Faucet, method for manufacturing the same, and mold for producing the faucet

Abstract

The application discloses a preparation method of a faucet, which comprises the following steps: preparing an inner container, wherein a cavity is arranged in the inner container; placing the inner container into a core of a mold, leaving a forming space between the inner container and the core, first pumping out the gas in the cavity of the inner container, then injecting filling oil into the cavity, and sealing the filling oil in the cavity; injecting alloy raw materials into the forming space, and releasing the filling oil in the cavity, wherein the alloy raw materials in the forming space are cooled and formed to obtain a finished product. The preparation method provided by the application has high production efficiency, does not need core-pulling forming, saves materials, and simultaneously obtains the faucet with a smooth cavity surface and uniform wall thickness.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of faucets, in particular to a faucet, a preparation method thereof and a mold for producing the faucet. BACKGROUND

[0002] In the prior art, the faucet is often made by low-pressure casting process, and the internal waterway needs to be formed by core pulling. With the increasing complexity of the structure of the faucet, and the internal waterway of the faucet is often designed to be curved, the low-pressure casting has the problems of low qualification rate and low production capacity. The existing high-pressure casting process cannot form a cavity by core pulling because the existing sand core is generally mainly made of resin, and the resin-made sand core cannot withstand the high pressure in the high-pressure casting process, and the sand core is often damaged during injection, resulting in that a complete cavity cannot be formed. SUMMARY

[0003] The technical problem to be solved by the present application is to provide a preparation method of a faucet, which has high production efficiency, does not need core forming, saves materials, and at the same time, the cavity surface of the faucet prepared by the method is smooth and the wall thickness is uniform.

[0004] The technical problem to be solved by the present application is also to provide a mold for producing a faucet, which can efficiently and stably prepare a faucet with a smooth cavity surface and uniform wall thickness.

[0005] The technical problem to be solved by the present application is also to provide a faucet with a smooth cavity surface and uniform wall thickness.

[0006] To solve the above technical problems, the present application provides a preparation method of a faucet, comprising the following steps:

[0007] Preparation of an inner container, wherein the inner container is provided with a cavity;

[0008] Placing the inner container into a core of a mold, leaving a forming space between the inner container and the core, first removing the gas in the cavity of the inner container, then injecting filling oil into the cavity, and sealing the filling oil in the cavity;

[0009] Injecting alloy raw materials into the forming space, and then releasing the filling oil in the cavity, wherein the alloy raw materials in the forming space are cooled and formed to obtain a finished product.

[0010] In an embodiment, after the filling oil is injected into the cavity of the inner container, the filling oil accounts for 98.5% to 99.5% of the volume of the cavity;

[0011] The temperature resistance range of the filling oil is 150℃ to 200℃;

[0012] The filling oil further comprises sand and / or steel balls.

[0013] In one embodiment, the inner container is prepared by a stamping process;

[0014] The raw material of the inner container is one of brass alloy, zinc alloy, and stainless steel alloy;

[0015] The wall thickness of the inner container is 0.2mm-0.5mm.

[0016] In one embodiment, the alloy raw material comprises the following components in percentage by mass: 59%-63% Cu, 2.8%-3.2% Si, 0.05%-0.07% P, 0.01%-0.04% Mg, 0.008%-0.012% B, 0.005%-0.009% Zr, and the balance Zn.

[0017] In one embodiment, the alloy raw material comprises the following components in percentage by mass: 59%-63% Cu, 2.8%-3.2% Si, 0.05%-0.07% P, 0.02%-0.03% Mg, 0.009%-0.011% B, 0.006%-0.008% Zr, and the balance Zn.

[0018] In one embodiment, the alloy raw material is injected into the forming space by using a high-pressure casting device or a low-pressure casting device, the filling oil in the cavity is released, and the finished product is obtained after cooling and forming.

[0019] In one embodiment, the alloy raw material is injected into the forming space by using a high-pressure casting device, the filling oil in the cavity is released, and the finished product is obtained after cooling and forming;

[0020] The process parameters of the high-pressure casting device during injection are as follows: injection pressure is 15Mpa-100Mpa, injection time is 0.01s-0.5s, and forming time is 0.01s-0.5s.

[0021] To solve the above problems, the application further provides a mold for producing a faucet, comprising an upper mold and a lower mold which are detachably connected and form a mold cavity for accommodating a core in the inside, the core is provided with an inner container, the shape of the core is matched with the shape of the inner container, and a forming space is left between the inner container and the core, the shape of the inner container is matched with the shape of the inner cavity of the faucet to be formed, and the inner container is provided with a cavity, one end of the cavity is sealingly connected with an oil inlet, and the other end of the cavity is sealingly connected with an oil outlet.

[0022] In one embodiment, the core is provided with a liquid injection port, and the liquid injection port is connected with the forming space;

[0023] The oil inlet is connected with an oil inlet cylinder, and the oil outlet is connected with an oil outlet cylinder.

[0024] Correspondingly, the application further provides a faucet prepared by the faucet preparation method.

[0025] The application has the following beneficial effects:

[0026] The faucet preparation method provided by the application uses an inner container with a hollow cavity to replace the filling core in the prior art, the inner container supports the inner container by injecting filling oil, and after molding, the filling oil is directly discharged to obtain a faucet with a smooth cavity, and the method has high production efficiency, saves materials, and makes the wall thickness of the faucet uniform.

[0027] The mold for producing the faucet provided by the application is matched with the faucet preparation method to efficiently and stably produce a faucet with a smooth cavity surface and uniform wall thickness. BRIEF DESCRIPTION OF DRAWINGS

[0028] Fig. 1 FIG. 1 is a structural schematic diagram of the mold for producing the faucet according to the application;

[0029] Fig. 2 FIG. 2 is a structural schematic diagram of the mold for producing the faucet according to the application, in which the upper mold is removed to expose the core;

[0030] Fig. 3 FIG. 3 is a structural schematic diagram of the mold for producing the faucet according to the application, in which the upper mold and the core are removed to expose the inner container. DETAILED DESCRIPTION

[0031] To make the object, technical scheme and advantages of the application clearer, the application is further described in detail below.

[0032] To solve the above technical problem, the application provides a faucet preparation method, which comprises the following steps:

[0033] S1, preparing an inner container, the inner container being provided with a cavity;

[0034] In an embodiment, the inner container is prepared by a stamping process; preferably, the inner container is obtained by bulging.

[0035] In an embodiment, the raw material of the inner container is one of brass alloy, zinc alloy and stainless steel alloy; preferably, the raw material of the inner container is stainless steel.

[0036] In an embodiment, the wall thickness of the inner container is 0.2mm-0.5mm. If the wall thickness of the inner container is too thin, bending deformation will occur during the molding process, which will eventually result in uneven wall thickness of the faucet. If the wall thickness of the inner container is too thick, it will increase the difficulty of manufacturing the inner container, which is not conducive to improving the production efficiency.

[0037] S2, placing the inner container into the core of the mold, leaving a molding space between the inner container and the core, first removing the gas in the cavity of the inner container, then injecting filling oil into the cavity, and sealing the filling oil in the cavity;

[0038] In an embodiment, the gas in the cavity of the inner container is first removed, so that the cavity is in a negative vacuum state, which is conducive to the automatic flow of the filling oil into the cavity. In an embodiment, after the filling oil is injected into the cavity of the inner container, the filling oil accounts for 98.5%-99.5% of the volume of the cavity. A certain space is left in the cavity when the filling oil is injected, which is conducive to forming a temperature difference between the inside and outside of the cavity, thereby playing a heat insulation role, so that the filling oil can better support the inner container. Finally, the filling oil is sealed in the cavity. The mold with a specific structure of the present application can seal the filling oil in the cavity and can withstand a certain pressure. In an embodiment, the temperature resistance range of the filling oil is 150℃-200℃. In this way, the filling oil can be prevented from cracking during the molding process, thereby losing the supporting effect. Preferably, the filling oil includes machine oil or lubricating oil, and more preferably, the filling oil further includes sand and / or steel balls, which can help the internal structure of the cavity to be molded.

[0039] S3, injecting alloy raw materials into the molding space, and then releasing the filling oil in the cavity, and the alloy raw materials in the molding space are cooled and molded to obtain a finished product.

[0040] In an embodiment, high-pressure casting equipment or low-pressure casting equipment is used to inject alloy raw materials into the molding space, and then release the filling oil in the cavity, and the alloy raw materials in the molding space are cooled and molded to obtain a finished product. Preferably, high-pressure casting equipment is used to inject alloy raw materials into the molding space, and then release the filling oil in the cavity, and the alloy raw materials in the molding space are cooled and molded to obtain a finished product.

[0041] It should be noted that in the prior art, the faucet often adopts low-pressure casting process, and the internal waterway needs to be formed by core pulling. With the increasing complexity of the structure of the faucet, and often with the design of a curved waterway inside the faucet, low-pressure casting has problems such as low qualification rate and low production capacity. Moreover, in the core pulling process, the surface of the cavity is often not fine enough, and the surface roughness is not uniform. The existing high-pressure casting process cannot form a cavity by core pulling, because the existing sand core is generally mainly made of resin, and the resin-made sand core cannot withstand the high-pressure environment in the high-pressure casting process, and often the sand core is damaged during injection, resulting in that a complete cavity cannot be formed. The inner container with a hollow cavity in the present application replaces the filling core in the prior art. The inner container supports the inner container by injecting filling oil. The inner container can withstand the high-pressure environment during high-pressure casting, and does not need to be formed by core pulling after forming. The filling oil is directly discharged to obtain a faucet with a smooth cavity.

[0042] In an embodiment, the process parameters of the high-pressure casting device during injection are as follows: the injection pressure is 15 Mpa-100 Mpa, the injection time is 0.01 s-0.5 s, and the forming time is 0.01 s-0.5 s. Under these conditions, the finished product has high dimensional accuracy, good stability, and good surface finish; the strength and hardness of the finished product are relatively high, the strength of the finished product is increased by 25-30% compared with that of the finished product produced by low-pressure casting; and the production efficiency is high, and the machine production rate is high.

[0043] Further, the present application uses an environmentally friendly lead-free silicon brass to prepare a faucet. In an embodiment, the alloy raw material comprises the following components in terms of mass percentage: 59%-63% Cu, 2.8%-3.2% Si, 0.05%-0.07% P, 0.01%-0.04% Mg, 0.008%-0.012% B, 0.005%-0.009% Zr, and the balance is Zn. Preferably, the alloy raw material comprises the following components in terms of mass percentage: 59%-63% Cu, 2.8%-3.2% Si, 0.05%-0.07% P, 0.02%-0.03% Mg, 0.009%-0.011% B, 0.006%-0.008% Zr, and the balance is Zn. It should be noted that the alloy raw material is not limited to the above composition, and the above alloy raw material can also be selected from other compositions of brass alloy or zinc alloy.

[0044] Specifically, the above-mentioned alloy raw material is a silicon-phosphorus environmentally friendly brass, which replaces lead, bismuth and other metals with silicon and phosphorus which are abundant in the earth's crust, which is conducive to sustainable development, and the silicon-phosphorus environmentally friendly brass has better casting performance and is more suitable for high-pressure casting. However, the existing silicon-phosphorus environmentally friendly brass has poor dezincification corrosion resistance, and can only be applied to medium and low-end bathroom products with low corrosion resistance requirements.

[0045] In order to improve the corrosion resistance and casting performance, the P content in the alloy raw material is 0.05% to 0.07%, when the P content is greater than 0.07%, the alloy raw material will produce hot brittle and cold brittle characteristics, and casting porosity defects will also appear, which will affect the tissue density; when the P content is less than 0.05%, the cutting performance of the alloy raw material will be reduced.

[0046] In addition, the addition of boron and zirconium to the alloy raw material can refine the alloy structure. When the addition range of B is 0.009% to 0.011%, the modification treatment has the best refining effect, the gamma phase is uniform and fine spherical particles, the mechanical properties of the alloy raw material are improved, and it is helpful for high pressure casting. When the addition range of Zr is 0.006% to 0.008%, the corrosion resistance of the alloy material can be obviously improved, the polarization resistance of the alloy material is improved, the corrosion current is reduced, and the dezincification corrosion resistance in the copper chloride solution is significantly improved.

[0047] In summary, the preparation method of the faucet provided by the present application uses an inner container with a hollow cavity to replace the filling core in the prior art. The inner container supports the inner container by injecting filling oil. After molding, the filling oil is discharged to obtain a faucet with a smooth cavity. The method has high production efficiency, saves materials, and the wall thickness of the faucet is uniform. Further, by selecting a specific alloy raw material and using a specific high-pressure casting process, a faucet product with high dimensional accuracy, good stability, good surface finish, high mechanical strength and hardness, and strong corrosion resistance can be obtained.

[0048] Correspondingly, the present application also provides a mold for producing a faucet, as shown in Figs. 1-3 The upper mold 1 and the lower mold 2 are detachably connected and form a mold cavity for accommodating the core 3 inside. The core 3 is provided with an inner container 4. The shape of the core 3 is matched with the shape of the inner container 4, and a molding space 5 is left between the inner container 3 and the core 4. The shape of the inner container 4 is matched with the shape of the inner cavity of the faucet to be molded, and the inner container 4 is provided with a cavity. One end of the cavity is sealingly connected with an oil inlet 41, and the other end of the cavity is sealingly connected with an oil outlet 42.

[0049] In one embodiment, the core 3 is provided with a liquid injection port connected with the molding space 5.

[0050] The oil inlet 41 is connected with an oil inlet cylinder 61, and the oil outlet 42 is connected with an oil outlet cylinder 62.

[0051] The mould for producing the faucet is matched with the faucet manufacturing method, and can efficiently and stably manufacture the faucet with smooth cavity surface and uniform wall thickness.

[0052] The application is further described in the following specific examples:

[0053] Example 1

[0054] The application provides a faucet manufacturing method, which comprises the following steps.

[0055] S1, preparing an inner container, wherein the inner container is provided with a cavity;

[0056] Specifically, the inner container is prepared by stamping process, the raw material of the inner container is stainless steel, and the wall thickness of the inner container is 0.3 mm.

[0057] S2, placing the inner container into a core of a mould, leaving a forming space between the inner container and the core, first removing the gas in the cavity of the inner container, then injecting filling oil into the cavity, and sealing the filling oil in the cavity;

[0058] The mould comprises an upper mould and a lower mould, the upper mould and the lower mould are detachably connected and internally form a cavity for accommodating the core, the core is provided with the inner container, the shape of the core is matched with the shape of the inner container, and a forming space is left between the inner container and the core, the shape of the inner container is matched with the shape of the inner cavity of the faucet to be formed, and the inner container is provided with the cavity, one end of the cavity is sealingly connected with an oil inlet, and the other end of the cavity is sealingly connected with an oil outlet.

[0059] S3, injecting alloy raw material into the forming space by using a high-pressure casting device, and then releasing the filling oil in the cavity, and the alloy raw material in the forming space is cooled and formed to obtain a finished product.

[0060] The process parameters of the high-pressure casting device during injection are as follows: injection pressure is 30 Mpa, injection time is 0.5 s, and forming time is 0.5 s.

[0061] The alloy raw material comprises the following components in percentage by mass: 59% Cu, 3.0 Si, 0.06% P, 0.03% Mg, 0.01% B, 0.007% Zr, and the balance is Zn.

[0062] Example 2

[0063] The alloy raw material includes the following components by mass percentage: 63% Cu, 2.8 Si, 0.05% P, 0.04% Mg, 0.012% B, 0.009% Zr, and the balance of Zn. The rest is the same as example 1.

[0064] Example 3

[0065] The alloy raw material includes the following components by mass percentage: 60% Cu, 3.2 Si, 0.07% P, 0.01% Mg, 0.008% B, 0.005% Zr, and the balance of Zn. The rest is the same as example 1.

[0066] Example 4

[0067] The alloy raw material includes the following components by mass percentage: 59% Cu, 3.0 Si, 0.06% P, 0.03% Mg, 0.014% B, 0.007% Zr, and the balance of Zn. The rest is the same as example 1.

[0068] Example 5

[0069] The alloy raw material includes the following components by mass percentage: 59% Cu, 3.0 Si, 0.06% P, 0.03% Mg, 0.01% B, 0.004% Zr, and the balance of Zn. The rest is the same as example 1.

[0070] Comparative Example 1

[0071] The embodiment provides a preparation method of a faucet, comprising the following steps:

[0072] S1, a solid inner liner is prepared by using resin, the shape of the inner liner is the same as that of a faucet to be formed.

[0073] S2, the solid inner liner is placed into a core of a mold, the shape of the core is matched with that of the inner liner, and a forming space is left between the inner liner and the core;

[0074] S3, an alloy raw material is injected into the forming space by using a low-pressure casting device, the solid inner liner is extracted after cooling and forming, and a finished product is obtained.

[0075] The composition of the alloy raw material is the same as that of example 1.

[0076] The wall thickness and the cavity surface roughness of the faucet prepared by the example 1 and the comparative example 1 are tested, the testing method is that the faucet prepared by the example 1 and the comparative example 1 is divided into 5 equal parts along the length direction, and each equal part is taken as a testing point, 5 testing points are obtained respectively, the average wall thickness and the average roughness of the 5 points are calculated, and the weight of the whole faucet is tested, and the testing results are shown in table 1.

[0077] Table 1 is the performance testing results of the faucet prepared by the example 1 and the comparative example 1

[0078]

[0079] From the above results, compared with the existing core forming method, the cavity surface of the faucet prepared by the preparation method of the faucet provided by the application is smooth, the wall thickness is uniform, and the weight reduction is close to 100g, the material is saved, and the production cost is low.

[0080] Further, the mechanical strength and corrosion resistance of the faucet prepared by the example 1 to 5 and the comparative example 1 are tested, the mechanical strength testing method refers to GB / T228.1-2010, the corrosion resistance testing method is that the sample is obtained by wire cutting, the exposed area of each sample is 120mm 2 ; the exposed surface of the sample is polished with sandpaper, washed and placed in a beaker containing copper chloride heated to 75℃±2℃ for corrosion test, and the timing is started at the same time, and the plastic film is covered on the beaker mouth and tightened. After 24h of corrosion, the sample is prepared by the method of metallographic test, grinding and polishing, and the thickness of the dezincification layer is observed and measured under the scanning electron microscope after the sample preparation. The testing results are shown in table 2.

[0081] Table 2 is the performance testing results of the faucet prepared by the example 1 to 5 and the comparative example 1

[0082]

[0083] From the data in table 2, the alloy raw material with specific composition is selected, and the high pressure casting process with specific process is matched, so that the faucet product with high size precision, good stability, good surface finish, high mechanical strength and hardness, and strong corrosion resistance can be prepared.

[0084] The above is the preferred embodiment of the application, it should be pointed out that for ordinary skilled in the art, without departing from the principle of the application, a number of improvements and refinements can be made, these improvements and refinements are also considered as the protection scope of the application.

Claims

1. A method for preparing a faucet, characterized in that, Includes the following steps: Prepare an inner liner, wherein the inner liner has a cavity; The inner liner is placed into the core of the mold, with a forming space between the inner liner and the core. First, the gas in the cavity of the inner liner is removed, then filling oil is injected into the cavity, and the filling oil is sealed in the cavity. Alloy raw materials are injected into the molding space, and then the filling oil in the cavity is released. After the alloy raw materials in the molding space are cooled and shaped, the finished product is obtained. After filling oil is injected into the cavity of the inner liner, the filling oil occupies 98.5% to 99.5% of the cavity volume; The temperature resistance range of the filler oil is 150℃~200℃; the filler oil also includes grease and steel balls; The inner liner is made of one of the following materials: brass alloy, zinc alloy, or stainless steel alloy; the wall thickness of the inner liner is 0.2mm to 0.5mm. Alloy raw materials are injected into the molding space using high-pressure casting equipment, and then the filling oil in the cavity is released. After cooling and molding, the finished product is obtained. The alloy raw material comprises the following components by mass percentage: 59%~63% Cu, 2.8%~3.2% Si, 0.05%~0.07% P, 0.01%~0.04% Mg, 0.008%~0.012% B, 0.005%~0.009% Zr, with the balance being Zn; The mold includes an upper mold and a lower mold, which are detachably connected and form a cavity inside to accommodate a core. The core has an inner liner, the shape of which is adapted to the shape of the inner liner, and a forming space is left between the inner liner and the core. The shape of the inner liner is adapted to the inner cavity shape of the faucet to be formed, and the inner liner has a channel. One end of the channel is sealed to the oil inlet, and the other end of the channel is sealed to the oil outlet.

2. The method for preparing a faucet as described in claim 1, characterized in that, The inner liner is manufactured using a stamping process.

3. The method for preparing a faucet as described in claim 1, characterized in that, The alloy raw material comprises the following components by mass percentage: 59%~63% Cu, 2.8%~3.2% Si, 0.05%~0.07% P, 0.02%~0.03% Mg, 0.009%~0.011% B, 0.006%~0.008% Zr, with the balance being Zn.

4. The method for preparing a faucet as described in claim 1, characterized in that, The process parameters for injection in the high-pressure casting equipment are: injection pressure of 15 MPa to 100 MPa, injection time of 0.01 s to 0.5 s, and molding time of 0.01 s to 0.5 s.

5. The method for preparing a faucet as described in claim 1, characterized in that, The core is provided with a liquid injection port, which is connected to the molding space; The oil inlet is connected to the oil inlet cylinder, and the oil outlet is connected to the oil outlet cylinder.

6. A faucet, characterized in that, The faucet is prepared according to the faucet preparation method according to any one of claims 1 to 5.

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