A casting outer mold structure for a housing of a new energy vehicle

Abstract

The present invention provides a casting outer mold structure for a housing of a new energy vehicle, which relates to the technical field of casting of vehicle housings. The casting outer mold structure for a housing of a new energy vehicle includes: an upper mold core; a lower mold core; inserts, a plurality of inserts being arranged between the opposite surfaces of the upper mold core and the lower mold core; and a driving assembly, which is drivingly connected to the inserts. When the driving assembly is in a high-temperature environment, the plurality of inserts, the upper mold core and the lower mold core are used to form a cavity for the housing to be formed; when the high-temperature environment where the driving assembly is located cools down, the plurality of inserts move away from the cavity. During the demolding process of the present invention, there is no contact between the surface of the insert after retraction and the motor end cover casting, thereby reducing the demolding resistance, eliminating the holding force between the casting and the mold, avoiding surface scratches or rib fractures caused by forced demolding of traditional molds, and greatly improving the yield rate.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive housing casting, and more particularly, to an outer mold structure for casting a housing for a new energy vehicle. Background Art

[0002] With the rapid development of the new energy vehicle industry, lightweight and high-strength aluminum alloy housings (such as motor end covers and battery pack housings) have become key components. Such housings typically have characteristics such as thin walls, multiple ribs, and complex curved surfaces, posing strict requirements for the casting process: not only ensuring dimensional accuracy and surface quality but also achieving efficient demolding and a low defect rate. However, traditional casting molds face the following technical bottlenecks when meeting such requirements.

[0003] When an aluminum alloy casting cools and shrinks, it is prone to generate a holding force with the mold cavity, especially in high-resistance areas such as ribs and bosses. Most traditional molds rely on ejector pins or lifters to force demolding, which easily causes scratches on the casting surface or breaks in the ribs, resulting in a poor yield rate. Summary of the Invention

[0004] To solve the above problems, the present invention provides an outer mold structure for casting a housing for a new energy vehicle.

[0005] The present invention provides an outer mold structure for casting a housing for a new energy vehicle, including: an upper mold core; a lower mold core; inserts, a plurality of the inserts being disposed between opposite surfaces of the upper mold core and the lower mold core; and a driving assembly, drivingly connected to the inserts. When the driving assembly is in a high-temperature environment, the plurality of inserts, the upper mold core, and the lower mold core are configured to form a cavity for housing molding; when the high-temperature environment where the driving assembly is located cools down, the plurality of inserts move away from the cavity.

[0006] The driving assembly includes a thermal expansion extension rod and a hollow positioning block. One end of the thermal expansion extension rod is connected to one end within the hollow positioning block, and the other end of the thermal expansion extension rod passes through the other end within the hollow positioning block and is connected to the insert.

[0007] Optionally, a first cooling channel is provided in the upper mold core. One end of the first cooling channel is in communication with the hollow positioning block, and the other end of the first cooling channel extends out of the upper mold core, and the path of the first cooling channel is a serpentine path along the rib groove of the upper mold core.

[0008] Optionally, a second cooling channel is provided in the lower mold core. One end of the second cooling channel is in communication with the hollow positioning block, and the other end of the second cooling channel extends out of the lower mold core.

[0009] Optionally, a first variable seal is provided at the connection between the hollow positioning block and the first cooling channel, and a second variable seal is provided at the connection between the hollow positioning block and the second cooling channel. The second variable seal has the same structure as the first variable seal. When the first variable seal and the second variable seal are in a high-temperature environment, the first cooling channel and the second cooling channel are respectively in a sealed state. When the high-temperature environment where the first variable seal and the second variable seal are located cools down, the sealed states of the first cooling channel and the second cooling channel are gradually released respectively.

[0010] Optionally, the driving assembly further includes a conduction frame, which is arranged inside the hollow positioning block and is connected to the thermal expansion extension rod.

[0011] Optionally, the top of the conduction frame is connected to the first variable seal, and the bottom of the conduction frame is connected to the second variable seal.

[0012] Optionally, the first variable seal includes a rubber ball and a copper rod. One end of the copper rod is connected to the conduction frame, and the other end of the copper rod is connected to the rubber ball.

[0013] Optionally, a first groove is provided on the bottom surface of the upper die core, and a second groove is provided on the top surface of the lower die core. When the upper die core and the lower die core are closed, the hollow positioning block is embedded in the first groove and the second groove. A communication groove is provided between the second groove and the cavity, and the insert is arranged in the communication groove.

[0014] Optionally, the first cooling channel is integrally formed in the upper die core, and the second cooling channel is integrally formed in the lower die core.

[0015] The beneficial effects of the casting outer mold structure of the shell for new energy vehicles of the present invention are as follows: After the upper die core and the lower die core are positioned and closed, the upper die core and the lower die core are preheated to a preset temperature. At this time, the driving assembly is in a high-temperature environment. Multiple inserts, the upper die core and the lower die core are used to form a cavity for the shell to be formed. The aluminum alloy metal liquid is injected into the cavity at high speed and high pressure through the gating system (injection cylinder and injection punch) to ensure that the aluminum alloy metal liquid can quickly and accurately fill the cavity. After maintaining pressure for a preset time, the upper die core and the lower die core are cooled to the preset temperature. At this time, the driving assembly is cooled to the preset temperature, so that the inserts move away from the cavity. In other words, the inserts can retreat outward synchronously. The ejection mechanism jacks up the motor end cover casting. Since there is no contact between the surface of the motor end cover casting and the inserts after the inserts retreat, the demolding resistance is reduced, the clamping force between the casting and the mold is eliminated, and the surface scratches or rib fractures caused by forced demolding of the traditional mold are avoided, greatly improving the qualified product rate. Description of the Drawings

[0016] Figure 1 Explosion schematic diagram of the casting outer mold structure for a new energy vehicle in an embodiment of the present invention;

[0017] Figure 2 Explosion schematic diagram of the casting outer mold structure for a new energy vehicle in another perspective in an embodiment of the present invention;

[0018] Figure 3 Schematic diagram of the structure of the lower mold core in the casting outer mold structure for a new energy vehicle in an embodiment of the present invention;

[0019] Figure 4 Cross-sectional view of the casting outer mold structure for a new energy vehicle in an embodiment of the present invention;

[0020] Figure 5 Variation state diagram of the driving component in the casting outer mold structure for a new energy vehicle in an embodiment of the present invention;

[0021] Figure 6 is Figure 5 Enlarged view of the structure at A in

[0022] Explanation of reference numerals: 1, upper mold core; 11, first groove; 12, first cooling channel; 2, lower mold core; 21, second groove; 22, communication groove; 23, second cooling channel; 3, insert block; 4, driving component; 41, thermal expansion extension rod; 42, conduction frame; 43, hollow positioning block; 5, first variable seal; 51, rubber ball; 52, copper rod; 6, cavity; 7, second variable seal. Detailed implementation manners

[0023] In order to make the above objects, features and advantages of the present invention more obvious and understandable, the following detailed description of the specific embodiments of the present invention will be given with reference to the accompanying drawings.

[0024] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, the terms "installation", "connection" and "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection or an integral connection; it can be a direct connection or an indirect connection through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0025] In the description of this specification, the descriptions referring to terms such as "embodiment", "one embodiment", "some embodiments", "exemplarily", and "one embodiment" mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or embodiment are included in at least one embodiment or embodiment of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or embodiment. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or embodiments.

[0026] The terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first", "second" may explicitly or implicitly include at least one of the features.

[0027] The embodiment of the present invention provides a casting outer mold structure for a new energy vehicle housing, including: an upper mold core 1; a lower mold core 2; inserts 3, a plurality of inserts 3 being arranged between the opposite surfaces of the upper mold core 1 and the lower mold core 2; and a driving assembly 4, drivingly connected to the inserts 3. When the driving assembly 4 is in a high-temperature environment, the plurality of inserts 3, the upper mold core 1, and the lower mold core 2 are used to form a cavity 6 for housing molding; when the high-temperature environment where the driving assembly 4 is located cools down, the plurality of inserts 3 move away from the cavity 6.

[0028] It should be noted that the outer mold structure designed in this solution is applicable to the manufacture of the housing of new energy vehicles, specifically for the manufacture of a motor end cover with reinforcing ribs. The casting equipment used to manufacture the motor end cover with reinforcing ribs includes the outer mold structure designed in this solution, which is used to form the outer contour and reinforcing ribs of the motor end cover; an inner mold structure (not shown in the figure): arranged inside the cavity 6, used to form the inner cavity, shaft hole, and mounting hole of the end cover; the inserts 3 are located between the upper mold core 1 and the lower mold core 2, surrounding the circumference of the cavity 6, used to form a complex contour structure of the housing (such as reinforcing ribs). If the housing needs to form multiple radial reinforcing ribs (rib strips), the inner side of the inserts 3 can be designed as a groove matching the outer contour of the reinforcing ribs (such as Figure 3), ensure that the ribs are full and there is no material shortage when the molten metal fills the mold. The gating system (not shown in the figure): includes a runner and ingates, which are distributed along the direction of the ribs of the lower mold core 2 to avoid the direct impact of the molten metal on the cavity 6; the ejection mechanism (not shown in the figure): is arranged at the bottom of the lower mold core 2 and is linked with the retraction movement of the insert 3 to ensure that the casting is demolded without deformation. The casting equipment also includes a fixed mold base, a moving mold base, a core-pulling mechanism, etc. This solution does not involve the improvement of the above components and will not be elaborated here. For example, when manufacturing a motor end cover with ribs, the motor end cover is a thin-walled aluminum alloy part with a thickness of 3-5 mm. The outer edge of the end cover is provided with radially distributed ribs (height 8-10 mm, width 4-6 mm) in a circular pattern, and a shaft hole is provided in the center, with bolt mounting holes and heat dissipation grooves distributed circumferentially.

[0029] In this alternative embodiment, as Figure 1 , Figure 2 , Figure 3 and Figure 4 shown, after the upper mold core 1 and the lower mold core 2 are positioned and clamped, the upper mold core 1 and the lower mold core 2 are preheated to a preset temperature. At this time, the driving assembly 4 is in a high-temperature environment. The multiple inserts 3, the upper mold core 1 and the lower mold core 2 are used to form a cavity 6 for the shell to be formed. The aluminum alloy molten metal is injected into the cavity 6 at high speed and high pressure through the gating system (injection cylinder and injection punch) to ensure that the aluminum alloy molten metal can quickly and accurately fill the cavity 6. After holding pressure for a preset time, the upper mold core 1 and the lower mold core 2 are cooled to the preset temperature. At this time, the driving assembly 4 is cooled to the preset temperature, causing the insert 3 to move away from the cavity 6. In other words, the insert 3 can retract synchronously outward. The ejection mechanism lifts the motor end cover casting. Since there is no contact between the surface of the casting and the insert 3 after the insert 3 retracts, the demolding resistance is reduced, the clamping force between the casting and the mold is eliminated, and the surface scratches or rib fractures caused by forced demolding in traditional molds are avoided, greatly improving the yield rate.

[0030] Optionally, the driving assembly 4 includes a thermal expansion extension rod 41 and a hollow positioning block 43. One end of the thermal expansion extension rod 41 is connected to one end inside the hollow positioning block 43, and the other end of the thermal expansion extension rod 41 passes through the other end inside the hollow positioning block 43 and is connected to the insert 3.

[0031] Further, a first cooling channel 12 is provided in the upper mold core 1. One end of the first cooling channel 12 is communicated with the hollow positioning block 43, and the other end of the first cooling channel 12 extends out of the upper mold core 1, and the path of the first cooling channel 12 is a serpentine path along the rib groove of the upper mold core 1.

[0032] Optionally, a second cooling channel 23 is provided in the lower mold core 2. One end of the second cooling channel 23 is communicated with the hollow positioning block 43, and the other end of the second cooling channel 23 extends out of the lower mold core 2.

[0033] In this alternative embodiment, in combination with Figure 2 , Figure 4 and Figure 5 as shown, during the cooling process, the coolant (aqueous solution) enters the hollow positioning block 43 through the second cooling channel 23 to cool the conduction frame 42 and the thermal expansion extension rod 41.

[0034] Optionally, a first variable seal 5 is provided at the connection between the hollow positioning block 43 and the first cooling channel 12, and a second variable seal 7 is provided at the connection between the hollow positioning block 43 and the second cooling channel 23. The second variable seal 7 has the same structure as the first variable seal 5. When the first variable seal 5 and the second variable seal 7 are in a high-temperature environment, the first cooling channel 12 and the second cooling channel 23 are respectively in a sealed state. When the high-temperature environment where the first variable seal 5 and the second variable seal 7 are located cools down, the sealed states of the first cooling channel 12 and the second cooling channel 23 are gradually released respectively.

[0035] Furthermore, the driving assembly 4 further includes a conduction frame 42. The conduction frame 42 is disposed inside the hollow positioning block 43 and is connected to the thermal expansion extension rod 41.

[0036] In this alternative embodiment, in combination with Figure 5 and Figure 6 as shown, the conduction frame 42 can be a copper mesh structure, and the conduction frame 42 can be connected to the inner wall of the hollow positioning block 43. The conduction frame 42 can be connected to the thermal expansion extension rod 41 through thermal conductive silicone grease, so as to quickly transfer heat to and from the thermal expansion extension rod 41 through the conduction frame 42.

[0037] Optionally, the top of the conduction frame 42 is connected to the first variable seal 5, and the bottom of the conduction frame 42 is connected to the second variable seal 7.

[0038] Furthermore, the first variable seal 5 includes a rubber ball 51 and a copper rod 52. One end of the copper rod 52 is connected to the conduction frame 42, and the other end of the copper rod 52 is connected to the rubber ball 51.

[0039] Specifically, the rubber ball 51 can be fluororubber. The conduction frame 42 can be connected to one end of the copper rod 52 through thermal conductive silicone grease, and the other end of the copper rod 52 can also be connected to the rubber ball 51 through thermal conductive silicone grease to improve the sensitivity of the rubber ball 51 in responding to thermal expansion and contraction. The rubber ball 51 expands when heated to seal the first cooling channel 12, and the rubber ball 51 contracts when cooled to open the first cooling channel 12.

[0040] In this alternative embodiment, in combination with Figure 5As shown, heat can be quickly transferred between the first variable seal 5 through the conduction frame 42, and the second variable seal 7 can be stably fixed at the connection between the hollow positioning block 43 and the second cooling channel 23 through the conduction frame 42. When the upper die core 1 and the lower die core 2 are preheated to a preset temperature, the thermal expansion extension rod 41 expands and elongates when heated, pushing the insert 3 towards the center of the cavity 6. The insert 3 is in close contact with the communication groove 22 and the bottom surface of the lower die core 2, thus closing to form a complete cavity 6. At this time, the first variable seal 5 and the second variable seal 7 respectively seal the first cooling channel 12 and the second cooling channel 23, improving the pressure holding effect. When cooling the upper die core 1 and the lower die core 2, by injecting coolant into the second cooling channel 23, the second variable seal 7 contracts when cooled, allowing the coolant to enter the hollow positioning block 43 to cool the thermal expansion extension rod 41. Thus, the thermal expansion extension rod 41 contracts and drives the insert 3 to retreat outwards. The first variable seal 5 gradually contracts when cooled, allowing the coolant to enter the first cooling channel 12 to cool the rib grooves of the upper die core 1, thereby specifically cooling the rib groove area of the high-stress end cover housing casting, eliminating shrinkage porosity at the root of the rib grooves, and improving the finished product quality of the motor end cover casting.

[0041] It should be emphasized that the coolant gradually cools the rubber ball 51, causing the rubber ball 51 to gradually contract. In other words, the distance between the outer peripheral surface of the rubber ball 51 and the inner wall of the first cooling channel 12 gradually increases. Therefore, the coolant entering the first cooling channel 12 gradually increases, avoiding internal stress concentration or cracking in the rib groove area of the end cover housing casting due to sudden cooling.

[0042] Furthermore, a first groove 11 is provided on the bottom surface of the upper die core 1, and a second groove 21 is provided on the top surface of the lower die core 2. When the upper die core 1 and the lower die core 2 are closed, the hollow positioning block 43 is embedded in the first groove 11 and the second groove 21. A communication groove 22 is provided between the second groove 21 and the cavity 6, and the insert 3 is arranged in the communication groove 22.

[0043] In this optional embodiment, in combination with Figure 1 、 Figure 2 and Figure 3 As shown, the first groove 11 is integrally formed on the upper die core 1, and the second groove 21 and the communication groove 22 are integrally formed on the lower die core 2. After the upper die core 1 and the lower die core 2 are closed, an installation space for the hollow positioning block 43 is formed. During the processes of closing the die, preheating, injecting aluminum alloy molten metal, and pressure holding, since the thermal expansion extension rod 41 is in a high-temperature environment, the surface of the insert 3 is in close contact with the communication groove 22 and the bottom surface of the lower die core 2, and the insert 3 remains in a closed state, ensuring that the ribs are formed fully. Multiple inserts 3 and the upper die core 1 and the lower die core 2 form a complete cavity 6; during the cooling process, due to cooling the high-temperature environment where the thermal expansion extension rod 41 is located, the insert 3 retreats outwards (in the direction away from the cavity 6).

[0044] Optionally, the first cooling channel 12 is integrally formed within the upper die core 1, and the second cooling channel 23 is integrally formed within the lower die core 2.

[0045] In this optional embodiment, in combination with Figure 1 , Figure 2 and Figure 4 as shown, the first cooling channel 12 and the second cooling channel 23 are integrally formed within the upper die core 1 and the lower die core 2 respectively, making the manufacturing of the first cooling channel 12 and the second cooling channel 23 more convenient and ensuring the uniformity and stability of the cooling effect.

[0046] Although the present invention is disclosed as above, the scope of protection of the present invention is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and these changes and modifications will all fall within the scope of protection of the present invention.

Claims

1. A casting outer mold structure for a new energy vehicle shell, characterized in that, Comprising: Upper die core (1); Lower die core (2); Inserts (3), a plurality of the inserts (3) are arranged between the opposite surfaces of the upper die core (1) and the lower die core (2); And A driving component (4), which is drivingly connected to the insert (3). When the driving component (4) is in a high-temperature environment, a plurality of the inserts (3), the upper die core (1) and the lower die core (2) are used to form a cavity (6) for the shell to be molded. When the high-temperature environment where the driving component (4) is located cools down, a plurality of the inserts (3) move away from the cavity (6); The driving component (4) includes a thermal expansion extension rod (41) and a hollow positioning block (43). One end of the thermal expansion extension rod (41) is connected to one end inside the hollow positioning block (43), and the other end of the thermal expansion extension rod (41) passes through the other end inside the hollow positioning block (43) and is connected to the insert (3); A first cooling channel (12) is provided in the upper die core (1). One end of the first cooling channel (12) is communicated with the hollow positioning block (43), and the other end of the first cooling channel (12) extends out of the upper die core (1), and the path of the first cooling channel (12) is a serpentine path along the rib groove of the upper die core (1); A second cooling channel (23) is provided in the lower die core (2). One end of the second cooling channel (23) is communicated with the hollow positioning block (43), and the other end of the second cooling channel (23) extends out of the lower die core (2); A first variable seal (5) is provided at the connection between the hollow positioning block (43) and the first cooling channel (12), and a second variable seal (7) is provided at the connection between the hollow positioning block (43) and the second cooling channel (23). The second variable seal (7) has the same structure as the first variable seal (5). When the first variable seal (5) and the second variable seal (7) are in a high-temperature environment, the first cooling channel (12) and the second cooling channel (23) are respectively in a sealed state. When the high-temperature environment where the first variable seal (5) and the second variable seal (7) are located cools down, the sealed states of the first cooling channel (12) and the second cooling channel (23) are gradually released.

2. The casting outer mold structure for the housing of a new energy vehicle according to claim 1, wherein, The driving component (4) further includes a conduction frame (42), the conduction frame (42) is arranged inside the hollow positioning block (43), and the conduction frame (42) is connected to the thermal expansion extension rod (41).

3. The outer mold structure for casting the housing of a new energy vehicle according to claim 2, characterized in that, The top of the conduction frame (42) is connected to the first variable seal (5), and the bottom of the conduction frame (42) is connected to the second variable seal (7).

4. The outer mold structure for casting the housing of a new energy vehicle according to claim 3, characterized in that, The first variable seal (5) includes a rubber ball (51) and a copper rod (52). One end of the copper rod (52) is connected to the conduction frame (42), and the other end of the copper rod (52) is connected to the rubber ball (51).

5. The casting outer mold structure for a new energy vehicle housing as described in claim 1, wherein, The bottom surface of the upper die core (1) is provided with a first groove (11), and the top surface of the lower die core (2) is provided with a second groove (21). When the upper die core (1) and the lower die core (2) are closed, the hollow positioning block (43) is embedded in the first groove (11) and the second groove (21). A communication groove (22) is provided between the second groove (21) and the cavity (6), and the insert block (3) is arranged in the communication groove (22).

6. The casting outer mold structure of the housing for new energy vehicles according to claim 1, characterized in that, The first cooling channel (12) is integrally formed in the upper die core (1), and the second cooling channel (23) is integrally formed in the lower die core (2).

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