CASTING MOLD FOR PRODUCING A CASTING HAVING A FRONT SIDE AND A REAR SIDE FROM A CURABLE CASTING COMPOUND

Abstract

A casting mold for producing a casting having a front side and a rear side from a curable casting compound, including at least a first mold part shaping the front side and a second mold part shaping the rear side, the mold parts together delimiting a casting cavity. A slide device, provided on one of the mold parts, includes a slide portion that can be driven into the casting cavity and on which a detachable insert part is or can be arranged. The insert part is able to be moved abutting against the opposite mold part and is able to be embedded into the curing casting compound, and is detached from the slide portion when the latter is moved back.

Claims

1. A casting mold for producing a casting having a front side and a rear side from a curable casting compound, comprising at least a first mold part shaping the front side and a second mold part shaping the rear side, said mold parts together delimiting a casting cavity, comprising a slide device, provided on one of the mold parts, comprising a slide portion which can be driven into the casting cavity and on which a detachable insert part is or can be arranged, said insert part being able to be moved abutting against the opposite mold part and being able to be embedded into the curing casting compound, and being detached from the slide portion when the latter is moved back.

2. The casting mold according to claim 1, wherein the mold part comprising the slide device has, on the side delimiting the casting cavity, a recess in which the slide portion is received and out of which the slide portion is at least partially movable.

3. The casting mold according to claim 2, wherein the slide portion has an encircling sealing element which provides sealing with respect to the wall of the recess.

4. The casting mold according to claim 2, wherein the insert part has a base plate and an encircling flange which peripherally adjoins said base plate, wherein, in the assembled position, the base plate sits on a supporting portion of the slide portion and the flange engages into an encircling receiving rabbet in the slide portion and is at least partially received in the recess.

5. The casting mold according to claim 2, wherein the recess and the slide portion are cylindrical, and in that the insert part has a round base plate and an annular flange which engages into an annular rabbet in the slide portion, or in that the recess and the slide portion have a cross-sectional shape which deviates from a circular shape, wherein the insert part has a base plate which is shaped correspondingly to this cross-sectional shape and a flange which engages into a receiving rabbet in the slide portion.

6. The casting mold according to claim 4, wherein the base plate is arranged flush with a peripheral surface, delimiting the recess, of that side of the mold part which delimits the casting cavity.

7. The casting mold according to claim 4, wherein the flange, in particular the annular flange, bears in sealing abutment against the wall of the recess at least when the insert part is in the position bearing against the other mold part.

8. The casting mold according to claim 7, wherein the receiving rabbet has a chamfer against which the free end of the flange bears, wherein, during the movement of the slide portion in the direction of the other mold part or upon contact against the other mold part, the flange slides along the chamfer of the rabbet and widens in encircling fashion against the wall.

9. The casting mold according to claim 8, wherein the wall thickness of the flange is reduced at its free end.

10. The casting mold according to claim 2, wherein the recess has, at the end facing the casting cavity, an encircling sealing edge which bears sealingly against the inserted insert part.

11. The casting mold according to claim 1, wherein the insert part has a chamfer at its facing outer edge in the position bearing against the other mold part.

12. The casting mold according to claim 1, wherein the slide device is also used as an ejector device for lifting off the cured casting from the mold part.

13. The casting mold according to claim 12, wherein a compressed-air distributing device is provided on the slide device and can be used to conduct compressed air onto the lower side of the insert part, said lower side being seated on the slide portion.

14. The casting mold according to claim 1, wherein the insert part is composed of a plastic, in particular of polypropylene.

15. The casting mold according to claim 1, wherein the first mold part has a first metal layer delimiting the casting cavity and the second mold part has a second metal layer delimiting the casting cavity.

16. The casting mold according to claim 15, wherein the recess is formed in one of the two metal layers.

17. The casting mold according to claim 1, wherein at least one or the metal layer of the mold part against which the insert part is moved is at least partially deformable for the purpose of changing the volume of the casting cavity, or in that at least one mold part is movable relative to the other mold part for the purpose of changing the volume of the casting cavity.

18. The casting mold according to claim 17, wherein the mold part has an areal intermediate layer which is composed of an elastically deformable and compressible material and against which the metal layer of the mold part is movable with build-up of a restoring force on the part of the deforming intermediate layer.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0032] FIG. 1 shows a diagrammatic illustration of a casting mold according to the invention in the closed state,

[0033] FIG. 2 shows the view of the lower mold part with the insert part not yet placed,

[0034] FIG. 3 shows the arrangement from FIG. 2 with the insert part placed,

[0035] FIG. 4 shows a sectional view through the insert part from FIGS. 2 and 3,

[0036] FIG. 5 shows a plan view of the insert part from FIG. 4,

[0037] FIG. 6 shows an enlarged partial view of region VI in FIG. 2,

[0038] FIG. 7 shows an enlarged partial view of region VII in FIG. 2,

[0039] FIG. 8 shows an enlarged partial view of a part of the lower mold part illustrating a part of the slide device, and

[0040] FIG. 9 shows a diagrammatic illustration of a further embodiment of a casting mold according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0041] FIG. 1 shows a diagrammatic illustration of a casting mold 1 according to the invention which is used to produce a casting, having a front side and a rear side, in the form of a kitchen sink consisting of a composite material. The casting mold 1 comprises a first mold part 2 which is used to shape or define the front side of the casting to be produced, and a second mold part 3 which is used to shape or define the rear side of the casting to be produced. Both mold parts 2, 3 bear peripherally against one another and delimit a casting cavity 4 into which a casting compound consisting of a curable polymer compound, that is to say a reaction compound, into which particulate fillers such as quartz sand and the like are introduced, can be introduced under pressure. To this end, a filling opening 35 is provided on the second, upper mold part 3 and can be used to introduce the casting compound into the casting cavity 4. While the first mold part 2 is positionally fixed, the second mold part 3 can be moved vertically, that is to say can be placed onto the lower first mold part 2 for the purpose of closing the casting cavity 4.

[0042] The casting cavity 4 is delimited by a first metal layer 5, which is arranged on the first mold part 2, and a second metal layer 6, which is arranged on the second mold part 3. Both metal layers are preferably nickel sheets. The introduced casting compound comes into contact with these two metal layers 5, 6, that is to say bears against these two metal layers 5, 6 in an areal manner. In this case, a first heating device 7, which covers the rear side of the first metal layer 5 in a virtually full-area manner, is arranged on the rear side of the metal layer 5. This heating device 7 can be used the temperature of the first metal layer 5, and said first metal layer can be used to heat the casting compound from the front side. The second mold part also has a second heating device 8 which is arranged on the rear side of the second metal layer, so as to ultimately cover it in a full-area manner. The second heating device 8 can be used to control the temperature of the second metal layer 6, and said second metal layer can be used to control the temperature of the casting compound, consequently it is thus possible to control the heat input into the casting compound from the rear side. The second heating device 8 is followed by an elastic and compressible intermediate layer 9, preferably composed of a foam rubber, which elastic, compressible intermediate layer constitutes a restoring means or restoring element which makes a certain degree of movability of the second metal layer 6 possible and which at the same time ensures that the second metal layer 6 can be returned back into a defined starting position.

[0043] If the casting operation is commenced, the second metal layer 6 is in its starting position, and the casting cavity 4 has a defined starting volume. The second metal layer 6 is at a defined spacing to the first metal layer 5, and the intermediate layer 9 is relaxed or compressed only to a slight extent, if at all. At the beginning of the casting operation, the casting compound, which may for example be a sufficiently flowable compound based on polyacrylate or polymethacrylate, is introduced into the casting cavity at a pressure of about 2-5 bar. As a result of the casting pressure, a correspondingly high surface pressure builds up in the direction of the two metal layers 5, 6. The position of the first metal layer 5 does not change, since it is supported directly on a first mold part carrier 10. By contrast, the second metal layer 6 evades the pressure which is building up, since it is supported via the intermediate layer 9 on the second mold part carrier 11. The volume of the casting cavity can consequently be increased due to the high injection pressure. The polymerization process is then initiated, usually by actuating the first heating device 7. Both the first heating device 7 and the second heating device 8 are tubular, hose-like heating elements which are laid, for example, in a meandering manner and through which a temperature-control fluid is guided. The heating elements are embedded into an appropriate thermally conductive compound. Heating of the casting compound in the casting cavity 4 occurs, said casting compound increasing in volume to some extent as a consequence of the temperature, which leads to further compression of the intermediate layer 9. If the local heating at the interface to the first metal layer 5 is so great that a polymerization start temperature is reached, the exothermic polymerization reaction begins at this interface, that is to say that the polymer matrix is polymerized to completion, wherein the polymerization front gradually migrates into the casting compound, that is to say moves in the direction of the second metal layer. In this case, the temperature of the second metal layer is also controlled in due course by way of the second heating device 8, in order to also control the polymerization reaction from this side. Because it is exothermic, the reaction progresses automatically from both sides within the volume.

[0044] The polymerization is also accompanied by shrinkage of the casting compound or of the polymerization body being produced, thus by a reduction in volume. In order to ensure that the casting compound or the completely polymerized outer skin of the casting is always in contact with both metal layers, the second metal layer 6 is then automatically moved by way of the compressed intermediate layer 9, which is relaxed and restored, that is to say the second metal layer 6 tracks the shrinkage, so as to compensate for it. The integration of the elastic, compressible intermediate layer 9 accordingly enables automatic adjustment, in order to achieve shrinkage compensation.

[0045] As described, the two mold parts 2, 3 also consist of corresponding mold part carriers 10, 11 which each consist of a polymer concrete, consisting of a polymer matrix containing embedded fillers such as gravel or sand particles or the like. The corresponding heating devices 7, 8 are connected to these mold part carriers 10, 11 by way of the corresponding thermally conductive compounds, or, in the case of the second mold part 3, by way of the elastic intermediate layer 9.

[0046] Provision is furthermore made of a slide device 12 which is used to form an aperture in the finished casting during the molding operation. This slide device comprises a slide portion 13 which can be driven into the casting cavity 4 and which, proceeding from FIG. 1, can be displaced vertically, which is effected by means of compressed air fed in via a suitable connection 14. The slide portion 13 is arranged on a corresponding piston rod 15 which can be displaced axially. The piston rod 15, for its part, is arranged in a suitable rod receptacle 16, which is in turn connected to the actual cylinder 17 into which the compressed air is introduced, and in which the corresponding piston or pistons connected to the piston rod are also provided. The cylinder 17, for its part, is screwed by way of suitable screw connections 18 to the rod receptacle 16 which, for its part, is again screwed by way of suitable screw connections 19 to the metal layer 5, which is reinforced in this region.

[0047] The metal layer 5 itself has a cylindrical recess 20 in which the cylindrical slide portion 13 is received. Arranged on the slide portion 13 is (see, in this regard, also the enlarged view according to FIG. 8) an encircling sealing element 21 which provides sealing with respect to the wall 22 of the recess 20.

[0048] In the working situation shown in FIG. 1, a cylindrical insert part 23, preferably composed of polypropylene, is placed on the slide portion 13 and completely covers the top side of the slide part 13. In the working position of the slide device 12 or of the slide portion 13 shown in FIG. 1, the latter is extended out of a non-working position, which will be described below, and driven into the casting cavity 4 filled with the casting compound, wherein the planar, free top side of the insert part 23 bears against the opposite metal layer 6, such that the insert part 23, the lower periphery of which is still received in the recess 20 even in the working position, produces an in this case cylindrical aperture in the casting compound which has not yet polymerized to completion. If the polymerization reaction subsequently begins, the insert part 23 is firmly embedded into the completely polymerized casting. The pushing down of the metal layer 6 by the elastic intermediate layer 9 for the shrinkage compensation ensures that the casting compound permanently laterally embeds the insert part. The slide device 12 or the slide portion 13 can also implement any shrinkage compensation during the polymerization operation, that is to say that the movement of the metal layer 6 against which the insert part 23 bears is also implemented by the slide portion 13 and it is pushed back slightly.

[0049] After complete polymerization, the slide portion 13 is moved vertically downward once the upper mold part 3 has been lifted off. Here, the insert part 23 which is firmly embedded in the casting is separated from the slide portion 13, and the insert part 23 remains in the casting which is then demolded.

[0050] FIG. 2 shows, in the form of an exploded view, the lower mold part 3 with the slide portion 13 in the non-working position. As FIG. 1 clearly shows, said slide portion is located inside the recess 20, that is to say is completely retracted, and its bottom side rests on the base 24 of the recess 20. The insert part 23 has not yet been placed, and it is located at a distance from the slide portion 13 and is placed thereon manually. This situation is shown in FIG. 3.

[0051] In FIG. 3, the insert part 23 sits firmly on the slide portion 13. In this situation, the second, upper mold part 3 can then be lowered and placed, after which the actual casting process as described above can begin.

[0052] The insert part 23 is of virtually lid-like embodiment and has an annular-disk-like base plate 25 (see, in this regard, also FIGS. 4 and 5) which is adjoined by an encircling annular flange 26. The insert part 23 engages by way of this annular flange 26 into a corresponding receiving rabbet, which is embodied here as an annular rabbet 27, in the slide portion 13, as is in particular shown by a comparison of FIGS. 2 and 3. For the insertion, the insert part 23 is placed from above onto the slide portion 13, such that the annular flange 26 engages into the annular rabbet 27, while the base plate 25 sits on the top side of the slide portion 13.

[0053] Details of the insert part 23 and of the slide portion 13 and of the metal layer 6 in the region of the recess 20 can be gathered from FIGS. 6 and 7.

[0054] FIG. 6 shows an enlarged partial view of region VI from FIG. 2. Part of the metal layer 6 in the region of the recess 20 and part of the slide portion 13 in the region of the annular rabbet 27 are shown. The annular rabbet 27 has a chamfer 28, that is to say a conical portion, which extends downward as seen vertically from above. The lower free end 29 of the annular flange 26 runs against this chamfer 28, wherein the material thickness of this lower free end 29 is reduced, see FIG. 7, and consequently is somewhat more pliable and deformable. This ensures that the insert part 23 or the annular flange 26 is pushed radially into a first firm sealing abutment against the wall 22 of the recess 20. This is because when the slide portion 13 provided with the insert part 23 is being extended, the insert part 23 already pushes against the introduced casting compound during the extending movement and attempts to displace it. By way of this pressure, the insert part 23, which until then may have had its base plate 25 positioned with a small spacing to the receiving region of the slide portion 13, is pushed entirely into abutment. This operation may also take place only upon direct contact with the opposite metal layer 6. In each case, the end 29 slides along the chamfer 28 and is in this case deformed or widened slightly toward the side, such that a firm sealing abutment against the wall 22 of the recess 20 is pushed. This deformation is also accompanied by a certain overall deformation of the annular flange 26, such that an areal sealing abutment with the metal layer 6 is provided and is maintained during the entire extending movement or abutting movement against the metal layer 6. This ensures that no casting compound can enter the region of the recess 20. A sealing edge 30 which is formed on the metal layer 6 and which borders the recess 20 at the end side in the form of a sharp edge is also conducive to the sealing. This sealing edge, which may also project slightly into the recess 20, constitutes an additional sealing plane with respect to the annular flange 26.

[0055] As also shown in FIG. 7, the insert part 23 has, at its outer edge facing the second mold part 3, a chamfer 31 which directly adjoins the planar base surface 32 with which the insert part 23 bears against the likewise planar metal layer 6 in the working position. This chamfer 31 defines an annular space which is inevitably filled with casting compound. In the completely polymerized state, a narrow annular periphery of the casting is formed, said annular periphery engaging over the insert part 23, serving as an abutment and ensuring that the insert part 23 is not pushed out in an uncontrolled manner during the later demolding with compressed air. The angle of the chamfer 31 is for example about 45?.

[0056] An angle ? is also illustrated in FIG. 7. The angle ? defines a certain conicity of the annular flange 26, and it enables easier insertion and an improved sealing function in the region of the sealing edge 30. The angle ? is for example about 1?.

[0057] FIG. 3 shows, as described, the non-working position when the insert part 23 has been placed onto the slide portion 13 but the latter is not yet completely in the recess 20. It is evident that the base surface 32 of the insert part 23 terminates flush with the sealing edge 30 of the metal layer 6, such that in this region a planar geometry is produced which ensures that the slide portion 13 and the insert part 23 do not constitute a flow obstacle for the casting compound flowing in under pressure and homogeneous filling of the casting cavity 4 is achieved.

[0058] As described, for the displacing of the slide portion 13 together with the insert part 23, compressed air is used which is guided via the compressed-air connection 14 into the cylinder 17, such that the respective piston arrangement, which is carried by the piston rod 15, is pushed axially upward and the slide portion 13 is displaced linearly in the recess 20 and moved in the direction of the second mold part 3 until the insert part 23 has achieved a firm areal abutment against the second metal layer 6. After full polymerization and possibly after the casting mold 1 has been opened by raising of the second mold part 3, the slide portion 13 is pulled back again, likewise in a manner controlled by compressed air, that is to say that the air distribution in the cylinder 17 is reversed. Since, however, the insert part 23 at this point in time is firmly embedded into the cured casting compound, that is to say the casting, it remains therein, thus it detaches from the downwardly moving slide portion 13. The subsequently shaped molding thus has the desired shape but also the insert part 23 which defines a defined cylindrical aperture, here a sink outflow. The insert part 23 is then knocked out in a simple manner mechanically, for example by means of a rubber hammer, after the casting has been completely demolded, that is to say has also been removed from the first mold part 2.

[0059] This demolding can be assisted by the slide device 12 by virtue of the slide device being used as an additional ejector device. To this end, the slide device 12 has (see FIG. 8) a compressed-air distributing device 33, comprising a further compressed-air connection 34 which is arranged on the rod receptacle 16 in which the piston rod 15 is in turn arranged with a spacing. The arrangement is such that the compressed air fed in flows to the side of the piston rod 15 and ultimately builds up an air pressure which is applied (see the flow arrows P) to the bottom side of the base plate 25. This means that ultimately a pushing action from below against the insert part 23 which is firmly embedded in the polymerized casting is effected by way of the compressed air, wherein the insert part 23, as described, is secured against a movement in this pushing direction by way of the polymerized annular periphery of the casting, said annular periphery filling the chamfer 31. This annular periphery consequently forms an abutment which prevents the insert part 23 from being, as it were, shot out by the compressed-air pressure applied to the bottom side. This air pressure from below can assist the lifting off of the finished molding from the first mold part 2.

[0060] After this final demolding, the insert part 23 is, as described, mechanically separated from the casting and pushed or knocked out. The insert part 23 preferably consists of a plastic, preferably a polypropylene, but the invention is not restricted thereto. A plastic which has the lowest possible adhesion to the polymer material from which the casting is formed should be selected, such that the insert part 23 consequently forms only a very weak materially bonded connection, if any, to the casting and the pushing out or knocking out of the insert part 23 can take place in a simple manner.

[0061] FIG. 9 shows a further variant of a casting mold 1 according to the invention, the same reference designations being used for the same components.

[0062] The casting mold 1 also comprises two mold parts 2, 3 which delimit a casting cavity 4 by way of two metal layers 5, 6 which can be heated by way of a heating device 7, 8 embedded into a thermally conductive compound. A slide device 12 according to the invention is also provided.

[0063] In contrast to the embodiment of the mold described above with integrated shrinkage compensation, here the two mold parts 2, 3 are movable relative to one another in order to compensate for shrinkage. An encircling, movable holder 36 for a sealing element 37 such as a sealing rubber is provided, which sealing element 37 bears tightly against the two mold parts 2, 3 or the two metal layers 5, 6. The holder 36 itself is arranged on a holder receptacle 38. The movable holder 36 is braced by way of spring elements 39, such that a sealing abutment of the sealing element 37 against the two metal layers 5, 6 is always provided, even when said metal layers or the two mold parts 2, 3 move relative to one another for shrinkage compensation. In this mold configuration, a very thin casting periphery, which has to subsequently be removed, is formed on account of the peripheral engagement of the metal layer 5 around the metal layer 6.

[0064] In the exemplary embodiments, a slide device is in each case shown in a cylindrical construction. It is alternatively conceivable for the recess and the slide portion to have a cross-sectional shape which deviates from a circular shape, wherein the insert part has a base plate which is shaped correspondingly to this cross-sectional shape and a flange which engages into a receiving rabbet in the slide portion. It is thus also possible for apertures which deviate from a circular shape to be generated by means of the slide device provided according to the invention.

[0065] Equally, the invention is not restricted to the shown constructions of the casting mold or of the mold parts. Rather, the invention covers any casting mold construction having two mold parts of any desired embodiment which delimit the casting cavity and which are used to produce a casting by any desired curing methods, i.e. both in heat-curing and cold-curing form.

[0066] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.