PRODUCTION OF A COIL, PERMANENT MOLD FOR A COIL, AND COIL

Abstract

The invention relates to a method for producing a helix (2). A permanent mold with mold halves which can be joined together on a mold separation plane is provided. The mold halves of the permanent mold are joined together such that the permanent mold has a cavity, which defines the shape of the helix (2) or the shape of a bent-up helix, when the permanent mold is joined together. The specified helix (2) or the bent-up helix has a flattened profiled winding cross-section which has two opposite flat faces (2.1, 2.1′), an outer face and an inner face (2.3) opposite the outer face. The mold separation plane runs at least partly along the flat faces (2.1, 2.1′) from the inner face to the outer face (2.3), wherein the permanent mold has a bulge (2.5) which extends along the mold separation plane and protrudes into the cavity at least in a region in which the mold separation plane runs along one of the flat faces (2.1, 2.1′) such that the cast body is provided with recesses (2.5) on the flat faces (2.1, 2.1′). The invention further relates to a permanent mold for carrying out the method and to a helix which has been produced using the method or using the permanent mold.

Claims

1. A method for producing a helix, at least comprising the following steps: providing a permanent mold including a first mold half and a second mold half configured to be joined together in a mold parting plane; joining together the first mold half and the second mold half of the permanent mold in the mold parting plane so that the permanent mold, when joined, has a cavity that defines a form of the helix or a form of a bent-up helix, wherein the defined helix or bent-up helix has a flattened winding cross-section profile including: a first flat side; a second flat side located opposite to the first flat side; an outer side; and an inner side opposite the outer side; introducing a casting material into the cavity to produce a casting having the form of the helix defined by the cavity or the form of the bent-up helix; opening the permanent mold ROI; and removing the casting, wherein the first flat side and the second flat side of the casting face each other when the casting is in the form of the helix or is brought into the form of the helix, wherein a mold parting line sectionally runs along the first flat side and the second flat side from the inner side to the outer side, and wherein the permanent mold, at least in a portion where the mold parting line runs along at least one of the first flat side or the second flat side, has a protrusion extending along the mold parting line that projects into the cavity so that the casting contains a first indentation on the first flat side and a corresponding second indentation on the second flat side.

2. The method according to claim 1, wherein the permanent mold, in each portion where the mold parting line runs along the first of the flat side, includes a first set of multiple protrusions extending along the mold parting line protruding into the cavity, such that the casting includes, on the first flat side, with a corresponding first set of indentations running in the mold parting line.

3. The method according to claim 2, wherein the permanent mold, in each portion where the mold parting line runs along the second flat side, includes at least one of: a second set of multiple protrusions extending along the mold parting line, such that the casting includes a second set of indentations running in the mold parting line, or has multiple recesses extending along the mold parting line, such that the helical casting includes on the first flat side in the mold parting line with the first set of indentations, and on the second flat side in the mold parting line with protrusions, wherein the protrusions lie within the first set of indentations when the casting is in the form of the helix.

4. The method according to claim 1, wherein the casting is bent into the form of the helix after removal.

5. The method according to claim 1, wherein the casting material comprises at least one of: aluminum or copper.

6. The method according to claim 1, wherein the casting is performed at a temperature above 1100° C.

7. The method according to claim 1, wherein the casting is performed using a die casting method, a permanent mold casting method, or a low-pressure die casting method.

8. The method according to claim 1, wherein the mold parting line runs at least in sections along at least one of: the outer side, the inner side, or from edges of a winding cross-section profile, and burrs extending on at least one of: the outer side, the inner side or the edges of the casting in the mold parting line are removed after the casting has been removed.

9. The method according to claim 8, wherein the cavity, in at least one portion where the mold parting line runs along at least one of: the outer side, the inner side or the edges of the winding cross-section profile, include multiple additional indentations to produce multiple sacrificial structures which extend along at least one of: the outer side, the inner side, or the edges of the casting in the mold parting line, wherein the multiple sacrificial structures are removed in a reworking step after the casting has been removed, together with the burrs that run along them.

10. The method according to claim 8, wherein a mandrel is inserted into the bent-up helix in order to at least one of: remove the burrs on the inner side or to bend together the bent-up helix to form the helix.

11. The method according to claim 8, wherein the mold parting line encloses an angle (α) of more than 0° and less than 180° with at least one of the outer side or the inner side.

12. A permanent mold for casting a helix, comprising: a first mold half; and a second mold half; wherein, the first mold half and the second mold half are configured to be joined together in a mold parting plane, the mold parting plane forming a mold parting line, wherein the first mold half and the second mold half, when joined, have a cavity that defines, for the casting, a form of at least one of the helix or a bent-up helix with a flattened winding cross-section profile, wherein the winding cross-section profile has a first flat side and a second flat side located opposite the first flat side, an outer side, and an inner side located opposite the outer side, wherein the first flat side and the second flat side face one another when the casting is in the form of the helix or is brought into the form of the helix, wherein the mold parting line, within each winding of the helix or bent-up helix defined by the cavity, runs along the first flat side and the second flat side from the inner side to the outer side, and wherein the cavity, at least in one portion where the mold parting line runs along the first flat side and the second flat side, has a protrusion extending along the mold parting line.

13. A cast helix comprising: a flattened winding cross-section profile, the flattened winding cross-section profile including: a first flat side; a second flat side located opposite the first flat side; an outer side; and an inner side opposite the outer side; wherein the first flat side and the second flat side face one another.

14. The cast helix according to claim 13, wherein multiple indentations running from the outer side to the inner side are located at least on one of the first flat side or the second flat side.

15. The cast helix according to claim 14, wherein either the indentations located on the second flat side, or multiple protrusions running from the outer side to the inner side are provided on the second flat side and project into the indentations located on the first flat side.

16. The permanent mold of claim 12, wherein the mold parting line runs at least in sections along at least one of: the outer side, the inner side, or from a first edge or a second edge of a winding cross-section profile.

17. The permanent mold of claim 12, wherein the mold parting line includes a set of multiple protrusions extending along the mold parting line protruding into the cavity, such that the casting includes, on the first flat side, with a corresponding set of indentations running in the mold parting line.

18. The permanent mold of claim 17, wherein in each portion where the mold parting line runs along the second flat side, the mold includes: a second set of multiple protrusions extending along the mold parting line such that the casting includes a second set of indentations running in the mold parting line.

19. The permanent mold of claim 17, wherein in each portion where the mold parting line runs along the second flat side, the mold includes: multiple recesses extending along the mold parting line such that the casting includes, on the first flat side in the mold parting line with the first set of indentations, and on the second flat side of the mold parting line with protrusions located to lie within the first set of indentations when the casting is in the form of the helix.

20. The permanent mold of claim 12, wherein the casting material comprises at least one of aluminum or copper.

Description

[0045] In the drawings

[0046] FIGS. 1 a-c show a casting in the form of a helix,

[0047] FIG. 1 d shows the casting in the form of a bent-up helix,

[0048] FIGS. 2 a-c, 3 and 4 show the casting within a cavity of a permanent mold,

[0049] FIGS. 5 a-c show cross-sectional views of the casting within the cavity of the permanent mold,

[0050] FIGS. 6 a and b show a finishing of the casting after removal from the permanent mold,

[0051] FIGS. 7 a and b show one mold half of the permanent mold with additional protrusions, and

[0052] FIGS. 8, 9 and 10 a and b show the casting with indentations on flat sides.

[0053] FIGS. 1 a-d show a casting which is in the form of a helix 2 in FIGS. 1 a-c and in the form of a bent-up helix 2′ in FIG. 1d. From the form shown in FIG. 1d, the casting may be bent over into the form of the helix 2 (as shown in FIG. 1a-c).

[0054] FIG. 1a shows an oblique view of the casting as a helix 2, FIG. 1b a side view, and FIG. 1c a plan view. The helix has a flattened winding cross-section profile. In the present case, the winding cross-section profile is rectangular and has two opposite flat sides 2.1, 2.1′, an outer side 2.2, and an inner side 2.3 opposite the outer side 2.2. An inner cavity of the helix 2, which is surrounded by the windings and delimited by the inner side 2.3, is also rectangular.

[0055] The outer dimensions of the helix, running around the outer side 2.2, are also rectangular or cuboid.

[0056] For the helix, adjacent windings may be defined such that each winding describes a complete revolution around the inner cavity of 360°. Seven windings are shown.

[0057] The winding cross-section as well as the embodiment of the cavity cannot be achieved by winding.

[0058] External dimensions of the helix in each direction may be, for example, between 2 cm and 20 cm.

[0059] This application relates firstly to the type of casting shown here as a helix or bent-up helix.

[0060] The helix may advantageously be produced by methods to which this application also relates. Furthermore, the helix may be advantageously produced with the aid of permanent molds, to which this application also relates. The helix, method and permanent mold are described in further detail below with reference to the remaining figures.

[0061] FIG. 2 shows the casting during a step of the method for its production, within a cavity 1.3 of a permanent mold 1. Only one mold half 1.1 of the permanent mold 1 is shown. A second mold half 1.2 of the permanent mold 1 is constructed in a manner complementary to the first mold half 1.1 and has been omitted for better illustration in FIG. 2. The second mold half is designed in such a way that the first mold half 1.1 and the second mold half 1.2 may be joined in a mold parting line 1.5 and the cavity 1.3 extends between the two mold halves. The course of the cavity 1.3 can be seen in the figure by the shown casting, which has the form of the helix 2 and fills the cavity 1.3. The features of the helix 2 may be transferred accordingly to the cavity 1.3 and vice versa. In other words, the cavity is also rectangular in shape and has the opposing flat sides 2.1, 2.1′, the outer side 2.2, and the inner side 2.3 opposite the outer side 2.2.

[0062] Furthermore, this figure thus also shows the shape of the second mold half 1.2.

[0063] The helix 2 is only slightly pulled apart but not bent up and otherwise has the features shown in FIG. 1.

[0064] As can be seen in the figure, the mold parting line 1.5 runs at least in sections along the outer side 2.2, along the inner side 2.3, as well as along edges of the winding cross-section profile. In particular, it extends in areas parallel to the inner side 2.3 and the outer side 2.2. It passes over each of the two flat sides 2.1, 2.1′ twice within each winding.

[0065] To produce the casting, a casting material is poured into the cavity 1.3 of the permanent mold 1. The permanent mold 1 has a corresponding opening for this purpose. Die casting, permanent mold casting or low-pressure die casting methods may be used. The casting material comprises aluminum and/or copper. A casting temperature is above 1100° C.

[0066] It is possible for casting material outside the cavity 1.3 to enter the mold parting line 1.5 between the two mold halves 1.1, 1.2. This may cause burrs 3. The position of the burrs 3 may thus be deduced from the course of the mold parting line 1.5. Possible burrs 3 thus extend in the casting removed from the permanent mold shown in FIG. 2, starting from the outer side 2.2 or the inner side 2.3 parallel to the outer side 2.2 or inner side 2.3, respectively, and in regions in which the mold parting line 1.5 runs along the flat sides 2.1, 2.1′, along the corresponding flat side 2.1, 2.1′ and orthogonally thereto.

[0067] FIGS. 2b and 2c each show the view from FIG. 2a again, with two areas marked in each case, for which sections through the helix 2 are shown enlarged below the respective views. The position and orientation of the possible burrs 3 are illustrated in the sections. As shown in connection with FIG. 2a, they extend from inner and outer edges on the outer side 2.2 and the inner side 2.3 due to the course of the parting line 1.5. They run parallel to the outer side 2.2 and the inner side 2.3, in each case only in the direction of one of the flat sides 2.1, 2.1′.

[0068] The burrs are removed in a method step after the casting has been removed from the permanent mold 1. Due to their location, removal is easy.

[0069] In FIG. 2c, it is also shown that the cavity 1.3 has additional indentations extending along the entire outer side 2.2 and the entire inner side 2.1, including the respective edges. The indentations are used to produce sacrificial structures 2.4, of the helical casting. They run in the mold parting line 1.5 in such a way that the burrs 3 run at least in some areas along the sacrificial structures 2.4. The sacrificial structures are removed in a finishing step after the casting has been removed, together with the burrs 3 that run along them.

[0070] FIGS. 3 and 4 show permanent molds 1 with cavities 1.3 designed so that the casting produced therein has the form of the bent-up helix 2′, which is bent into the form of the helix 2 after removal. Again, in each case, only the first mold half 1.1 is shown and the second mold half 1.2 is omitted for reasons of visibility. The bent-up helix 2′ may be produced here with only two mold halves and without the use of cores or slides.

[0071] To produce the casting, a casting material is poured into the cavity 1.3 of the permanent mold 1. The permanent mold 1 has a corresponding opening for this purpose. Die casting, permanent mold casting or low-pressure die casting methods may be used. The casting material comprises aluminum and/or copper. A casting temperature is above 1100° C.

[0072] The mold parting line 1.5, a part of which is shown in an exemplary manner in FIGS. 3 and 4, has in the case of FIG. 3 an angle α of approximately 45° to both the outer side 2.2 and the inner side 2.3 of the bent-up helix 2′. Accordingly, possible burrs 3, one of which is shown by way of example, extend away from the outer side 2.2 or the inner side 2.3, respectively, at this angle α. This is in contrast to the embodiment shown in FIG. 2, where the burrs 3 run parallel to the outer side 2.2 or inner side 2.3, respectively. This has the effect that the burrs 3 may be removed even more easily. In FIG. 4, the mold parting line 1.5 is such that the angle α of the burrs 3 to the inner side 2.3 is approximately 45° and to the outer side 90°.

[0073] FIG. 5 shows sections through the two mold halves 1.1, 1.2 of the permanent mold 1 and the casting lying in the cavity 1.3 formed between them, illustrating in particular the mold parting line 1.5 and its position in relation to the casting. This may be the casting in the form of the helix 2 or in the form of the bent-up helix 2′.

[0074] In the area of the section shown in FIG. 5a (it may be, for example, a section through the configuration of FIG. 3), the angle α between the outer side 2.2 and the mold parting line 1.5 is approximately 45°. The mold parting line 1.5 extends here from an edge located on the outer side 2.2. The angle α between the inner side 2.2 and the mold parting line 1.5 is also approx. 45° and the mold parting line 1.5 extends here from an edge lying on the inner side 2.2.

[0075] In the area of the section shown in FIG. 5b (it may be, for example, a section through the configuration of FIG. 4), the mold parting line 1.5 again extends starting from edges located on the inner side 2.3 or outer side of the casting or cavity 1.3. The angle α between the inner side 2.3 and the mold parting line 1.5 is approx. 45°. The angle α between the outer side 2.2 and the mold parting line 1.5 is approx. 90°.

[0076] FIG. 5c shows a variation of the illustration in FIG. 5b. In this case, the mold parting line 1.5 does not extend directly from the edge of the casting on the outer side, but adjoins a sacrificial structure 2.4, which is provided as additional casting material arranged on the outer side 2.2 and may then be removed together with a possible burr 3.

[0077] Therefore, in all configurations from FIGS. 5 a to c, the mold parting line 1.5 encloses an angle of more than 0 degrees and less than 180 degrees with the outer side 2.2 and/or the inner side 2.3, and is therefore not parallel to either side.

[0078] FIG. 6 shows how, in a method according to this application, burrs 3 located on the inner side 2.3 of the casting are removed. The burrs extend into the inner cavity of the casting when it is in the form of the helix 2. To remove the burrs, a mandrel 4 is inserted into the inner cavity, which has the dimensions of the inner cavity. Any excess material extending from the casting into the inner cavity is thereby bent over or removed. This excess material comprises in particular the burrs 3. Furthermore, as shown here, it may comprise sacrificial structures 2.4 positioned on the inner side 2.3 of the helix 2. The mandrel 4 may be inserted into the inner cavity even if the casting is initially, after removal from the permanent mold 1, in the shape of the helix 2, but slightly pulled apart. Similarly, the mandrel 4 may be inserted into the inner cavity if the casting is initially in the form of the bent-up helix 2 after removal from the permanent mold 1. The mandrel 4 has a flat part at one end which engages the flat side 2.1′ and may bend the casting, with simultaneous counterpressure from the other flat side 2.1, into the form of the helix.

[0079] FIG. 7 shows the first mold half 1.1 of the permanent mold 1 with the cavity 1.3. FIG. 7 a shows an oblique view from the side and FIG. 7 b an oblique view from above. Here, the permanent mold 1 has protrusions 1.4 extending along the mold parting lines 1.5 in some of the areas where the mold parting line 1.5 runs along one of the flat sides 2.1, 2.1′, which project into the cavity 1.3 and taper it. The casting produced with this permanent mold 1 thus has corresponding indentations 2.5 on the flat sides 2.1, 2.1′, which are complementary to the protrusions 1.4 and run from the inner side 2.3 to the outer side 2.2. Since the mold parting line 1.5 runs along this protrusion 1.4, the burrs 3 may be laid in the indentations 2.5 with this permanent mold.

[0080] The described embodiment is also possible for tools that otherwise have the features from FIGS. 2-5.

[0081] To produce the casting, a casting material is poured into the cavity 1.3 of the permanent mold 1. The permanent mold 1 has a corresponding opening for this purpose. Die casting, permanent mold casting or low-pressure die casting methods may be used. The casting material comprises aluminum and/or copper. A casting temperature is above 1100° C.

[0082] FIGS. 8 and 9 illustrate castings produced, for example, with the permanent mold 1 of FIG. 7. They have the indentations 2.5 on one or both of the flat sides 2.1, 2.1′.

[0083] FIG. 8 shows sections of windings of the casting in which indentations are arranged on the first flat side 2.1. The indentations 2.5 run orthogonally to the edges of the casting, connecting the outer side 2.2 and the inner side 2.3. The position of possible burrs 3 is indicated in FIG. 8. According to the embodiment of the permanent mold 1 shown in FIG. 7, they run diagonally through the indentations 2.5 and are thus harmless, since they do not touch the second flat side 2.1′ even when the casting is compressed as a helix 2. In the area of the edges, when the mold parting line 1.5 and thus the burrs 3 come into the area of the outer side 2.2 or inner side 2.3, the mold parting line 1.5 and thus the burr 3 are guided along the edge and may be removed in a finishing step, together with any sacrificial structures 2.4 present there. In FIG. 8, no indentation 2.5 is provided on the second flat side 2.1′, since burrs 3 running there are predetermined by the mold parting line 1.5 in such a way that they project into the recesses 2.5 of the first flat side 2.1 when the helix 2 is compressed and are thus also harmless.

[0084] FIG. 9 illustrates further possible embodiments in which burrs 3 lying on flat sides are rendered harmless by indentations 2.5.

[0085] At the top of the figure, the helix 2 is shown in the side view from FIG. 1 b. In this side view, an area Z is marked, which is shown enlarged at the bottom in FIG. 9 for three embodiments (i), (ii), (iii) of the helix.

[0086] The center of FIG. 9 shows the plan view from FIG. 1c, in which the course of the mold parting line 1.5 and thus the course of the burrs 3 over the flat sides 2.1, 2.1′, from the outer side 2.2 to the inner side 2.3, is shown. It is precisely this burr 3 that is now shown enlarged below in the figure for the three embodiments (i), (ii), (iii).

[0087] Embodiment (i) is an embodiment in which there is no indentation 2.5 at all. In such embodiments, the burrs 3 may have to be removed in a finishing step on the outer side 2.2 and/or inner side 2.3 and/or the flat sides 2.3.

[0088] Embodiment (ii) shows an indentation 2.5 on only one flat side 2.1′. The burr 3 runs on both flat sides 2.1, 2.1′ within this indentation 2.5, wherein the burr 3 on one flat side 2.1 is offset with respect to the other flat side 2.1′ in such a way that the burrs 3 of the flat sides 2.1, 2.1′ facing one another do not touch even when the helix 2 is completely compressed as shown here.

[0089] Embodiment (iii) is an embodiment in which indentations 2.5 are present on both flat sides 2.1, 2.1′. The burrs 3 are offset from each other as in (ii) and cannot touch. In this embodiment, even larger burrs 3 may be tolerated than in (ii).

[0090] FIG. 10 again shows the helix 2, in which burrs running along flat sides are to be rendered harmless. The view is selected as in FIG. 9 at the bottom.

[0091] Similarly to embodiment (iii), FIG. 10 a has indentations 2.5 on both flat sides 2.1, 2.1′. The corresponding permanent mold 1 thus has protrusions 1.4 complementary to the indentations 2.5 on both flat sides 2.1, 2.1′.

[0092] In contrast, the embodiment shown in FIG. 10 b has indentations 2.5 on the flat side 2.1′, but protrusions 2.6 on the other flat side 2.1. These protrusions 2.6 of the helix 2 are positioned similarly to the indentations 2.5, i.e. they run along the mold parting line 1.5. Burrs 3 therefore also extend along the protrusions 2.6. When the helix 2 is compressed as shown in FIG. 10 b, the protrusions 2.6 and the burrs 3 located thereon are pressed into the indentations 2.5. The dimensions of the protrusions 2.6 are smaller here than the dimensions of the indentations 2.5, so that the protrusions 2.6 and the burrs 3 may be accommodated in the indentations 2.5. The additional material provided in the form of protrusions 2.6 on the flat side 2.1 may at least partially compensate for a loss of cross section. For the production of such a casting as shown in FIG. 10 b, the permanent mold 1 has recesses on one of the flat sides 2.1, 2.1′ which extend in the mold parting line 1.5 and, by correspondingly enlarging the cavity 1.3, define the protrusions 2.6. On the other of the two flat sides 2.1, 2.1′, on the other hand, it has the protrusions 1.4 that define the indentations 2.5.

LIST OF REFERENCE NUMERALS

[0093] 1 permanent mold [0094] 1.1 first mold half [0095] 1.2 second mold half [0096] 1.3 cavity [0097] 1.4 protrusion of the permanent mold [0098] 1.5 mold parting line [0099] 2 helix [0100] 2′ bent-up helix [0101] 2.1, 2.1′ flat side [0102] 2.2 outer side [0103] 2.3 inner side [0104] 2.4 sacrificial structure [0105] 2.5 indentation [0106] 2.6 protrusion [0107] 3 burr [0108] 4 mandrel