A die cast assembly and method of manufacturing the same

Abstract

The application provides a die-casting assembly and a manufacturing method thereof, comprising an outer shell and an inner core, the outer shell is die-cast and formed in two stages, and has a first cavity and a second cavity connected with each other; the inner core is filled in the second cavity and extends to the first cavity at least partially, and comprises a first half shell and a second half shell which are die-cast; wherein the first cavity and the second cavity are both provided with openings; and the two half shells are spliced to form a closed inner cavity, which is configured to be opened by mechanical processing in the direction of the openings of the two cavities or at the positions of the openings, so as to form a channel which communicates the first cavity and the second cavity. The inner core is formed by two half shells, so that the structure of the existing faucet body is improved, the smoothness of the inner cavity is ensured, and the water quality is prevented from being polluted again.

Description

Technical Field

[0001] This invention relates to a die-casting component (particularly a faucet body) and a method for manufacturing the die-casting component. Background Technology

[0002] As people's aesthetic and quality requirements increase, more and more products are using metal materials. For example, faucet bodies. In pursuit of unique functions and appearances, the structure of faucet bodies is becoming increasingly complex, leading to greater difficulty in mold forming. Currently, the main forming methods for faucet bodies are low-pressure casting (two-stage forming) or die casting (direct core pulling). Low-pressure casting (two-stage forming) involves first forming a sand core, then placing the sand core into a low-pressure mold and pouring it to form the casting. Finally, the sand core is removed from the casting. This results in an uneven inner cavity, and incomplete sand core removal easily leads to sand core residue. If water is directly passed through a faucet body with sand core residue, it will cause water pollution. Therefore, it is difficult to obtain a smooth, flat, and clean inner cavity during the production of existing faucet body structures. Summary of the Invention

[0003] This invention discloses a die-casting component, which aims to improve the structure of existing faucet bodies to ensure the smoothness and flatness of the inner cavity, while avoiding secondary pollution of water quality.

[0004] The present invention adopts the following solution:

[0005] A die-cast assembly includes a housing and an inner core, the housing being formed by die casting in two stages and having a first chamber and a second chamber connected together; the inner core filling the second chamber and extending at least partially into the first chamber, the inner core comprising a first half-shell and a second half-shell formed by die casting.

[0006] Both the first chamber and the second chamber are provided with openings;

[0007] The two half-shells are joined together to form a closed inner cavity. The closed inner cavity is constructed by mechanically opening the two chambers in the opening direction or at the opening position to form a channel connecting the first chamber and the second chamber.

[0008] As a further improvement, the two shell halves are assembled, riveted, or welded to form the closed inner cavity.

[0009] As a further improvement, the second half-shell is provided with support columns and / or reinforcing ribs, the ends of which are disposed against or close to the inner wall of the first half-shell to prevent deformation of the first half-shell.

[0010] As a further improvement, parallel guide ribs are provided along the extension direction of the channel to allow water pipes to pass through.

[0011] As a further improvement, the outer shell is die-cast from a first material, and the two half-shells are die-cast from a second material, wherein the melting point of the first material is not higher than the melting point of the second material.

[0012] As a further improvement, the first material is at least one of zinc alloy, aluminum alloy, copper alloy, magnesium alloy, ceramic, and plastic.

[0013] As a further improvement, the second material is at least one of zinc alloy, copper alloy, aluminum alloy, magnesium alloy, ceramic, and plastic.

[0014] Another method for manufacturing the die-cast component as described above includes the following steps:

[0015] S1: Die-cast the first and second half-shells;

[0016] S2: Weld the first half-shell and the second half-shell together to form the inner core;

[0017] S3: Place the inner core from step S2 into the mold for secondary die casting. The molten metal enters the mold cavity through the die casting machine to form the outer shell.

[0018] S4: Remove the outer shell from step S3, and perform mechanical processing to open the sealed inner cavity.

[0019] As a further improvement, in step S2, the inner core is provided with a positioning part at least corresponding to one of the opening positions. The positioning part abuts against and limits the inner wall of the mold cavity to reduce the number of mold core-pulling sliders.

[0020] As a further improvement, the die-casting machine has a material temperature of 200-800℃, an injection pressure of 50-150 kg / cm2, an injection time of 0.5-3 s, and a cooling time of 2.5-7.5 s.

[0021] By adopting the above technical solution, the present invention can achieve the following technical effects:

[0022] This application utilizes two die-cast half-shells to form a core with a closed inner cavity, preventing molten metal from entering the closed inner cavity during the outer shell molding process, thus achieving a smooth and flat inner cavity. Simultaneously, the two-half-shell design of the inner core allows for direct die-casting of the functional structure of the inner cavity, reducing production costs, avoiding sand core residue issues, and ensuring that the closed inner cavity will not pollute water quality. Furthermore, it allows for uniform wall thickness of the outer shell containing the inner core and enables machining to open through the closed inner cavity from the opening direction or position, facilitating machining. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the structure of one embodiment of the present invention;

[0025] Figure 2 This is a cross-sectional view along one section of one embodiment of the present invention;

[0026] Figure 3 A cross-sectional view of the inner core along one of the sections of one embodiment of the present invention;

[0027] Figure 4 It simulates the deformation of the inner core during the secondary die-casting process when no support pillars are set;

[0028] Figure 5 It simulates the deformation of the inner core during the secondary die-casting process when the support columns are set;

[0029] Figure 6 This is a schematic diagram of the mold structure according to one embodiment of the present invention;

[0030] Figure 7 yes Figure 6 A magnified view of A in the middle.

[0031] Icons: 1-Outer shell; 11-First chamber; 111-First opening; 12-Second chamber; 121-Second opening;

[0032] 2-Inner core; 21-First half-shell; 22-Second half-shell; 221-Support column; 23-Closed inner cavity; 24-Guide rib; 25-Positioning part;

[0033] 3-Mold cavity; 31-Slider. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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 a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to represent selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Example

[0036] Combination Figures 1 to 3 This embodiment provides a die-casting assembly, including an outer shell 1 and an inner core 2. The outer shell 1 is formed by die casting and has a first chamber 11 and a second chamber 12 connected to each other. The inner core 2 fills the second chamber 12 and extends at least partially into the first chamber 11. The inner core 2 includes a first half-shell 21 and a second half-shell 22 formed by die casting. The first chamber 11 and the second chamber 12 are both provided with openings. The two half-shells are joined together to form a closed inner cavity 23. The closed inner cavity 23 is configured to be opened by mechanical processing in the direction of the opening of the two chambers or at the opening position to form a channel connecting the first chamber 11 and the second chamber 12.

[0037] It should be noted that in this embodiment, the inner core 2 with a closed inner cavity 23 is formed by two die-cast half-shells to prevent molten metal from entering the closed inner cavity 23 during the molding of the outer shell 1, thereby obtaining a smooth and flat inner cavity. Simultaneously, the inner core 2 adopts a two-half-shell design, which can be directly die-cast, reducing production costs, avoiding sand core residue problems, and ensuring that the closed inner cavity will not pollute the water quality. Furthermore, this design allows for a uniform wall thickness of the outer shell 1 filled with the inner core 2, and the closed inner cavity 23 can be machined through from the opening direction or opening position to facilitate machining.

[0038] For example, the portion of the inner core 2 extending into the first chamber 11 exactly encircles half of the first chamber 11. The inner core 2 located in the first chamber 11 is machined along the direction of the first opening 111 on the first chamber 11 so that the closed inner cavity 23 communicates with the first chamber 11. In other embodiments, the inner core 2 completely fills the first chamber 11, and the closed inner cavity 23 is simultaneously machined open when the first opening 111 is machined, but not limited to this.

[0039] In a preferred embodiment, the two half-shells are assembled, riveted, or welded to form a closed inner cavity 23. Assembly can be achieved using screws, clips, or other methods, without specific limitation. The gap between the two half-shells must be sealed to prevent metal from entering the closed inner cavity 23. The two half-shells can be symmetrically arranged front-to-back or asymmetrically arranged vertically to facilitate the division of the two half-shells during molding, thereby reducing or eliminating the need for core pulling and sliders in the half-shell molding mold, further reducing production costs.

[0040] In another embodiment, the second half-shell 22 is provided with support columns 221, the ends of which abut against or are close to the inner wall of the first half-shell 21 to prevent deformation of the first half-shell 21. For example, the bottom of the first half-shell 21 is horizontal, and multiple support columns 221 are symmetrically arranged on the second half-shell 22 near the side wall along the extending direction of the enclosed inner cavity 23. Figure 4 The simulation showed the deformation of the inner core 2 under a 30MPa pressure from molten metal when the second half-shell 22 was not supported by a support column 221. The maximum deformation at point B was 4.75 mm, which is too large to meet production requirements. Combined with... Figure 5 The simulation showed the deformation of the inner core 2 under a 30MPa pressure from molten metal when supported by the support column 221. The maximum deformation at point C was 3.56, which was within a controllable range and did not affect the product's function, thus meeting production requirements.

[0041] Furthermore, parallel guide ribs 24 are provided along the extension direction of the channel to facilitate the installation of the water pipe. The guide ribs 24 are preferably located on the second half-shell 22, but can also be located on the first half-shell 21, or guide ribs 24 can be provided at corresponding positions on both half-shells. For example, the first chamber 11 is used to install the valve core, the opening of the second chamber 12 is the water outlet, one end of the water pipe is connected to the valve core, and the other end passes through the channel and along the guide ribs 24 to the opening of the water outlet to connect with the water outlet structure on the water outlet.

[0042] Based on the above embodiments, in an optional embodiment of the present invention, the outer shell 1 is die-cast using a first material, and the two half-shells are die-cast using a second material. The melting point of the first material is not higher than that of the second material. Specifically, the first material is at least one of zinc alloy, aluminum alloy, copper alloy, magnesium alloy, ceramic, and plastic. The second material is at least one of zinc alloy, copper alloy, aluminum alloy, magnesium alloy, ceramic, and plastic.

[0043] Combination Figure 6 and Figure 7 Another method for manufacturing a die-cast component as described in any of the above embodiments is provided, comprising the following steps:

[0044] S1: The first half-shell 21 and the second half-shell 22 are die-cast. During the casting process, deformation of the half-shells must be prevented.

[0045] S2: Weld the first half-shell 21 and the second half-shell 22 to form the inner core 2. The welding should be uniform and without gaps.

[0046] S3: The inner core 2 from step S2 is placed into the mold for secondary die casting. The molten metal enters the mold cavity 3 through the die casting machine to form the outer shell 1.

[0047] S4: Remove the outer shell 1 from step S3 (eject and remove the product under the action of the die-casting machine), perform machining to open the opening and open the closed inner cavity 23, wherein the machining to open the opening includes threading, etc.

[0048] Furthermore, in step S2, the inner core 2 has a positioning part 25 protruding at least one of the opening positions. The positioning part 25 abuts against and limits the inner wall of the mold cavity 3 to reduce the number of mold core-pulling sliders. In one embodiment, the inner core 2 has a first positioning part and a second positioning part, wherein the first positioning part protrudes at the position of the first opening 111, and the second positioning part protrudes at the position of the second opening 121. Both positioning parts 25 abut against the inner wall of the mold cavity 3, thereby reducing the number of sliders at the two openings. In another embodiment, a positioning part 25 is formed at one end of the inner core 2, which protrudes at the second opening 121 to save the core-pulling slider at the second opening 121. The other end of the inner core 2 is located at the position of the first chamber 11 and cooperates with the slider 31 to form the first chamber 11 and the first opening 111. This is not limited to this embodiment and is not specifically limited.

[0049] Preferably, in the mold-closed state, the die-casting machine maintains a material temperature of 200-800℃, an injection pressure of 50-150 kg / cm², an injection time of 0.5-3 s, and a cooling time of 2.5-7.5 s. For example, the die-casting machine maintains a material temperature of 425±15℃, an injection pressure of 110±10 kg / cm², an injection time of 1.3 s±0.2 s, and a cooling time of 4.5 s±1 s, thereby ensuring that the die-cast product has a defect-free appearance.

[0050] It should be mentioned that the manufacturing method of this embodiment is simple and stable, with high production efficiency and low production cost. The die-cast product has a smooth inner wall, which can effectively avoid secondary pollution of water quality during the use of the product.

[0051] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions that fall within the scope of the present invention are within the scope of protection of the present invention.

Claims

1. A die cast assembly, characterized by, The device includes an outer shell and an inner core. The outer shell is formed by die casting and has a first chamber and a second chamber connected to each other. The inner core fills the second chamber and extends at least partially into the first chamber. The inner core includes a first half-shell and a second half-shell formed by die casting. Both the first chamber and the second chamber are provided with openings; The two half-shells are joined together to form a closed inner cavity. The closed inner cavity is constructed by mechanically opening the two chambers in the opening direction or at the opening position to form a channel connecting the first chamber and the second chamber. Two half-shells are welded together, and the joint between the two half-shells is sealed to form the closed inner cavity. The bottom of the first half-shell is horizontal, and multiple support columns are symmetrically arranged on the second half-shell near its side wall along the extension direction of the closed inner cavity. The end of each support column abuts against the inner wall of the first half-shell. Parallel guide ribs are provided on the second half-shell along the extension direction of the channel. The die-casting assembly also includes a valve core and a water pipe installed in the first chamber. The opening of the second chamber is the water outlet. One end of the water pipe is connected to the valve core, and the other end passes through the channel and along the guide rib to the opening of the water outlet to connect with the water outlet structure on the water outlet.

2. The die-casting assembly according to claim 1, characterized in that, The outer shell is die-cast from a first material, and the two half-shells are die-cast from a second material. The melting point of the first material is not higher than that of the second material.

3. The die-casting assembly according to claim 2, characterized in that, The first material is at least one of zinc alloy, aluminum alloy, copper alloy, magnesium alloy, ceramic, and plastic.

4. The die-casting assembly according to claim 2, characterized in that, The second material is at least one of zinc alloy, copper alloy, aluminum alloy, magnesium alloy, ceramic, and plastic.

5. A method for manufacturing a die-cast component as described in claim 1, characterized in that, Includes the following steps: S1: Die-cast the first and second half-shells; S2: The first half-shell and the second half-shell are welded evenly without leaving any gap for the secondary die-casting molten metal to enter the closed inner cavity, so as to form an inner core; the inner core is provided with a positioning part at least corresponding to one of the opening positions of the first chamber and the second chamber, so that the positioning part abuts against and limits the inner wall of the mold cavity of the secondary die-casting mold. S3: The inner core is placed into the secondary die-casting mold, and the molten metal enters the mold cavity through the die-casting machine to form an outer shell covering the inner core; S4: Remove the outer shell from step S3, and perform mechanical processing to open the sealed inner cavity.

6. The method for manufacturing a die-cast component according to claim 5, characterized in that, The inner core has a first positioning part and a second positioning part. The first positioning part protrudes from the opening of the first chamber, and the second positioning part protrudes from the opening of the second chamber. Both positioning parts abut against and limit the inner wall of the mold cavity to reduce the number of mold core-pulling sliders.

7. The method for manufacturing a die-cast component according to claim 5, characterized in that, The die-casting machine has a material temperature of 200-800℃, an injection pressure of 50-150 kg / cm², an injection time of 0.5-3 s, and a cooling time of 2.5-7.5 s.

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