A multi-station casting vacuum injection molding machine

Abstract

This invention relates to the field of casting molding machine technology and discloses a multi-station casting vacuum casting machine, comprising: a mounting base and a casting mold, the casting mold including two separate molds; a vacuum head performs a vacuuming operation on the interior of the casting mold; the casting operation only begins when the vacuum sensor detects that the vacuum level inside the casting mold meets a preset value. Existing vacuum casting equipment suffers from insufficient mold sealing reliability. When using recycled polyurethane and other plastic waste to prepare recycled replica products, residual gas easily remains in the mold cavity, resulting in a high incidence of product defects such as bubbles and shrinkage cavities, and a low yield. This invention, by adopting a separate mold structure and controlling the opening and closing by a drive push rod, triggers the casting action only when the vacuum sensor confirms that the cavity has reached the set vacuum level. Through the timing logic of docking, vacuuming, and casting, it ensures that the mold cavity is in an effective vacuum state before casting, avoiding product defects caused by residual gas and improving molding quality and yield.

Description

Technical Field

[0001] This invention relates to the field of casting molding machine technology, specifically to a multi-station casting vacuum casting machine. Background Technology

[0002] Vacuum casting is a key process in polyurethane (PU) resin casting molding. It can be used for the preparation of new product prototypes and as an important means of recycling and remanufacturing plastic waste. Recycled polyurethane plastic waste is prepared into liquid resin, which is then cast and cured in a vacuum environment, achieving the recycling and reuse of solid plastic waste. This process typically involves first preparing a silicone master mold, then injecting liquid polyurethane or recycled resin into the mold cavity in a vacuum environment, and finally curing to obtain the target part.

[0003] A vacuum injection molding machine is disclosed in the prior art (application number CN202111658912.4). The quantitative feeding module includes multiple accommodating boxes, multiple cartridge-type material bottles, multiple connecting units, and multiple material handling units. Each cartridge-type material bottle contains a flexible storage bag for storing liquid materials and has a needle valve-type discharge port. Each connecting unit has a needle body and is located within the accommodating boxes. The cartridge-type material bottle is inserted into the accommodating box so that the needle body drives the needle valve-type discharge port to open. The connecting unit is connected to the material handling units, which quantitatively deliver the material to the automatic casting module. This machine features a high degree of automation, automatically measuring silicone material and molding material, improving teaching efficiency and quality. The cartridge-type material bottle structure for storing liquid molding material provides good sealing and convenient material replenishment.

[0004] However, existing technologies, especially this particular solution, still have the following problems: Lack of effective vacuum control and casting sequence linkage mechanism: Although the existing technology has automatic feeding and quantitative casting functions, it does not set up logical linkage control between vacuum detection and casting action. Casting operation may be performed when the mold cavity does not reach the required vacuum level, resulting in the inability of residual gas in the cavity to be effectively discharged, which can easily produce molding defects such as bubbles and shrinkage cavities, affecting the compactness and surface quality of the molded product. Insufficient mold sealing and lack of dynamic sealing protection structure: Existing equipment adopts an integral or simple split mold structure, without setting a dedicated flexible sealing gasket on the mold mating surface, and there is no pressing and sealing mechanism for the mold closing process. Air leakage is prone to occur during vacuuming and pouring, making it difficult to maintain a stable high vacuum environment, thereby reducing process repeatability and product consistency. Summary of the Invention

[0005] The purpose of this invention is to provide a technical solution that adopts a split mold structure and sets up docking vacuum casting timing logic to solve the problems in the prior art mentioned in the background.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A multi-station casting vacuum casting machine includes: a mounting base and a casting mold. A mold base is slidably mounted on the mounting base via a moving rod. The casting mold includes two split molds. One split mold is mounted on the mounting base, and the other split mold is correspondingly mounted on the mold base. A drive push rod for driving the two split molds to open and close is provided on the mounting base. The casting mold is equipped with a pouring head and a vacuum head. The upper and lower parts of the casting mold are equipped with interfaces. The pouring head and the vacuum head correspond to the upper and lower interfaces, respectively. A vacuum sensor is installed inside the casting mold. After the pouring head and the vacuum head are connected to the pouring mold, the vacuum head begins to evacuate the inside of the pouring mold; when the vacuum sensor detects that the vacuum level inside the pouring mold meets the preset value, the vacuum head begins to pour the contents of the pouring mold.

[0007] Preferably, the casting mold is internally designed with a heating component and multiple temperature sensors. During the process of the air extraction head pouring into the casting mold, the heating component and multiple temperature sensors work together to maintain the temperature inside the casting mold within a preset range.

[0008] Preferably, a sealing gasket is provided on the mating surface of the two split molds of the casting mold. The sealing gasket is a flexible sealing gasket to ensure that the two split molds fit tightly together, thereby ensuring the sealing effect inside the casting mold cavity.

[0009] Preferably, the mold base and the mounting base are provided with mold mounting grooves, and multiple sets of casting molds are installed side by side on the mold base and the mounting base through the mold mounting grooves.

[0010] Preferably, the movable rod is slidably inserted into the mounting base, and a displacement sensor is provided between the mounting base and the movable rod. The displacement sensor is used to record the different movement strokes of the movable rod when loading different casting molds.

[0011] Preferably, an end plate is fixedly installed at the end of the movable rod, and the end plate is connected to the mounting base through a connecting rod and a movable linkage group. The telescopic end of the drive push rod is movably connected to the movable linkage group, and the drive push rod pulls the mold base through the movable linkage group, thereby realizing the closure between the two separate molds of the casting mold.

[0012] Preferably, the mounting base is installed on the machine base, and the machine base is equipped with a controller. The controller controls the pouring head and the air extraction head.

[0013] Preferably, it includes a vacuum pump and a control valve, the vacuum pump being used to provide vacuum drive for the pumping head, and the liquid raw material being poured entering the mold cavity of the casting mold through the control valve and the pouring head.

[0014] Preferably, a fixed base is installed on the mold base, and a telescopic component one for driving the lifting and lowering of the pouring head is installed on the fixed base, and a telescopic component two for driving the lifting and lowering of the air extraction head is provided on the machine base.

[0015] Preferably, the venting pipes of the pouring head and the venting head of the multiple pouring molds are independent of each other, and each pipe is equipped with a one-way shut-off valve. When a leak occurs at a certain station, the one-way shut-off valve at that station will automatically close.

[0016] Technical effects and advantages of the present invention: Compared with the prior art, the multi-station casting vacuum molding machine proposed in this invention has the following advantages: This invention employs a split mold structure, in which one mold is fixed to the mounting base and the other mold moves with the sliding mold base, its opening and closing controlled by a drive push rod; the pouring head and the vacuum head correspond to the mating interfaces of the upper and lower parts of the mold, respectively, and the system is allowed to start vacuuming only after the physical mating is completed; the pouring action is triggered only when the vacuum sensor confirms that the cavity has reached the set vacuum level. By employing a sequential logic of docking, vacuuming, and pouring, the cavity is ensured to be in an effective vacuum state before pouring, avoiding product defects caused by residual gas; the split mold, in conjunction with the drive mechanism, achieves reliable closure, providing a foundation for sealing and subsequent processes; vacuum degree, as a prerequisite for pouring, makes the process controllable and highly repeatable, improving molding quality and yield. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the external structure of the multi-station casting vacuum molding machine of the present invention; Figure 2 This is a schematic diagram of the internal structure of the multi-station casting vacuum molding machine of the present invention; Figure 3 This is a front structural diagram of the multi-station casting vacuum molding machine of the present invention; Figure 4 For the present invention Figure 3 Enlarged structural diagram at point A; Figure 5 This is a schematic diagram of the structure of the casting mold, casting head, and air extraction head in an embodiment of the present invention; Figure 6 This is a schematic diagram of the mold base and mounting base in an embodiment of the present invention.

[0018] In the picture: 11. Base; 12. Mounting base; 13. Control valve; 21. Mold base; 22. Mounting base; 23. Moving rod; 24. Casting mold; 25. Sealing gasket; 26. Movable connecting rod; 27. Drive push rod; 28. Vacuum pump; 29. ​​Casting head; 210. Evacuation head; 211. Telescopic assembly one; 212. Telescopic assembly two; 213. Connecting rod; 214. Displacement sensor; 215. Mold mounting slot; 216. Heating assembly; 217. Temperature sensor; 218. Vacuum sensor; 219. Interface. Detailed Implementation

[0019] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0020] The invention provides, for example Figures 1 to 6 As shown, a multi-station casting vacuum casting machine includes: Mounting base 22 and casting mold 24. Mold base 21 is slidably mounted on mounting base 22 via moving rod 23. Casting mold 24 includes two split molds. One split mold is mounted on mounting base 22 and the other split mold is correspondingly mounted on mold base 21. Mounting base 22 is provided with driving push rod 27 for driving the two split molds to open and close. The casting head 29 and the vacuum head 210 are provided with interface 219 on both the upper and lower parts of the casting mold 24. The casting head 29 and the vacuum head 210 correspond to the interface 219 on the upper and lower parts respectively. A vacuum sensor 218 is provided inside the casting mold 24. After the pouring head 29 and the vacuum head 210 are connected to the pouring mold 24, the vacuum head 210 begins to perform a vacuuming operation inside the pouring mold 24; when the vacuum sensor 218 detects that the vacuum level inside the pouring mold 24 meets the preset value, the vacuum head 210 begins to perform a pouring operation inside the pouring mold 24.

[0021] Working principle: By adopting a split mold structure, one mold is fixed to the mounting base 22, and the other mold moves with the sliding mold base 21 and is controlled to open and close by the drive push rod 27; the pouring head 29 and the vacuum head 210 correspond to the mating interface 219 of the upper and lower parts of the mold, respectively. The system is allowed to start vacuuming only after the physical docking is completed; the pouring action is triggered only when the vacuum sensor 218 confirms that the cavity has reached the set vacuum level.

[0022] By employing a sequential logic of docking, vacuuming, and pouring after reaching the required standard, the cavity is ensured to be in an effective vacuum state before pouring, avoiding product defects caused by residual gas. The split mold, in conjunction with the drive mechanism, achieves reliable closure, providing a foundation for sealing and subsequent processes. Vacuum degree, as a prerequisite for pouring, makes the process controllable and highly repeatable, improving molding quality and yield.

[0023] like Figure 2 As shown, in order to ensure that the resin flows and cures under the optimal temperature conditions and improve the molding quality and consistency, the casting mold 24 is internally designed with a heating component 216 and multiple temperature sensors 217. During the process of the vacuum head 210 pouring into the casting mold 24, the heating component 216 and multiple temperature sensors 217 work together to always maintain the interior of the casting mold 24 within the preset temperature range.

[0024] like Figure 3 and Figure 4 As shown, a flexible sealing structure is used to compensate for mold manufacturing errors, prevent air leakage after mold closing, and ensure the reliability of the vacuum environment. Sealing gaskets 25 are provided on the mating surfaces of the two split molds of the casting mold 24. The sealing gaskets 25 are set as flexible sealing gaskets to ensure that the two split molds fit tightly together, thereby ensuring the sealing effect inside the cavity of the casting mold 24.

[0025] like Figure 5 and Figure 6 As shown, regarding the realization of multiple molds installed side by side to support a true multi-station continuous production mode; the mold base 21 and the mounting base 22 are provided with mold mounting grooves 215, and multiple sets of casting molds 24 are installed side by side on the mold base 21 and the mounting base 22 through the mold mounting grooves 215.

[0026] like Figure 4 As shown, in order to adapt to the changing needs of molds of different sizes, the optimal mold closing stroke is automatically memorized and reproduced to avoid manual adjustment; the moving rod 23 is slidably inserted into the mounting base 22, and a displacement sensor 214 is provided between the mounting base 22 and the moving rod 23. The displacement sensor 214 is used to record the different moving strokes of the moving rod 23 when loading different casting molds 24.

[0027] like Figure 2 and Figure 3 As shown, the linear motion of the drive push rod 27 is smoothly converted into the closing action of the mold base 21 through the linkage mechanism, improving the synchronization of mold closing and the uniformity of force distribution; the end plate is fixedly installed at the end of the moving rod 23, and the end plate is connected to the mounting base 22 through the connecting rod 213 and the movable linkage group 26. The telescopic end of the drive push rod 27 is movably connected to the movable linkage group 26. The drive push rod 27 pulls the mold base 21 through the movable linkage group 26, thereby realizing the closure between the two split molds of the casting mold 24.

[0028] like Figure 1 As shown, in order to integrate the central control system, coordinate the pouring and vacuuming actions, and realize the automation of the process, the mounting base 22 is installed on the machine base 11, and the machine base 11 is equipped with a controller 14. The controller 14 controls the pouring head 29 and the vacuuming head 210.

[0029] like Figure 1 and Figure 2 As shown, in order to clarify the power source and fluid passage structure of vacuum and casting, and to ensure the integrity of system function, a vacuum pump 28 and a control valve 13 are included. The vacuum pump 28 is used to provide vacuum drive for the pump head 210. The liquid raw material to be cast enters the mold cavity of the casting mold 24 through the control valve 13 and the casting head 29.

[0030] like Figures 1 to 3 As shown, independent lifting control of the pouring head 29 and the vacuum head 210 is achieved to ensure precise and reliable docking. A fixed base 12 is installed on the mold base 21, and a telescopic component 211 for driving the lifting of the pouring head 29 is installed on the fixed base 12. A second telescopic component 212 for driving the lifting of the vacuum head 210 is installed on the machine base 11. To isolate the fluid systems of each station, prevent single-point leakage from causing overall machine vacuum failure, and improve the stability and fault tolerance of multi-station operation, the vacuum lines of the pouring heads 29 and vacuum heads 210 of multiple pouring molds 24 are independent, and each line is equipped with a one-way shut-off valve. When a leak occurs at a certain station, the one-way shut-off valve at that station automatically closes to prevent affecting the vacuum stability of other stations.

[0031] This invention also includes a method based on a multi-station casting vacuum injection molding machine, the specific operation steps of which are as follows: Step S1, Mold Installation and Mold Closure Preparation: The casting mold 24, consisting of two separate molds, is installed on the mounting base 22 and the sliding mold base 21 respectively; the mold base 21 is pushed along the moving rod 23 by the drive push rod 27, so that the two separate molds close to form a sealed cavity; Step S2: Automatic docking of fluid connectors. Control telescopic components 1 211 and 2 212 to drive the pouring head 29 and the air extraction head 210 to descend, so that they can physically dock with the interface 219 of the upper and lower parts of the pouring mold 24. Step S3: Start the vacuuming operation. Only after confirming that the pouring head 29 and the vacuum head 210 are properly connected, turn on the vacuum pump 28 and use the vacuum head 210 to evacuate the internal cavity of the pouring mold 24. Step S4: Real-time monitoring and judgment of vacuum level. The vacuum level is continuously detected by the vacuum sensor 218 installed in the cavity; the controller 14 determines whether the vacuum level has reached the preset threshold. Step S5, Condition-triggered casting: The controller 14 opens the control valve 13 only when the vacuum degree fed back by the vacuum degree sensor 218 meets the preset value, allowing the liquid raw material to be injected into the casting mold 24 through the casting head 29. Step S6: Temperature control is maintained synchronously. During the vacuuming and pouring process, the heating component 216 and the temperature sensor 217 work together to stabilize the temperature inside the mold within the optimal molding range of the resin material. Step S7: Independent operation of multiple workstations. Multiple casting molds 24 arranged side by side each execute the above process independently without interfering with each other. If a leak occurs at any workstation, the one-way shut-off valve in its pipeline will automatically isolate the leak, ensuring the vacuum stability of other workstations.

[0032] In summary, the present invention also has the following combined effects: Split mold structure and automatic mold closing: The casting mold 24 consists of two split molds, which are respectively installed on the mounting base 22 and the sliding mold base 21; by driving the push rod 27 in conjunction with the movable connecting rod 26, the linear motion is smoothly converted into the movement of the mold base 21, so as to realize the synchronous and uniform closing of the two split molds 25.

[0033] The vacuum casting process is controlled sequentially: vacuuming is only started after the casting head 29 and the vacuum head 210 have completed physical docking with the mold interface 219; the controller only allows the control valve 13 to be opened for casting when the vacuum sensor 218 detects that the vacuum level in the cavity has reached the preset value, ensuring that the process conditions are strictly controlled.

[0034] Temperature closed-loop control: The mold integrates a heating component 216 and multiple temperature sensors 217 to regulate and maintain the temperature of the mold cavity within the optimal molding range of the resin during vacuuming and pouring, thereby improving molding quality and consistency.

[0035] Flexible sealing and manufacturing error compensation: The joint surface of the two-part mold is equipped with a flexible sealing gasket, which effectively compensates for manufacturing or assembly errors, ensures the sealing performance after mold closing, and prevents air leakage from affecting the vacuum environment.

[0036] Multi-station parallel and independent fluid system: Multiple sets of molds are installed side by side through mold mounting slot 215 to support continuous production; the pouring and exhaust pipelines of each station are independent and equipped with one-way shut-off valves, which can automatically isolate the leakage in any station to avoid affecting the operation of other stations.

[0037] Stroke memory and adaptive mold closing: The stroke of the moving rod 23 corresponding to different molds is recorded by the displacement sensor 214, so as to realize automatic adaptation and optimal mold closing position reproduction for molds of different sizes, reducing manual adjustment; Independent lifting docking mechanism: The pouring head 29 and the air extraction head 210 are driven by independent telescopic components to ensure accurate and reliable docking action and avoid interference.

[0038] The process boasts high reliability, employing a logical control system of pre-connection, followed by vacuuming, and final pouring after achieving the required standards to prevent air ingress and ensure product density and performance. Molding quality is stable, with the temperature control system and vacuum environment working in tandem to ensure resin flow and curing under optimal conditions. Excellent sealing performance is achieved through a flexible sealing structure that effectively addresses manufacturing tolerances and enhances vacuum retention capabilities. High production efficiency is ensured through multi-station parallel operation, supporting continuous production and significantly increasing capacity. The system exhibits strong fault tolerance, with independent fluid pathways and one-way shut-off valves enabling localized fault isolation and guaranteeing overall machine stability. Operation is intelligent and automated, integrating a central controller for automatic execution of the entire process. Adaptive mold replacement capability reduces the need for manual intervention.

[0039] The embodiments of the present invention have been described above, but the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention, all of which are within the protection scope of the present invention.

Claims

1. A multi-station casting vacuum molding machine, characterized in that, include: The mounting base (22) and the casting mold (24) are provided. The mold base (21) is slidably mounted on the mounting base (22) via a moving rod (23). The casting mold (24) includes two split molds. One split mold is mounted on the mounting base (22), and the other split mold is correspondingly mounted on the mold base (21). The mounting base (22) is provided with a drive push rod (27) for driving the two split molds to open and close. The casting head (29) and the vacuum head (210) are provided with interface (219) at the top and bottom of the casting mold (24). The casting head (29) and the vacuum head (210) correspond to the interface (219) at the top and bottom respectively. A vacuum sensor (218) is provided inside the casting mold (24). After the pouring head (29) and the vacuum head (210) are connected to the pouring mold (24), the vacuum head (210) begins to perform a vacuuming operation inside the pouring mold (24); when the vacuum sensor (218) detects that the vacuum level inside the pouring mold (24) meets the preset value, the vacuum head (210) begins to perform a pouring operation inside the pouring mold (24).

2. The multi-station casting vacuum molding machine according to claim 1, characterized in that, The casting mold (24) is internally designed with a heating component (216) and multiple temperature sensors (217). During the process of the air extraction head (210) pouring into the casting mold (24), the heating component (216) and multiple temperature sensors (217) work together to maintain the interior of the casting mold (24) within the preset temperature range.

3. A multi-station casting vacuum molding machine according to claim 2, characterized in that, Sealing gaskets (25) are provided on the joint surfaces of the two split molds of the casting mold (24). The sealing gaskets (25) are set as flexible sealing gaskets to ensure that the two split molds fit tightly together, thereby ensuring the sealing effect inside the cavity of the casting mold (24).

4. A multi-station casting vacuum molding machine according to claim 3, characterized in that, The mold base (21) and the mounting base (22) are provided with mold mounting grooves (215), and multiple sets of casting molds (24) are installed side by side on the mold base (21) and the mounting base (22) through the mold mounting grooves (215).

5. A multi-station casting vacuum molding machine according to claim 4, characterized in that, The movable rod (23) is slidably inserted into the mounting base (22). A displacement sensor (214) is provided between the mounting base (22) and the movable rod (23). The displacement sensor (214) is used to record the different movement strokes of the movable rod (23) when loading different casting molds (24).

6. A multi-station casting vacuum molding machine according to claim 5, characterized in that, The end plate is fixedly installed at the end of the moving rod (23). The end plate is connected to the mounting base (22) through the connecting rod (213) and the movable connecting rod group (26). The telescopic end of the driving push rod (27) is movably connected to the movable connecting rod group (26). The driving push rod (27) pulls the mold base (21) through the movable connecting rod group (26), thereby realizing the closure between the two split molds of the casting mold (24).

7. A multi-station casting vacuum casting machine according to claim 4, characterized in that, The mounting base (22) is mounted on the machine base (11), and the machine base (11) is equipped with a controller (14). The controller (14) controls the pouring head (29) and the air extraction head (210).

8. A multi-station casting vacuum molding machine according to claim 7, characterized in that, Includes a vacuum pump (28) and a control valve (13). The vacuum pump (28) is used to provide vacuum drive for the pump head (210). The liquid raw material to be poured enters the mold cavity of the casting mold (24) through the control valve (13) and the pouring head (29).

9. A multi-station casting vacuum molding machine according to claim 8, characterized in that, A fixed seat (12) is installed on the mold base (21), and a telescopic component one (211) for lifting and driving the pouring head (29) is installed on the fixed seat (12). A telescopic component two (212) for lifting and driving the air extraction head (210) is provided on the machine base (11).

10. A multi-station casting vacuum molding machine according to claim 9, characterized in that, The pouring heads (29) and the air extraction heads (210) of the multiple casting molds (24) have independent air extraction pipelines, and each pipeline is equipped with a one-way shut-off valve. When a leak occurs at a certain station, the one-way shut-off valve at that station will automatically close.

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