Device, system and method for die-casting metallic material in the thixotropic state

Abstract

A device for die-casting metal material, including a screw unit for bringing the material into a thixotropic state and a cylinder/piston unit fed by the screw unit for applying pressure to the thixotropic material for the die casting, wherein a thermally controllable valve is arranged between the screw unit and the cylinder/piston unit.

Claims

1. A device for die-casting metal material, comprising; a screw unit for bringing the material into a thixotropic state; a cylinder/piston unit fed by the screw unit for applying pressure to the thixotropic material for the die casting; and a thermally controllable valve arranged between the screw unit and the cylinder/piston unit; wherein the thermally controllable valve includes a connection channel having controllable means for cooling of material located therein until said material is below the solidification temperature thereof, and wherein the connection channel widens in the direction from the screw unit to the cylinder/piston unit so that material solidified therein forms a form-fitting plug which widens in the direction of the cylinder/piston unit to prevent movement of the plug back into the screw unit and reliably keep high injection pressures of the cylinder/piston unit away from the screw unit; wherein the screw of the screw unit is axially displaceable and, on its side facing the valve, has a cone seal for sealing with respect to a conical annular shoulder on the inner periphery of the screw unit.

2. The device according to claim 1, wherein the connection channel is equipped with controllable means for heating and/or cooling the material located therein.

3. The device according to claim 1, wherein the screw unit and the cylinder/piston unit form a gap therebetween, said gap, except for thermal insulators, being bridged only by the valve.

4. The device according to claim 1, wherein the cone seal, at the tip thereof, carries a tappet which can be introduced into the connection channel.

5. The device according to claim 1, wherein the cylinder/piston unit is arranged approximately horizontally, and the screw unit is arranged approximately vertically.

6. The device according to claim 1, wherein the screw is provided with a heater.

7. The device according to claim 1, wherein the screw unit is formed with at least two screws which rotate in opposite directions and mesh with one another in a gear-like manner.

8. The device according claim 1, wherein at least one temperature sensor is arranged in the piston of the cylinder/piston unit.

9. The device according to claim 1, wherein at least one pressure sensor is arranged in the piston of the cylinder/piston unit.

10. The device according to claim 1, wherein the screw unit and/or the cylinder/piston unit is/are equipped with controllable means for forced cooling.

11. A system for die-casting metal material in a thixotropic state, comprising the device according to claim 1, a die-casting hydraulic system for applying pressure to the piston of the cylinder/piston unit, and a die-casting mould fed from the cylinder/piston unit for die-casting metal material in the thixotropic state.

12. The device according to claim 1, wherein the widening of the connection channel is conical or stepped.

13. A device for die-casting metal material, comprising; a screw unit for bringing the material into a thixotropic state; a cylinder/piston unit fed by the screw unit for applying pressure to the thixotropic material for the die casting; and a thermally controllable valve arranged between the screw unit and the cylinder/piston unit; wherein the thermally controllable valve includes a connection channel having controllable means for cooling of material located therein until said material is below the solidification temperature thereof, and wherein the connection channel widens in the direction from the screw unit to the cylinder/piston unit so that material solidified therein forms a form-fitting plug which widens in the direction of the cylinder/piston unit to prevent movement of the plug back into the screw unit and reliably keep high injection pressures of the cylinder/piston unit away from the screw unit; wherein at least one stirring element is arranged on an effective piston area of the piston, and the piston can additionally be driven in rotation.

14. The device according to claim 13, wherein a torque measured at a rotary drive of the piston determines a state of the thixotropic material in an injection chamber of the cylinder piston unit.

15. A method for die-casting metal material in a thixotropic state, comprising: bringing the metal material into the thixotropic state in a screw unit, feeding the thixotropic material from the screw unit via a connection channel into a cylinder/piston unit, wherein the connection channel widens in the direction from the screw unit to the cylinder/piston unit, allowing the material located in the connection channel to solidify to form a form-fitting plug widening in the direction of the cylinder/piston unit, injecting the thixotropic material from the cylinder/piston unit into a die-casting mould whilst the connection channel is blocked by the solidified material therein to reliably keep high injection pressures of the cylinder/piston unit away form the screw unit, and wherein the thixotropic material is stirred in the cylinder/piston unit before and/or during the injection procedure.

16. The method according to claim 15, further including the step of heating the connection channel until the material located therein is able to flow again for preparation of a renewed execution of the method.

17. The method according to claim 15, wherein the material is allowed to solidify as a result of forced cooling of the connection channel.

18. The method according to claim 15, wherein the material is allowed to solidify by switching off a heater of the connection channel.

19. The method according to claim 15, wherein the widening of the connection channel is conical or stepped.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be explained in greater detail hereinafter on the basis of an exemplary embodiment illustrated in the accompanying drawings, in which:

(2) FIG. 1 shows a side view of a metal injection moulding system comprising a device according to the invention;

(3) FIG. 2 shows a longitudinal section of the screw unit of the device from FIG. 1; and

(4) FIG. 3 shows a longitudinal section of the valve and the cylinder/piston unit of the device from FIG. 1.

DETAILED DESCRIPTION

(5) According to FIG. 1, a metal injection moulding system 1 has a device 2 for die-casting metal materials in the thixotropic state in a die-casting mould 3, a die-casting hydraulic system 4 for applying pressure to the device 2, and an electronic control unit (not illustrated) for process-control of the system 1 as a whole. The system 1 can also be constructed on the basis of a conventional die-casting system, which is modified specifically for metal injection moulding by installing the device 2 between a (conventional) die-casting hydraulic system 4 and a (conventional) die-casting mould 3, possibly also subsequently, in which case the device 2 forms a retrofit kit or adapter kit.

(6) The device 2 comprises an approximately vertical screw unit 5, a valve 6 and an approximately horizontally arranged cylinder/piston unit 7 formed of a piston 7′ and cylinder 7″. Metal material (not shown) is brought into the thixotropic state in the screw unit 5 and is thereby fed via the valve 6 to the cylinder/piston unit 7. The die-casting hydraulic system 4 then acts on the piston 7′ of the cylinder/piston unit 7 in order to inject the thixotropic material from the cylinder/piston unit 7 into the die-casting mould 3.

(7) All parts of the die-casting system 1 are mounted on bearing rails 8. The device 2 sits in an adjustment arrangement 9 on a holding cup 10, and this in turn sits on the bearing rails 8. The adjustment arrangement 9 adapts the position of installation of the device 2 to the die-casting mould 3 and the die-casting hydraulic system 4 in terms of the height and angle; the adjustment arrangement 9 and/or holding cup 10 can be omitted optionally.

(8) Both the screw unit 5 and the cylinder/piston unit 7 have carrying eyes 11. The carrying eyes 11 are used to manipulate the device 2 as a whole, for example when exchanging the device 2 for any other die-casting device or for example for maintenance purposes, or to lift the screw unit 5 from the cylinder/piston unit 7, for example in order to exchange the valve 6.

(9) During the injection procedure, the die-casting hydraulic system 4 actuates the piston 7′ of the cylinder/piston unit 7 via a piston rod 13, and thixotropic material is conveyed from the cylinder/piston unit 7 via an injection nozzle 14 to the die-casting mould 3, as will be explained further below in greater detail. The die-casting mould 3, as known in the prior art, is generally formed at least in two parts and is held by a tensioning frame 15 by means of centering bolts 16. To remove a finished diecast shaped part once said part has solidified in the die-casting mould 3, the tensioning frame 15 and die-casting mould 3 are opened at the division thereof in a manner known to a person skilled in the art.

(10) An optional stirring drive 17 drives the piston rod 13 and therefore the piston 7′ of the cylinder/piston unit 7 in rotation about the axis thereof via a transmission 18. Here, at least one gearwheel of the transmission 18 may be provided with extra wide teeth to compensate for the axial movements of the piston 7′ during die-casting. Another drive known in the prior art, for example a belt drive, but also a direct drive (possibly a hydraulic direct drive) can be used instead of the transmission 18.

(11) A maintenance hydraulic system 19 (likewise optional) is used to move the piston 7′ independently of the hydraulic system 4 into a maintenance position 20 (FIG. 3), as explained in detail further below, should this function not be performed by the die-casting hydraulic system 4 itself.

(12) FIG. 2 shows the screw unit 5 in detail. The screw unit 5 brings metal material into a thixotropic state for preparation for the subsequent die casting. Metal material, for example in granule or chip form, can be fed to the screw unit 5 via funnel-shaped delivery channels 21, which are distributed over the periphery of a screw cylinder 22 and are optionally adapted in terms of their axial position on the screw cylinder 22 to the inclination of the screw. The delivery channels 21 run through the wall of the screw cylinder 22 in a downwardly sloped manner, preferably at an angle between approximately 45° and approximately 60°, which facilitates the uniform feeding.

(13) Apart from metal material, inert gas or another gaseous, liquid and/or solid material can also be fed as required to the screw unit 5 and therefore to the system 1 as a whole. Here, the material may be material that improves the metal injection moulding in terms of the process, for example for grain refinement or flame resistance, or material that influences the properties of the subsequent diecast part, for example for alloying or as a result of introduction of fibres. Inert gas for flame resistance, given its high mass, infiltrates the screw unit 5 and the system 1 due to gravity, wherein it displaces oxidising oxygen located therein, for example.

(14) A screw drive 23 drives a screw 24, which is rotatably mounted so as to be axially displaceable in the screw cylinder 22 and which exerts onto the material the shear forces necessary to bring the material into the thixotropic state. The material in the screw unit 5 is heated via a controllable screw heater 25, encompassing the screw cylinder 22, preferably divided in the direction of the axis of the screw cylinder 22 into at least two segments S′, S″, and having a design known per se. Here, the segments S′, S″ can generate different temperature zones in the screw cylinder 22 as a result of selective control.

(15) Due to the action of the shear forces and the heating of the metal material in the screw unit 5, the material is brought into a thixotropic state. At the same time, it is conveyed in the direction of the valve 6 by the movement of the screw 24. Here, the device 2 can be formed such that the screw unit 5 feeds thixotropic material continuously to the cylinder/piston unit 7 via the valve 6, similarly to a conventional extruder. In accordance with FIG. 2, the thixotropic material in the screw unit 5 can alternatively by collected in a preparatory manner in the lower region of the screw cylinder 22 in that the screw 24 in the screw cylinder 22 is moved continuously upwards and brings thixotropic material into the lower region of the screw cylinder 22. This movement can be assisted actively by a screw hydraulic system 26. If, in this case, the intended quantity of thixotropic material is prepared in the screw cylinder 22, said material is thus conveyed into the cylinder/piston unit 7 by the screw 24, acted on by the screw hydraulic system 26, via the valve 6.

(16) As shown in FIG. 2, the screw 24, at the lower end thereof facing the valve 6, may have a cone seal 27 for sealing with respect to a conical annular shoulder 28 on the inner periphery of the screw cylinder 22. With the aid of the screw hydraulic system 26, the screw 24 can be moved into the sealing position thereof (not illustrated) in which it abuts the conical annular shoulder 28 in a sealing manner and can be locked in this sealing position by means of an optional bayonet closure 29. The screw unit 5 can thus be sealed with respect to the valve 6 without further energy expenditure. Instead of the bayonet closure 29, another locking type known in the prior art may also be used.

(17) A cylindrical tappet 30 protruding from the tip of the cone seal 27 can enter the mouth of a central connection channel 31 of the valve 6 in the sealing position of the screw 24. The tappet 30 simplifies the exchange of the valve 6 by distancing any solidified material located therein from the screw unit 5. A valve exchange is thus possible in the cold state without a risk of damage for the screw unit 5 and valve 6. The tappet 30 may alternatively have a different shape adapted to the valve 6 or optionally can be omitted. The conical annular shoulder 28 could also be formed directly in the mouth of the central connection channel 31 of the valve 6.

(18) Alternatively or additionally to the screw heater 25 on the screw cylinder 22, the screw 24 can be equipped with an inner heater (not illustrated), for example an inner heater that is likewise segmented. If such an inner heater is formed as an electrical heater, it may preferably be constructed with heating coils, which are wound around bimetal pipe sections slitted in the axial direction and which are formed such that they can be displaced in the screw 24 in the cold state and can rest fixedly against the inner wall of the screw 24 in the hot state.

(19) The screw 24 optionally has one or more distributed internally arranged temperature sensors (not illustrated). Since the screw rotates, the signal transmission of the temperature sensors and the energy supply of the sensors and the inner heater are to be adapted to the rotational movement. The signal transmission can be performed wirelessly, for example via radio or via slip rings (not illustrated) on the screw 24. The same possibilities exist for the energy supply, wherein the comparatively low energy demand of the temperature sensors can be covered wirelessly or via energy harvesting from the surrounding environment, whereas slip rings are preferred for the inner heater.

(20) Alternatively to the illustration in FIG. 2, the screw unit 5 can also be formed with at least two screws 24, which rotate in opposite directions and mesh with one another in a gear-like manner.

(21) FIG. 3 shows the valve 6 in detail. The valve 6 is fixed via an upper flange 32 in a connection opening 33 in the screw unit 5 and via a lower flange 34 in a connection opening 35 in the cylinder/piston unit 7. The valve 6 creates a connection for the thixotropic material prepared in the screw unit 5 for feeding the cylinder/piston unit 7 and prevents a backflow of the material from the cylinder/piston unit 7 into the screw unit 5 during the injection. Here, the valve 6 is used in particular to keep the high pressure, created with the injection movement of the piston 7′ in the cylinder/piston unit 7, away from the screw unit 5. The valve 6 is formed in accordance with FIG. 3 as a pipe section 36 with a central controllable connection channel 31 for selectively connecting the interior of the screw cylinder 22 to the interior of the cylinder 7″ of the cylinder/piston unit 7 serving as an injection chamber 37.

(22) The valve 6 illustrated in FIG. 3 functions thermally and for this purpose has a heatable and/or coolable connection channel 31, which penetrates the pipe section 36 and is optionally widened towards the cylinder/piston unit 7. In FIG. 3 the connection channel 31 is illustrated such that it is widened in a staggered or stepped manner, but alternatively may also be conical (see FIG. 2), conically stepped, conically bulbous, bulbous or simply cylindrical; a number of the above-mentioned forms may also be arranged in succession in the axial direction.

(23) To act on the connection channel 31 thermally and to thereby control the valve 6, said valve is equipped with a controllable heater 39 and/or controllable coolants 40 for forced cooling. By means of the heater 39, material located in the connection channel 31 can be kept in the thixotropic state, and any solidified material located in said connection channel can be made able to flow again in order to “release” the valve 6. Similarly to that described with reference to the screw heater 25, the heater 39 can be divided into segments for zonewise temperature control.

(24) By allowing the connection channel 31 to cool, the material located therein conversely can be made to solidify and then forms a solid plug in the connection channel 31, said plug preventing the passage of material through the connection channel 31 and thus “blocking” the valve 6.

(25) The material in the connection channel 31 can be allowed to solidify by switching off the heater 39 and/or by switching on the coolants 40 for forced cooling. For example, the coolants 40 for forced cooling may comprise gaseous coolant in cooling channels 40 in the pipe section 36.

(26) In order to produce particularly quick cycle times in the case of a cyclical metal injection moulding process, the heater 39 can be formed preferably as an inductive pulse heater, and the coolants 40 for forced cooling can be formed as CO.sub.2 gas cooling. Alternatively, other heaters and/or cooling devices known from the prior art can be used for the valve 6.

(27) The heater 39 and/or the coolants 40 for forced cooling can be arranged in or on the wall of the pipe section 36 or in one or more insert cartridges passing for example transversely through the wall of the pipe section 36 and the connection channel 31.

(28) A gap 41 is formed between the screw unit 5 and cylinder/piston unit 7 and is bridged from a thermal point of view only by the valve 6 and thus ensures an extensive thermal decoupling of the screw unit 5 and cylinder/piston unit 7. For additional support of the screw unit 5 on the cylinder/piston unit 7, thermal insulators 42, for example made of ceramic, can be provided.

(29) To fix the valve 6, together with the flanges 32, 34 thereof, in the connection openings 33, 35, threaded rings 43 having outer threads engage with inner threads of the connection openings 33, 35. The threaded rings 43 are preferably cut in the axial direction thereof, whereby they can be handled independently of the valve 6 and, even after their insertion into the connection openings 33, 35, can be placed around the pipe section 36 and can be rotated into the inner thread of the respective connection opening 33, 35.

(30) For the engagement of a tightening or loosening tool, the threaded rings 43 may optionally have corresponding recesses on their exposed engagement faces 44. Buffers (not illustrated) in the slits of the threaded rings 43 prevent said rings from shifting and becoming wedged, since they fill the saw gap created during the production of the threaded rings from a one-piece ring and the subsequent sawing. Alternatively, conventional flange fastenings, for example by means of screwing through bores in the flanges (not illustrated), can be used to fix the valve 6 in the connection openings 33, 35.

(31) The mouth 45 of the connection channel 31 leads directly or, as illustrated, via an auxiliary channel 48 in the wall of the cylinder 7″ of the cylinder/piston unit 7 between the piston 7′ and injection nozzle 14 into the injection chamber 37 of the cylinder 7″. A gate valve 46, which protrudes from the effective piston area 47 of the piston 7′, closes the mouth 45 of the valve 6 when the piston 7′ is moved into the maintenance position 20 in that said gate valve enters the auxiliary channel 48 and is arranged in front of the mouth 45. The cross section of the gate valve 46 may be round, oval, polygonal or egg-shaped or lenticular, for example, but may also be asymmetrical, and for example may comprise concave segments. The gate valve 46 can alternatively be entrained by the piston 7′ via a rod assembly, and may also be guided outside the cylinder 7″ or in a separate guide (not illustrated), for example in the wall of the cylinder 7″.

(32) The piston movement into the maintenance position 20 is performed by the maintenance hydraulic system 19 generally for maintenance purposes, for example for the exchange of the valve 6; with the injection procedure under normal operating conditions, the piston 7′ generally does not move so far as to close the mouth 45 by means of the gate valve 46.

(33) The auxiliary channel 48 is arranged parallel to the stroke direction 49 of the piston 7′ and has a cross section adapted to the cross section of the gate valve 46. Alternatively, the auxiliary channel 48 may also have a cross section different from the gate valve 46, provided the gate valve 46 can seal the mouth 45 of the valve 6 with respect to the injection chamber 37. To lead away the material located in the auxiliary channel 48 as the gate valve 46 is retracted, the auxiliary channel 48 is open on both sides towards the injection chamber 37.

(34) When feeding the cylinder/piston unit 7 with thixotropic material from the screw unit 5 via the valve 6 into the injection chamber 37, the piston 7′ either moves backwards from the screw unit 5 as a result of the pressure, or is actively moved back by the die-casting hydraulic system 4, wherein it can also assist the screw unit 5 as a result of a suction effect during the feeding process. The thixotropic material is thereby collected in the injection chamber 37 for the now subsequent injection.

(35) In order to ensure the thixotropic state of the material in the injection chamber 37 as best as possible, the cylinder/piston unit has a cylinder heater 51. The cylinder heater 51 is optionally segmented and can be controlled according to zones, similarly to the screw heater 25. To also clean and empty the screw unit 5, the valve 6 and the cylinder/piston unit 7, the screw heater 25, heater 39 and cylinder heater 55 respectively can liquefy the material located in said screw unit, valve and cylinder/piston unit. In addition, the screw unit 5 and cylinder/piston unit 7 can be equipped with coolants for forced cooling, for example in the manner of the coolants 40 for forced cooling of the valve 6, for quick cooling for maintenance and module exchange purposes.

(36) One or more stirring elements 52 can be arranged, additionally to the gate valve 46, on the effective piston area of the piston 7′. The stirring elements 52 for example are nubs inclined with respect to the axis of the piston, but may also be vane-shaped or annular or may have another form suitable for stirring the thixotropic material located in the injection chamber 37, or may also be formed by the gate valve 46 itself.

(37) If the piston 7′ is rotated via the piston rod 13 from the stirring drive 17 via the transmission 18, the stirring elements 52 in the injection chamber 37 thus encounter a different resistance depending on the state of the thixotropic material located in said injection chamber. By measuring the torque at the piston rod or in the stirring drive 17, or by means of a separate measuring cell (not illustrated), it is thus possible to determine the state of the thixotropic material in the injection chamber 37.

(38) Further information concerning the state of the thixotropic material located in the injection chamber 37 can be supplied by temperature and pressure sensors in the injection chamber 37. In accordance with FIG. 3, at least one temperature sensor 53 and/or at least one pressure sensor 54 is/are provided in the piston 7′. The signals 55 of the sensors 53, 54 are transmitted for example by the piston rod 13 and possibly, as described above, via slip rings or radio to an externally arranged signal evaluation unit (not illustrated).

(39) If a quantity of material in the thixotropic state sufficient for the subsequent die-casting procedure is present in the injection chamber 37, the valve 6 is closed by switching off the heater 39 and/or switching on the coolants 40 for forced cooling, which prepares the device 2 for the injection of the material into the die-casting mould 3. For injection, the die-casting hydraulic system 4 applies pressure to the piston 7′ via the piston rod 13, whereby the thixotropic material is injected from the injection chamber 37 through the injection nozzle 14 into the die-casting mould 3, where it solidifies and can be removed later as a shaped article.

(40) The piston 7′ can be provided with one or more piston rings against the inner wall of the cylinder 7″ for improved sealing of the injection chamber 37. For example, the piston rings can be formed in a manner known per se as compression rings, of which the contact pressure against the inner wall of the cylinder 7″ is provided primarily by the pressure of the thixotropic material in the injection chamber 37, for example via suitable shaping of the compression rings or by additional pressure channels in the piston 7′ between the injection chamber 37 and compression rings. A lubrication of the inner wall of the cylinder 7″ is also optionally possible; for this purpose, lubricants could be fed for example through lubricant bores in the wall of the cylinder 7″ or via the chamber in the cylinder 7″ arranged on the side of the piston 7′ remote from the die-casting mould 3.

(41) The injection nozzle 14, which leads into the die-casting mould 3, preferably has a nozzle heater 56. The injection nozzle 14, as a result of this, can be formed as what is known as a hot runner in order to prevent a solidification of the material in the interior of said nozzle. FIG. 3 additionally shows an optional insulating sleeve 57 for thermal insulation around the injection nozzle 14. Such an insulating sleeve 57 can also be used in suitable size for thermal insulation of the screw unit 5, the valve 6 and/or the cylinder/piston unit 7.

(42) Once the thixotropic material has been injected into the die-casting mould 3 and the valve 6 has been opened by heating, the method can be performed again.

(43) The invention is not limited to the presented embodiments, but includes all variants and modifications within the scope of the accompanying claims. For example, the mouth 45 of the valve 6 could thus also lead on the side of the piston 7′ remote from the die-casting mould 3 into a feed chamber (not illustrated) of the cylinder 7″. In this alternative embodiment the screw unit 5 feeds this feed chamber instead of the injection chamber 37 via the valve 6. If the piston 7′ then moves back and allows thixotropic material to pass from the feed chamber into the injection chamber 37 via a check valve, the valve 6 can protect the screw unit 5 against the pressure and/or suction effect.