Die-casting and injection molding integrated forming equipment and forming method

Abstract

The invention discloses die-casting and injection molding integrated forming equipment and a forming method. The die-casting and injection molding integrated forming equipment comprises a fixed mold plate and a movable mold plate, and a die-casting unit is integrally arranged on one side of the fixed mold plate; an injection unit is integrally arranged on one side of the movable template and synchronously moves along with the movable template; the die-casting unit and the injection unit are arranged in a bijection structure, and the high-strength molecular-level combined metal-plastic composite part is integrally formed through one-time die assembly of the die-casting unit and the injection unit. According to the die-casting and injection-molding integrated forming equipment, die-casting and injection-molding dual-process integrated forming is adopted, the dual processes are deeply fused, an aluminum alloy high-pressure die-casting technology and an engineering plastic precise injection-molding technology are integrated in the same machine table, and high-strength molecular-level combination of metal and plastic is achieved; assembling links of traditional multi-process manufacturing are reduced, the production period is shortened, and the manufacturing efficiency is improved; and an intelligent temperature control and pressure regulation system is adopted, so that high bonding strength of an aluminum-plastic interface is ensured, and material deformation and defects are avoided.

Description

Technical Field

[0001] This invention relates to the field of special molding equipment technology, specifically to a composite molding equipment that integrates die casting and injection molding processes, and more particularly to an integrated die casting and injection molding equipment and molding method. Background Technology

[0002] In traditional manufacturing processes, the combination of metal die-casting parts and plastic parts usually requires separate molding followed by secondary assembly or injection molding of inserts. This presents the following technical challenges: process separation leads to long production cycles, increasing labor time by an average of 40%; cumulative errors from multiple positioning steps, typically ±0.15mm; insufficient interfacial bonding strength after cooling and subsequent bonding with the injection-molded part, with peel strength typically <15N / mm²; high energy consumption, requiring die casting followed by transfer to an injection mold for inserts; and the need to transfer from the die-casting machine to the injection molding machine, requiring two or more sets of molds.

[0003] Chinese patent document CN205185340U discloses an integrated injection molding and die-casting machine, including a machine base and a moving mold assembly, a fixed mold plate, and an injection molding mechanism arranged horizontally and linearly on the top surface of the machine base. It also includes a die-casting mechanism arranged parallel to the injection molding mechanism in a direction perpendicular to the top surface of the machine base. This machine simultaneously provides both injection molding and die-casting mechanisms, both powered by electric motors. Its compact size makes it convenient for classroom instruction of injection molding and die-casting techniques. However, this technical solution is for the convenience of classroom instruction and does not solve the technical problem addressed in this application.

[0004] Based on the trends of automotive lightweighting and intelligent manufacturing, and in the face of the accelerating evolution of the lightweighting wave in new energy vehicles, it is necessary to develop and set up a molding equipment that deeply couples die casting and injection molding processes.

[0005] In particular, it is suitable for the integrated production of metal-plastic composite structural components, as well as the integrated production of aluminum alloy-plastic composite structural components formed at both ends of a steel frame. Summary of the Invention

[0006] The purpose of this invention is to solve the problems in the existing technology of combining metal die-casting parts and plastic parts, such as process separation leading to long production cycles; large cumulative errors due to multiple positioning; insufficient interface bonding strength when combining the metal die-casting part with the injection molded part after cooling; high energy consumption, requiring die-casting first and then transferring to the injection mold for inserts; low production efficiency when transferring from the die-casting machine to the injection molding machine; high cost due to the need for two or more sets of molds; and low product precision. The invention provides a die-casting and injection molding integrated molding equipment and method that can achieve one-time positioning, one-time mold closing, and one-time molding of metal die-casting parts and plastic parts, with high interface bonding strength, convenient operation, short production cycle, high efficiency, and high product quality.

[0007] The technical solution adopted by this invention to achieve its objective is: a die-casting and injection molding integrated molding equipment, including a fixed template and a movable template. A die-casting unit is integrated on one side of the fixed template; an injection unit is integrated on one side of the movable template, and the injection unit moves synchronously with the movable template; the die-casting unit and the injection unit are arranged in a through-shot die-casting injection molding structure, and a high-strength molecularly bonded metal-plastic composite part is integrally molded through a single mold closing of the die-casting unit and the injection unit. This die-casting and injection molding integrated molding equipment, through a completely new design of the injection molding equipment, integrates the injection unit of the plastic part with the movable template, and the injection unit moves synchronously with the movable template; the die-casting unit that forms the metal die-casting part is integrated on one side of the fixed template, and the die-casting unit and the injection unit are arranged in a through-shot die-casting injection molding structure and achieve a single mold closing, thus enabling the integral molding of a high-strength molecularly bonded metal-plastic composite part. This die-casting and injection molding integrated molding equipment can perform one-time mold forming on the molding equipment when it is necessary to make metal-plastic composite structural parts. It can achieve integrated molding without opening and changing the mold. In specific operation, the die-casting unit first performs high-speed and high-pressure die casting from the fixed template side into the molding mold, and the injection unit injects plastic from the moving template side at ultra-high speed and ultra-high pressure. Finally, the metal-plastic composite structural parts or steel frame-metal die-casting-injection molding composite structural parts are formed in one piece. This die-casting and injection molding integrated molding equipment uses a die-casting unit and an injection unit to perform one-piece molding of metal-plastic composite structural parts, reducing the need to change equipment and molds and greatly improving production efficiency. Since intermediate transfer is eliminated, it avoids impacting product quality, significantly improving overall quality. Metal-plastic composite parts are molded within the same molding cavity, or steel frame-metal die-casting-injection molding composite structural parts are simultaneously molded with the steel frame. This reduces the porosity at the interface between different materials to below 0.01%, greatly improving product dimensional accuracy and resulting in high bonding strength, achieving molecular-level bonding between metal and plastic. Furthermore, this die-casting and injection molding integrated molding equipment has a simple overall structure and low cost, making it widely applicable in core application scenarios such as battery pack frames, body structures, and chassis components for new energy vehicles. It can achieve a weight reduction ratio of 30%-50%, demonstrating significant advantages in improving strength, extending range, and ensuring safety, and aligns with the trend of green manufacturing.

[0008] Preferably, the injection unit employs an ultra-high-speed, ultra-high-pressure injection unit. This unit achieves high-strength molecular-level bonding between components made of different materials, such as metal and plastic, metal and steel frame, and plastic and steel frame, ensuring high precision and high quality in the molding of complex structural parts.

[0009] Preferably, the injection unit includes an injection guide rail and an injection mechanism; the injection mechanism includes an injection power assembly, a plasticizing assembly, and a feeder. The injection power assembly provides high-speed, high-pressure injection power to the injection unit, while the plasticizing and injection operations are performed on the plastic component, and the feeder injects the plastic into the plastic component.

[0010] Preferably, the injection molding power assembly is used to provide ultra-high speed and ultra-high pressure power, and the injection molding power assembly includes an electric pre-plasticizing servo motor and a gearbox. The injection molding power assembly uses an electric pre-plasticizing servo motor in conjunction with a gearbox to provide ultra-high speed and ultra-high pressure power, which can improve the performance and production efficiency of the injection unit, and achieve a more efficient, intelligent, and energy-saving production process.

[0011] By controlling the output torque of the electro-pre-plasticizing servo motor, precise control of the injection molding process pressure can be achieved, thus enabling precise control of ultra-high pressure power.

[0012] Preferably, the plasticizing components mainly include a barrel, a screw, and a nozzle.

[0013] Preferably, the die-casting unit is controlled by an intelligent temperature and pressure regulation system to achieve ultra-high-speed, high-pressure dynamic injection molding. The intelligent temperature and pressure regulation system, achieving dynamic injection force, ensures high bonding strength at the aluminum-plastic interface, preventing material deformation and defects.

[0014] Preferably, the die-casting unit includes a high-speed, high-pressure power unit and a die-casting assembly; the die-casting assembly includes an injection cylinder, an injection rod connected to the injection cylinder, and an injection hammer head disposed at the front end of the injection rod. A feed cylinder is disposed on the fixed template, and the injection hammer head is driven by the injection cylinder to push the molten metal inside the feed cylinder into the forming mold.

[0015] Preferably, the high-speed, high-pressure power unit includes a nitrogen supply device and an accumulator. The accumulator injects hydraulic oil into the cylinder at extremely high speeds, thereby achieving high-speed, high-pressure die casting of the hydraulic cylinder. Hydraulic oil is supplied through the accumulator's nitrogen supply device and the hydraulic pump, achieving dual-controlled pressurization. The dynamic injection force surpasses the injection performance of conventional equipment by 40%, and ultra-high-speed acceleration exceeding 50G ensures dense forming of the aluminum alloy.

[0016] Preferably, the molding machine mold bridge also includes a dual-support, separate structure. This mold bridge comprises parallel, recessed mold bridge support rails and independent moving template sliding foot support rails. The recessed mold bridge support rails and the independent moving template sliding foot support rails are separate and do not interfere with each other. The recessed mold bridge support rails feature a recessed design, resulting in a narrower mold bridge span and a significantly shorter minimum mold thickness, making it suitable for a wider range of mold thickness applications. The separate dual support structure provides a more rational transmission path. Mold bridge vibration amplitude is significantly reduced, mold surface parallelism is greatly improved, mold bridge rigidity is enhanced, deformation is reduced, and the frame experiences more even stress. It is compatible with smaller mold sizes, reduces material usage in the frame design, and significantly extends maintenance cycles. It fully utilizes space, as the minimum mold thickness is not limited by space constraints, meeting the die-casting needs of molds with varying thicknesses.

[0017] Preferably, the molding equipment also includes a mold-moving cylinder that moves the moving template and injection unit, a direct-pressure mold-locking system, and a rear brake device. The direct-pressure mold-locking system achieves mold locking, generating a predetermined mold-locking force at the mold parting surface. The hydraulic system maintains the set pressure, which improves the quality of the one-piece molded metal-plastic composite parts.

[0018] Preferably, the direct-pressure mold-locking system uses a servo motor pump station to provide hydraulic power, and the direct-pressure mold-locking system includes at least one high-pressure mold-locking cylinder.

[0019] The technical solution adopted by the present invention to achieve its second objective is: a die casting and injection molding integrated molding method, which uses the aforementioned die casting and injection molding integrated molding equipment.

[0020] As a preferred embodiment, a die-casting injection molding method includes the following steps: S1: Mold Closure: The moving mold cylinder pushes the moving template to close the mold. S2: The rear brake device closes the brake, forming a rigid mechanical support; S3: Mold clamping: The high-pressure mold clamping cylinder is activated, causing a predetermined mold clamping force to be generated at the mold parting surface, and the hydraulic system maintains the set pressure. S4: Die-cast metal matrix: The die-casting unit and the injection unit operate in steps or simultaneously, forming an injection from both sides of the mold to integrally mold a metal die-cast-plastic composite part. S5: Mold opening and ejection of composite parts.

[0021] Preferably, in step 4, when forming the metal die-casting and injection molding composite part, the die-casting unit and the injection unit operate in separate steps: First, the die-casting unit operates, injecting molten metal into the integrated metal-plastic molding cavity under high pressure, and the molten metal solidifies to form a metal matrix; then, the cooling system cools the molding mold, reducing the temperature of the molding mold to the injection molding requirements; finally, the injection unit operates, injecting plastic from one side of the moving template into the integrated metal-plastic molding cavity to cover the metal matrix, thus forming a combined plastic part and a die-cast metal part.

[0022] Preferably, in step 4, when forming the steel skeleton, metal die casting, and injection molding composite part, the die casting unit and the injection unit operate synchronously: the die casting unit operates by injecting molten aluminum into the die casting mold under high pressure from the fixed template side, the molten aluminum covers the steel skeleton and solidifies to form an integral die casting part of the metal steel skeleton; the injection unit operates simultaneously by injecting plastic into the injection mold from the moving template side to cover the steel skeleton, and integrally molding the plastic part on the steel skeleton, forming a composite part of the three materials of metal die casting and plastic part integrally molded on the steel skeleton.

[0023] The beneficial effects of this invention are as follows: This die-casting and injection molding integrated molding equipment and method adopts a dual-process integrated molding of die casting and injection molding, with deep integration of the two processes. It integrates high-pressure die casting of aluminum alloy and precision injection molding of engineering plastics in the same machine, achieving high-strength molecular-level bonding between metal and plastic, metal and steel skeleton, and plastic and steel skeleton. The molding equipment performs one mold closing and one molding, eliminating the need for mold opening and transfer, thus achieving integrated molding. This reduces the assembly links in traditional multi-process manufacturing, shortens the production cycle, and improves manufacturing efficiency. The intelligent temperature control and pressure regulation system ensures high bonding strength at the interfaces of aluminum-plastic, aluminum-steel, and steel-plastic, avoiding material deformation and defects.

[0024] Employing an ultra-high-speed, ultra-high-pressure dynamic injection unit, high-strength molecular-level bonding is achieved between components of different materials, ensuring high precision and high quality in the molding of complex structural parts. An intelligent temperature and pressure control system manages the die-casting unit, dynamically adjusting the injection force to exceed the injection performance of conventional equipment by 40%, while ultra-high-speed acceleration exceeding 50G ensures dense molding of aluminum alloys.

[0025] It can be widely used in core application scenarios such as battery pack frames, body structures, and chassis components of new energy vehicles, achieving a weight reduction ratio of 30%-50%. It demonstrates significant advantages in improving strength, extending range, and ensuring safety, and is in line with the trend of green manufacturing. Attached Figure Description

[0026] Figure 1 This is a front view of the die-casting and injection molding integrated molding equipment of the present invention.

[0027] Figure 2 This is a top view of the die-casting and injection molding integrated molding equipment of the present invention.

[0028] Figure 3 This is a schematic diagram of a structure in which the injection unit and the movable template are connected in this invention.

[0029] Figure 4 yes Figure 3 The main view of the injection unit and the moving template.

[0030] Figure 5 yes Figure 3 Top view of the injection unit and the moving template.

[0031] Figure 6 This is a schematic diagram of the injection unit of the present invention.

[0032] Figure 7 This is a schematic diagram illustrating the relative positional relationship between the die-casting unit and the fixed template in this invention.

[0033] Figure 8 yes Figure 7 Front view of the relative positional relationship between the intermediate die-casting unit and the fixed template.

[0034] Figure 9 yes Figure 7 A top view showing the relative positions of the die-casting unit and the fixed template.

[0035] Figure 10 This is a schematic diagram of one structure of the die-casting unit in this invention.

[0036] Figure 11 This is a schematic diagram of a four-cylinder direct-pressure mold-locking system in this invention.

[0037] Figure 12 This is a front view of the four-cylinder direct-pressure mold-locking system of the present invention.

[0038] Figure 13 This is a schematic diagram of a structure of the equipment frame in this invention.

[0039] Figure 14 This is a schematic diagram of one type of integral molding mold in this invention.

[0040] In the diagram: 100, Equipment mold bridge frame; 101, Molding machine mold bridge; 102, Retractable mold bridge special support rail; 103, Independent moving template sliding foot support rail; 104, Moving mold bridge; 105, Fixed mold bridge. 1. Equipment frame; 2. Set template; 21. Injection hole; 3. Move template; 4. Large line; 5. Die casting unit; 51. Injection tie rod; 52. Injection cylinder; 53. Injection rod; 54. Injection hammer; 55. Feed cylinder; 56. Nitrogen supply device; 57. Accumulator; 58. Die casting plate. 6. Injection unit; 61. Injection transfer guide rail; 62. Gearbox; 63. Thrust seat assembly; 64. Transfer cylinder; 65. Plasticizing assembly; 651. Barrel; 652. Nozzle; 67. Electric pre-plasticizing servo motor; 68. Feeder; 69. Injection bracket. 7. Tail rack; 8. Direct pressure mold clamping system; 81. High pressure mold clamping cylinder; 82. Rod pulling cylinder; 9. Mold moving cylinder; 10. Rear brake device; 200. Integrated molding die; 201. Moving mold; 202. Fixed mold; 203. Integrated metal-plastic molding cavity; 204. Plastic part molding cavity; 205. Metal die-casting part molding cavity; 206. Control mechanism; 207. Cooling channel. Detailed Implementation

[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Components not specifically described in the present invention are existing components or general components.

[0042] Example 1: In Figure 1, Figure 2 The illustrated embodiment describes a die-casting and injection molding integrated molding equipment, specifically an aluminum-plastic integrated large automotive structural component compression molding equipment. It is particularly suitable for the high-end manufacturing of new energy vehicles. This equipment employs a dual-process integrated molding technology of die casting and injection molding, providing an efficient and reliable solution for the production of lightweight, high-performance automotive structural components.

[0043] An integrated die-casting and injection molding equipment includes a fixed template 2 and a movable template 3. A die-casting unit 5 is integrated on one side of the fixed template 2, and an injection unit 6 is integrated on one side of the movable template 3. The injection unit 6 moves synchronously with the movable template 3. The die-casting unit 5 and the injection unit 6 are arranged in a facing configuration, and an integrated metal-plastic composite part is formed by the die-casting unit 5 and the injection unit 6 in a single mold closing operation.

[0044] Specifically, the die-casting and injection molding integrated molding equipment also includes a machine frame 1. On the machine frame 1, an inwardly parallel structure is separately arranged a retractable mold bridge support rail 102 and an independent movable template sliding foot support rail 103. An adjustable moving mold bridge 104 and an adjustable fixed mold bridge 105 are arranged on the independent movable template sliding foot support rail 103. The moving mold and the fixed mold bridge are respectively mounted on the moving mold bridge 104 and the fixed mold bridge 105. The movable template 3 is mounted on the independent movable template sliding foot support rail 103.

[0045] The fixed template 2 and the movable template 3 are connected by a set of large bars 4 to form a two-plate type photoelectric structure.

[0046] The die-casting and injection molding integrated molding equipment also includes a direct-pressure mold-locking system 8, a mold-moving cylinder 9, and a rear brake device 10.

[0047] The mold-moving cylinder 9 is slidably mounted on the equipment frame 1. The piston rod of the mold-moving cylinder 9 is connected to the moving template 3 and drives the moving template 3 to slide on the equipment frame 1, thereby realizing mold closing and opening.

[0048] like Figure 3 , Figure 4 , Figure 5 , Figure 6 As shown, an injection unit 6 is integrated on one side of the movable template 3. During mold closing and opening, the injection unit 6 moves synchronously with the movable template 3. A tailstock 7 is provided on the outer side of the movable template 3.

[0049] In this embodiment, the injection unit 6 is a 9500i type ultra-high speed and ultra-high pressure injection unit. The injection unit 6 includes an injection transfer guide 61 and an injection molding mechanism. The injection molding mechanism slides along the injection transfer guide 61 and performs mold closing and opening movements together with the moving template 3.

[0050] The injection molding mechanism includes an injection carriage 69, an injection power assembly, a plasticizing assembly 65, and a feeder 68 mounted on the injection carriage 69.

[0051] The injection molding power assembly provides ultra-high speed and ultra-high pressure power to the injection molding unit. The injection molding power assembly includes an electric pre-plasticizing servo motor 67 and a reduction gearbox 62 driven by the electric pre-plasticizing servo motor 67. The use of the electric pre-plasticizing servo motor 67 can improve the performance and production efficiency of the injection unit, achieving a more efficient, intelligent, and energy-saving production process.

[0052] By controlling the output torque of the electric pre-plasticizing servo motor 67, precise control of the injection molding process pressure can be achieved, thus enabling precise control of ultra-high pressure power.

[0053] The plasticizing component 65 is connected to the reduction gearbox 62 and rotates via the reduction gearbox 62, thereby enabling smooth operation and high-precision control of the electric pre-plasticizing servo motor 67. The feeding machine 68 provides injection plastic to the plasticizing component 65.

[0054] The plasticizing component 65 mainly includes a barrel 651, a screw, and a nozzle 652.

[0055] The injection molding mechanism also includes a thrust seat assembly 63 and a moving cylinder 64 mounted on the injection carriage 69, which allows the entire injection molding mechanism to be moved away from the moving template 3 when the barrel and screw in the plasticizing component need to be replaced, making operation easier.

[0056] The electric pre-plasticizing servo motor 67 drives the gearbox 62 to rotate, and the gearbox 62 drives the screw to rotate and the feeder 68 to feed the plasticizing components.

[0057] In this embodiment, the injection unit 6 employs a four-cylinder direct-pressure mold-locking system to achieve mold locking. For example... Figure 11 , Figure 12 As shown, the four-cylinder direct-pressure mold-locking system includes four high-pressure mold-locking cylinders 81. The high-pressure mold-locking cylinders 81 are mounted on the moving template 3 and correspond to the main support 4. The rear brake device 10 is mounted on the main support outside the high-pressure mold-locking cylinders 81, cooperating with the high-pressure mold-locking cylinders 81 to achieve mold-locking and braking. A support pull cylinder 82 is also mounted on the tailstock 7.

[0058] In other embodiments, the injection unit 6 employs a multi-cylinder direct-pressure clamping system to achieve clamping. In yet another embodiment, clamping can also be achieved using a single hydraulic cylinder for direct-pressure clamping.

[0059] Four high-pressure clamping cylinders (81) are powered by a servo motor pump station to achieve direct-pressure high-pressure clamping. This reduces the overall size of the equipment, increases the clamping stroke, provides high control precision, and results in excellent clamping performance. The molding equipment utilizes a servo motor pump station for hydraulic power, achieving energy conservation and reduced consumption.

[0060] like Figure 7 , Figure 8 , Figure 9 , Figure 10 As shown, a die-casting unit 5 is integrated on one side of the fixed template 2.

[0061] The die-casting unit 5 includes a high-speed, high-pressure power unit and a die-casting assembly. The die-casting assembly includes a set of injection tie rods 51 connected to the fixed template 2, an injection cylinder 52, an injection rod 53 connected to the injection cylinder, an injection hammer head 54 located at the front end of the injection rod, and a feed cylinder 55 provided on the fixed template 2. The injection hammer head 54 feeds molten aluminum metal into the feed cylinder 55 via a feeder and pushes it into the forming mold.

[0062] The die-casting unit 5 further includes a die-casting plate 58, and the injection cylinder 52 is mounted on the die-casting plate 58. The piston rod of the injection cylinder is connected to the injection rod 53. One end of the injection pull rod 51 is connected to the fixed template 2, and the other end is connected to the die-casting plate 58.

[0063] Correspondingly, an injection hole 21 is provided on the fixed template 2, and the feed cylinder 55 is provided inside the injection hole 21 for injecting the die-casting aluminum liquid into the metal-plastic integrated molding cavity at high speed.

[0064] The high-speed, high-pressure power unit includes a nitrogen supply device 56 and an accumulator 57. The nitrogen supply device 56 includes several nitrogen cylinders for providing power. The nitrogen cylinders are connected to the accumulator 57 via nitrogen pipes. The accumulator injects hydraulic oil into the cylinder at high speed, thereby achieving high-speed, high-pressure die casting of the hydraulic cylinder.

[0065] The accumulator 57 is connected to the injection cylinder 52 and is controlled to be switched on and off via a control valve. In use, the die-casting unit 5 can dynamically adjust the injection pressure according to the die-casting requirements. When opening the mold, it can perform slow and fast opening operations as needed. When the die-casting unit 5 is working, it provides hydraulic oil through the nitrogen supply device 56 of the accumulator and the hydraulic pump to achieve dual-control pressure boosting.

[0066] The die-casting unit 5 uses an intelligent temperature control and pressure regulation system to dynamically adjust the pressure, thereby achieving dynamic injection operation, which breaks through the injection performance of conventional equipment by 40%. It uses 50G ultra-high speed acceleration injection to ensure dense forming of aluminum alloy.

[0067] Example 2: exist Figure 13 In the illustrated embodiment, a die-casting and injection molding integrated molding equipment includes a fixed template 2 and a movable template 3. A die-casting unit 5 is integrated on one side of the fixed template 2, and an injection unit 6 is integrated on one side of the movable template 3. The injection unit 6 moves synchronously with the movable template 3. The die-casting unit 5 and the injection unit 6 are arranged in a facing configuration, and an integrated metal-plastic composite part is achieved by the die-casting unit 5 and the injection unit 6 closing the mold in one step.

[0068] like Figure 13As shown in the figure, in this embodiment, the die casting injection molding integrated molding equipment also includes a mold bridge frame 100, which includes a molding machine mold bridge 101 with a split support structure and an equipment frame 1.

[0069] The molding machine mold bridge 101 adopts a double-support separate structure. The molding machine mold bridge 101 includes a parallel-arranged inward-retracting mold bridge special support rail 102 and an independent moving template sliding foot support rail 103. The inward-retracting mold bridge special support rail is located inside the independent moving template sliding foot support rail and is arranged parallel to each other inside the equipment frame 1.

[0070] The machine utilizes a retractable mold bridge support rail, which is narrower and features a retractable design, significantly reducing the minimum mold thickness and adapting to a wider range of mold thicknesses. This results in a more rational transmission path between the mold bridge and the moving template. The retractable mold bridge support rail 102 and the independent moving template sliding foot support rail 103 can each bear a portion of the weight. Because the retractable mold bridge support rail 102 and the independent moving template sliding foot support rail 103 are designed separately and operate independently, the vibration amplitude of the mold bridge can be effectively reduced by up to 60%. The parallelism of the mold surface is greatly improved, the rigidity of the mold bridge is enhanced, deformation is reduced, the stress on the frame is more even, it is compatible with smaller mold sizes, the frame design uses less material, and the maintenance cycle is extended to 6000 hours.

[0071] In existing technologies, the mold bridge and template sliding foot share the same frame support rail, resulting in an excessively large support span. Under the action of large machines and oversized molds, the deflection in the middle of the mold bridge can reach over 0.3 mm / m, leading to insufficient structural rigidity. This invention employs a separate design of an inward-retractable mold bridge dedicated support rail 102 and an independent movable template sliding foot support rail 103, significantly shortening the support span of the mold bridge and effectively solving the problem of insufficient structural rigidity.

[0072] In existing technologies, the shared support structure between the mold bridge and the moving template results in low space utilization. Furthermore, the shared support structure requires space for the sliding foot movement and the mold bridge thickness itself, thus limiting the minimum mold thickness. This invention employs a separate design of the recessed mold bridge dedicated support rail 102 and the independent moving template sliding foot support rail 103. This design fully utilizes space, eliminating space limitations on the minimum mold thickness and meeting the die-casting needs of molds with varying thicknesses.

[0073] Existing technologies use a shared support structure, which concentrates the weight of the frame onto a single support rail, easily causing excessive local deformation of the guide rail; thermal deformation interference: the heat generated by the sliding friction of the template (up to 80℃) is directly conducted to the support surface of the template bridge and the frame surface. This invention adopts a separate design of the inward-retracting template bridge dedicated support rail 102 and the independent moving template sliding foot support rail 103, which solves the problem of concentrated stress.

[0074] Example 3: like Figure 14 As shown, a die-casting and injection molding integrated molding method is used, which employs the die-casting and injection molding integrated molding equipment described in the above embodiments. The die-casting unit can mold various alloy parts such as aluminum alloy die-castings and magnesium alloy die-castings, while the injection unit can mold various plastic injection molded parts.

[0075] In this embodiment, a large integrated aluminum-plastic automotive structural component is used as an example for illustration.

[0076] In the die casting and injection molding process, an integral molding mold is set according to the shape of the product. In this embodiment, the integral molding mold adopts the following structure.

[0077] The molding die 200 includes a moving die 201 and a fixed die 202, with an integrated metal-plastic molding cavity 203 disposed within both the moving and fixed dies. A plastic part molding cavity 204 is disposed within the moving die 201, and a metal die-casting part molding cavity 205 is disposed within the fixed die 202. The plastic part molding cavity 204 and the metal die-casting part molding cavity 205 are interconnected after mold closing, forming the integrated metal-plastic molding cavity 203. A cooling channel 207 is disposed within the molding die 200 for cooling the die.

[0078] A control mechanism 206 is provided between the plastic part molding cavity 204 and the metal die-casting part molding cavity 205. The control mechanism 206 controls the opening and closing of the plastic part molding cavity 204 and the metal die-casting part molding cavity 205. In this embodiment, the control mechanism uses a driving component to drive a movable slider to control the opening and closing of the cavity.

[0079] In use, the control mechanism 206 is in the closed state, and the plastic part molding cavity 204 and the metal die casting part molding cavity 205 are not connected to each other. Metal die casting is performed by the die casting unit 5, and then the temperature is cooled down to the injection molding temperature. Then the control mechanism 206 is turned on, so that the plastic part molding cavity 204 and the metal die casting part molding cavity 205 are connected to each other. At this time, the metal die casting part has been formed. The injection unit 6 directly injection molds the plastic part onto the formed metal die casting part, thereby forming a metal-plastic composite structural part.

[0080] A die-casting injection molding method includes the following steps: Step 1: Mold closing: The piston rod of the moving mold cylinder 9 extends and pushes the moving template 3 to move along the axis of the large rod 4, so that the moving mold 201 and the fixed mold 202 in the integrated molding mold 200 close and contact to close the mold, forming the metal-plastic integrated molding cavity 203; Step 2: The rear brake device 10 closes, clamping and fixing the tail end of the main bar 4 to form a mechanical rigid support; Step 3: Mold clamping: The pistons of four high-pressure mold clamping cylinders 81 advance forward, applying axial tensile force to the large rod 4, so that the parting surface of the one-piece molding mold 200 generates a predetermined mold clamping force, and the hydraulic system maintains the set pressure. Step 4: Die-casting metal matrix: The control mechanism 206 is in the closed state, and the plastic part molding cavity 204 and the metal die-casting part molding cavity 205 are not connected to each other. The die-casting unit 5 operates, injecting molten metal under high pressure into the metal die-casting part molding cavity 205 of the integrated metal-plastic molding cavity. The molten metal cools and solidifies inside the metal die-casting part molding cavity 205 to form a metal matrix; Step 5: Cooling: The cooling system cools the one-piece mold 200, reducing the overall temperature of the one-piece mold 200 to the temperature required for injection molding; Step 6: Injection Molding: Activate the control mechanism 206 to connect the plastic part molding cavity 204 and the metal die-casting part molding cavity 205. The injection unit 6 operates, injecting plastic from the moving template 3 into the plastic part molding cavity 204 of the integrated metal-plastic molding cavity and into the metal die-casting part molding cavity 205 to cover the metal substrate. The plastic injection molded part is then formed on the metal substrate. After cooling, a combination of the integrated plastic part and the metal die-casting part is obtained. Step 7: Mold opening and ejection: After molding, the mold is opened and the ejector pins push out the metal-plastic composite structural part, completing the die casting injection molding.

[0081] In step 6, the injection pressure of injection unit 6 shall not be less than 201 MPa, the air injection rate shall not be less than 1066 g / s, the screw speed shall be at least 109 rpm, the maximum injection speed shall be at least 86 mm / s, and the injection stroke shall be at least 550 mm.

[0082] In this embodiment, the injection pressure of the injection unit 6 in step 6 is 201 MPa, the air injection rate is 1066 g / s, the screw speed is 109 rpm, the maximum injection speed is 86 mm / s, and the injection stroke is 550 mm.

[0083] This system achieves simultaneous metal die casting and engineering plastic reinforcement molding within a single machine, breaking through the bottleneck of traditional single-process equipment. Utilizing dynamic injection force, it surpasses conventional equipment injection performance by 40%, with 70G ultra-high-speed acceleration ensuring dense aluminum alloy molding. Precision control and an autonomous closed-loop control algorithm achieve high precision injection speed control and strong stability at low speeds. Ultra-high pressure injection molding is employed: a 9500i ultra-high pressure injection unit combined with a two-platen clamping mechanism ensures high precision and high quality in the molding of complex structural parts. Improved production efficiency: reduced machine tool and mold changes; reduced intermediate transfer steps (cycle time reduced by 37.5%). Improved quality: interface porosity reduced to below 0.01%; high product dimensional accuracy and high bonding strength, achieving molecular-level bonding between metal and plastic. Cost advantages: equipment investment reduced by 42% (compared to two independent machines); labor costs reduced by 60%.

[0084] This die-casting and injection molding integrated molding method adopts a dual-process integrated molding of die casting and injection molding, with deep integration of the two processes. It integrates high-pressure die casting of aluminum alloy and precision injection molding of engineering plastics in the same machine, realizing high-strength molecular-level bonding between metal and plastic; it reduces the assembly links of traditional multi-process manufacturing, shortens the production cycle, and improves manufacturing efficiency; it adopts an intelligent temperature control and pressure regulation system to ensure high bonding strength of aluminum-plastic interface and avoid material deformation and defects.

[0085] It can be widely used in core application scenarios such as battery pack frames, body structures, and chassis components of new energy vehicles, achieving a weight reduction ratio of 30%-50%. It demonstrates significant advantages in improving strength, extending range, and ensuring safety, and is in line with the trend of green manufacturing.

[0086] Example 4: A die-casting injection molding integrated molding method, which uses the die-casting injection molding integrated molding equipment described in the above embodiments.

[0087] In this embodiment, the integrated aluminum-plastic large automobile A-pillar is illustrated by taking the integral molding of aluminum alloy die-cast parts and injection molded parts on a steel frame as an example.

[0088] In the die-casting and injection molding process, an integrated molding mold is set according to the shape of the product. In this embodiment, the integrated molding mold includes a die-casting mold for integrally casting aluminum alloy onto a steel frame and an injection mold for integrally molding the injection molded part onto the steel frame. Specifically, the die-casting mold is set according to the shape of the aluminum alloy die-casting part, and the injection mold is set according to the shape of the injection molded part. That is, in the die-casting and injection molding process, the steel frame and a portion of the aluminum alloy die-casting part serve as the die-casting substrate, and the aluminum alloy die-casting part is directly formed on the die-casting substrate through die casting. Similarly, in the die-casting and injection molding process, the steel frame and a portion of the injection molded part serve as the injection molding substrate, and the injection molded part is directly formed on the injection molding substrate through injection molding.

[0089] Because the steel frame of the A-pillar is relatively large, and the aluminum alloy die-casting parts and plastic parts are located at a relatively far position on the A-pillar, the aluminum alloy die-casting parts and plastic parts can be formed on the steel frame simultaneously using this die-casting injection molding machine.

[0090] Specifically, a die-casting injection molding integrated molding method includes the following steps: Mold closing stage: Step 1: Mold Moving Drive Stage: The piston rod of the mold moving cylinder extends, pushing the moving template to move along the axis of the main rod, causing the moving template to move towards the fixed template. At the same time, the die-casting mold and the injection mold close.

[0091] Step 2: Pre-locking stage: The rear brake device closes, clamping and fixing the tail end of the boom to form a mechanical rigid support.

[0092] Step 3: High-pressure clamping stage: The piston of the high-pressure clamping cylinder moves forward, applying axial tensile force to the main block, so that the parting surfaces of the die-casting mold and the injection mold generate a predetermined clamping force, and the hydraulic system maintains the set pressure.

[0093] Step 4: The die-casting unit operates, injecting molten aluminum under high pressure into the die-casting mold from the fixed template side. The molten aluminum encapsulates the steel frame and solidifies to form a single die-cast metal frame. Simultaneously, the injection unit operates, injecting plastic into the injection mold from the moving template side to encapsulate the steel frame. The plastic part is then integrally molded onto the steel frame, forming a composite component consisting of a metal die-cast part and a plastic part integrally molded onto the steel frame.

[0094] Step 5: The cooling system cools and lowers the temperature of the die-casting mold and the injection mold.

[0095] Step 6: Mold opening and ejection: After molding, the die-casting mold and the injection mold open simultaneously, and the ejector pins push out the composite part.

[0096] Mold making stage: Step 1: Mold clamping force release stage: The hydraulic circuit of the high-pressure mold clamping cylinder is switched to the pressure relief state, and the piston rod retracts to release the axial tension of the main clamp.

[0097] Step 2: Mechanical unlocking stage: The rear brake device is released, releasing the radial constraint on the main beam.

[0098] Step 3: Template retraction stage: The piston rod of the mold moving cylinder retracts, driving the moving template and moving mold to retreat along the main shaft axis to the set mold opening position, realizing the mold opening operation, taking out the metal-plastic integrated molded part, and completing the molding and production of the aluminum-plastic integrated large automotive structural part.

[0099] This system achieves simultaneous molding of metal die casting and metal skeleton, as well as metal skeleton and engineering plastic reinforcement structures, within a single machine, breaking through the bottleneck of traditional single-process equipment. It employs dynamic injection force, exceeding the injection performance of conventional equipment by 40%, and 70G ultra-high-speed acceleration ensures dense molding of aluminum alloys. Precision control and an autonomous closed-loop control algorithm achieve high precision in injection speed control and strong stability in low-speed ranges. Ultra-high pressure injection molding is used: a 9500i ultra-high pressure injection unit combined with a two-platen clamping mechanism ensures high precision and high quality in the molding of complex structural parts. Improved production efficiency: reduced machine tool and mold changes; reduced intermediate transfer steps (cycle time reduced by 37.5%). Improved quality: interface porosity reduced to below 0.01%; high product dimensional accuracy and high bonding strength, achieving molecular-level bonding between metal and plastic. Cost advantages: equipment investment reduced by 42% (compared to two independent machines); labor costs reduced by 60%.

[0100] This equipment can be widely used in core application scenarios such as battery pack frames, body structures, and chassis components of new energy vehicles. It can achieve a weight reduction ratio of 30%-50%, and shows significant advantages in terms of improving strength, extending range, and ensuring safety, while also aligning with the trend of green manufacturing.

[0101] This die-casting and injection molding integrated molding equipment adopts a dual-process integrated molding of die casting and injection molding, with deep integration of the two processes. It integrates high-pressure die casting of aluminum alloy and precision injection molding of engineering plastics in the same machine, realizing high-strength molecular-level bonding between metal and plastic; it reduces the assembly links of traditional multi-process manufacturing, shortens the production cycle, and improves manufacturing efficiency; it adopts an intelligent temperature control and pressure regulation system to ensure high bonding strength of aluminum-plastic interface and avoid material deformation and defects.

[0102] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A die-casting injection molding integrated molding equipment, comprising a fixed template (2) and a movable template (3), characterized in that: A die-casting unit (5) is integrated on one side of the fixed template (2); an injection unit (6) is integrated on one side of the movable template (3), and the injection unit (6) moves synchronously with the movable template (3); the die-casting unit (5) and the injection unit (6) are arranged in a shooting configuration, and the integral metal-plastic composite part is achieved by the die-casting unit (5) and the injection unit (6) closing the mold in one go.

2. The die-casting and injection molding integrated molding equipment according to claim 1, characterized in that: The injection unit (6) adopts an ultra-high speed and ultra-high pressure injection unit; the injection unit (6) includes an injection transfer guide (61) and an injection mechanism; the injection mechanism includes an injection power component, a plasticizing component (65) and a feeder (68).

3. The die-casting and injection molding integrated molding equipment according to claim 2, characterized in that: The injection molding power assembly is used to provide ultra-high speed and ultra-high pressure power. The injection molding power assembly includes an electric pre-plasticizing servo motor (67) and a gearbox (62). The plasticizing assembly (65) mainly includes a barrel (651), a screw and a nozzle (652).

4. The die-casting and injection molding integrated molding equipment according to any one of claims 1 to 3, characterized in that: The die-casting unit (5) includes a high-speed, high-pressure power unit and die-casting components controlled by an intelligent temperature and pressure regulation system.

5. The die-casting and injection molding integrated molding equipment according to claim 4, characterized in that: The die-casting assembly includes an injection cylinder (52), an injection rod (53) connected to the injection cylinder (52), and an injection hammer (54) located at the front end of the injection rod (53). A feed cylinder (55) is provided on the fixed template (2). The injection hammer (54) is driven by the injection cylinder (52) to push the molten metal inside the feed cylinder (55) into the molding die. The high-speed high-pressure power unit includes a nitrogen supply device (56) and an accumulator (57).

6. The die-casting and injection molding integrated molding equipment according to any one of claims 1 to 3, characterized in that: It also includes a molding machine mold bridge (101) with a dual-support separation structure, wherein the molding machine mold bridge (101) includes a parallel-arranged inward-retracting mold bridge special support rail (102) and an independent moving template sliding foot support rail (103).

7. The die-casting and injection molding integrated molding equipment according to any one of claims 1 to 3, characterized in that: The molding equipment also includes a mold-moving cylinder (9) that moves the moving template (3) and the injection unit (6), a direct-pressure mold-locking system (8), and a rear brake device (10); the direct-pressure mold-locking system (8) uses a servo motor pump station to provide hydraulic power.

8. A method for integral die casting and injection molding, characterized in that: It employs the die-casting and injection molding integrated molding equipment as described in any one of claims 1 to 7, and specifically includes the following steps: S1: Mold Closure: The moving mold cylinder pushes the moving template to close the mold. S2: The rear brake device closes the brake, forming a rigid mechanical support; S3: Mold clamping: The high-pressure mold clamping cylinder is activated, causing a predetermined mold clamping force to be generated at the mold parting surface, and the hydraulic system maintains the set pressure. S4: Die-cast metal matrix: The die-casting unit and the injection unit operate in steps or simultaneously, forming an injection from both sides of the mold to integrally mold a metal die-cast-plastic composite part. S5: Mold opening and ejection of composite parts.

9. The die-casting and injection molding integrated molding method according to claim 8, characterized in that: In step 4, during the formation of the metal die-casting and injection molding composite part, the die-casting unit and the injection unit operate in separate steps: First, the die-casting unit operates, injecting molten metal into the integrated metal-plastic molding cavity under high pressure, where the molten metal solidifies to form a metal matrix; then, the cooling system cools the molding mold, reducing its temperature to the injection molding requirements; finally, the injection unit operates, injecting plastic from one side of the moving template into the integrated metal-plastic molding cavity to coat the metal matrix, thus forming a combined plastic and metal die-cast part.

10. The die-casting and injection molding integrated molding method according to claim 8, characterized in that: In step 4, during the formation of the steel skeleton, metal die casting, and injection molding composite, the die casting unit and the injection unit operate synchronously: the die casting unit operates by injecting molten aluminum into the die casting mold under high pressure from the fixed template side, and the molten aluminum covers the steel skeleton and solidifies to form an integral die casting of the metal steel skeleton; the injection unit operates simultaneously by injecting plastic into the injection mold from the moving template side to cover the steel skeleton, and integrally molding the plastic part on the steel skeleton, thus forming a composite part of the three materials: metal die casting and plastic part integrally molded on the steel skeleton.

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