure the machining precision. A surface (also called decorated surface) of the aluminum plate was subjected to anodic oxidation to form an oxide film on the decorated surface of the aluminum plate, thus forming a metal plate with colorful appearance, improved density, good thermal resistance, and good wear resistance.
c) Coating Adhesive
The other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material. The adhesive forms a layer with a thickness of about 0.03 mm, thus preventing the influence on the appearance of the metal plate caused by the leakage of the adhesive during the die casting step.
d) Die Casting The metal plate and magnesium alloy were placed in corresponding locations of the mold and integrally die cast to form the die cast product. During the die casting process, the parameters were well controlled to ensure fine appearance of the die cast product. The die casting was performed under conditions of: a magnesium alloy temperature of about 600-65CTC , a mold temperature of about 210-27CTC , an injection pressure of 34.34-46.80MPa, and a cooling time of 3.0-5.0 s. The temperature of the movable mold part was 250°C , which was higher than that of the fixed mold part, i.e. , 210°C .
e) Further Treatment
Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1200 meshes to meet the requirements of different customers.
EMBODIMENT 4
A process for preparing a die cast product using magnesium alloy as a raw material comprises the following steps.
a) Producing Casting Mold
A structural drawing of the die cast product was designed, in which the location of a metal plate was determined. A mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
b) Manufacturing Metal Plate
A stainless steel plate with a thickness of about 0.1 -0.3 mm was stamped and machined. During the process, the dimensional tolerance of the stainless steel plate was strictly controlled to ensure the machining precision. A surface (also called decorated surface) of the stainless steel plate was subjected to anodic oxidation to form an oxide film on the decorated surface of the stainless steel plate, thus forming a metal plate with colorful appearance, improved density, good thermal resistance, and good wear resistance.
c) Coating Adhesive
The other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material. The adhesive forms a layer with a thickness of about 0.03 mm, thus preventing the influence on the appearance of the metal plate caused by the leakage of the adhesive during the die casting step.
d) Die Casting
The metal plate and magnesium alloy were placed in corresponding locations of the mold and integrally die cast to form the die cast product. During the die casting process, the parameters were well controlled to ensure fine appearance of the die cast product. The die casting was performed under conditions of: a magnesium alloy temperature of about 600-650°C , a mold temperature of about 210-270°C , an injection pressure of 34.34-46.80MPa, and a cooling time of 3.0-5.0 s. The temperature of the movable mold part was 250°C , which was higher than that of the fixed mold part, i.e. , 210°C .
e) Further Treatment
Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1500 meshes to meet the requirements of different customers. EMBODIMENT 5
A process for preparing a die cast product using aluminum alloy as a raw material comprises the following steps.
a) Producing Casting Mold
A structural drawing of the die cast product was designed, in which the location of a metal plate was determined. A mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
b) Manufacturing Metal Plate
An aluminum plate with a thickness of about 0.1 -0.3 mm was stamped and machined. During the process, the dimensional tolerance of the aluminum plate was strictly controlled to ensure the machining precision. A surface (also called decorated surface) of the aluminum plate was sprayed with various kinds of paints to form a metal plate with rich and colorful visual effects.
c) Coating Adhesive
The other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material. The adhesive forms a layer with a thickness of about 0.04 mm, thus preventing the influence on the appearance of the metal plate caused by the leakage of the adhesive during the die casting step.
d) Die Casting
The metal plate and aluminum alloy were placed in corresponding locations of the mold and integrally die cast to form the die cast product. During the die casting process, the parameters were well controlled to ensure fine appearance of the die cast product. The die casting was performed under conditions of: an aluminum alloy temperature of about 700-730°C , a mold temperature of about 220-260°C , an injection pressure of 34.34-46.80MPa, and a cooling time of 4.0-6.0 s. The temperature of the movable mold part was 240°C , which was higher than that of the fixed mold part, i.e. , 230°C .
e) Further Treatment
Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1200 meshes to meet the requirements of different customers. EMBODIMENT 6
A process for preparing a die cast product using aluminum alloy as a raw material for die cast product comprises the following steps.
a) Producing Casting Mold
A structural drawing of the die cast product was designed, in which the location of a metal plate was determined. A mold was produced according to the structural drawing, in which the location of the metal plate was determined and a positioning device was placed to ensure the accurate positioning of the raw material and the metal plate.
b) Manufacturing Metal Plate
A stainless steel plate with a thickness of about 0.1 -0.3 mm was stamped and machined. During the process, the dimensional tolerance of the stainless steel plate was strictly controlled to ensure the machining precision. A surface (also called decorated surface) of the stainless steel plate was sprayed with various kinds of paints to form a metal plate with rich and colorful visual effects.
c) Coating Adhesive
The other surface of the metal plate was coated with an adhesive to improve the adhesion force between the metal plate and the raw material. The adhesive forms a thickness of about 0.04 mm, thus preventing the influence on the appearance of the metal plate caused by the leakage of the adhesive during the die casting step.
d) Die Casting
The metal plate and aluminum alloy were placed in corresponding locations of the mold and integrally die cast to form the die cast product. During the die casting process, the parameters were well controlled to ensure fine appearance of the die cast product. The die casting was performed under conditions of: an aluminum alloy temperature of about 700-730°C , a mold temperature of about 220-260°C , an injection pressure of 34.34-46.80MPa, and a cooling time of 4.0-6.0 s. The temperature of the movable mold part was 240°C , which was higher than that of the fixed mold part, i.e., 230°C .
e) Further Treatment
Slugs and sharps of the die cast product were grounded and polished by using abrasive paper with 1500 meshes to meet the requirements of different customers.
According to embodiments of the present disclosure, the metal plate and the raw material are placed in corresponding locations of the mold, and integrally die cast to form the die cast product. Because the outer surface of the die cast product has been subjected to treatment, surface treatment for the final die cast product may be avoided, thus shortening the production cycle of forming the die cast product and reducing the production cost. Further, the die cast product is formed by integrally die casting the metal plate and the raw material, which may have advantages of both the metal plate and the raw material and may have rich and colorful appearance. The die cast product may be directly used as the shell of electronic products such as cell phones, MP3s or notebooks without surface treatment.
Although explanatory embodiments have been shown and described, it would be appreciated by those skilled in the art that changes, alternatives, and modifications all falling into the scope of the claims and their equivalents can be made in the embodiments without departing from spirit and principles of the disclosure.

Claims

What is claimed is:
1 . A process of preparing a die cast product comprising the steps of:
disposing a metal plate in a predetermined position within a mold;
disposing a raw material of the die cast product onto the metal plate; and
die casting the metal plate and the raw material integrally to form the die cast product.
2. The process according to claim 1 , wherein a surface of the metal plate to be contacted with the raw material is previously coated with an adhesive.
3. The process according to claim 2, wherein the adhesive forms a layer having a thickness of 0.03-0.05mm.
4. The process according to claim 1 , wherein the outer surface of the metal plate was previously subjected to at least one treatment selected from the group consisting of spray painting, electroplating, etching, and laser engraving.
5. The process according to claim 1 , wherein the outer surface of the metal plate was previously subjected to anodic oxidation.
6. The process according to claim 1 , wherein the metal plate has a thickness of about 0.1 -0.3 mm.
7. The process according to claim 1 , wherein the metal plate is made of aluminum, stainless steel, or any combination thereof.
8. The process according to claim 1 , wherein the raw material is at least one select from zinc alloy, magnesium alloy, aluminum alloy, copper alloy, and tin-lead alloy.
9. The process according to claim 1 , further comprising a step of polishing the outer surface of the die cast product.
10. The process according to claim 9, wherein the step of polishing are performed by using abrasive paper.
11 . The process according to claim 1 , wherein the step of die casting is performed under conditions of: a mold temperature of about 180-280°C , an injection pressure of about 4-50 MPa, and a cooling time of about 2.0-6.0 s.
12. The process according to claim 1 , wherein the mold comprises a movable mold part and a fixed mold part, and the temperature of the movable mold part is higher than that of the fixed mold part.
13. The process according to claim 12, wherein the temperature of the movable mold part is about 210°C-250°C , and the temperature of the fixed mold part is about
190°C-230°C .
14. A die cast product obtainable through the method according to claim 1 .
PCT/CN2011/074107 2010-06-25 2011-05-16 Die cast product and process of preparing the same WO2011160508A1 (en)

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