Method and apparatus for molding a curable molding compound

Abstract

The present invention relates to an apparatus (10) and a method for shaping a curable molding compound (202), comprising introducing the curable molding compound (202) in a fluid state into a cavity (14) delimited by a first molding part (100) and at least one second molding part (101) of a molding tool (12), and generating at least a first relative movement between the first molding part and the second molding part (100, 101) such that the cavity (14) becomes smaller, thereby curing the molding compound (202).

Description

Technical Field

[0001] The present invention relates to a method and an apparatus for molding a curable molding compound. Thereby, in particular, it becomes possible to manufacture parts by primary molding.

[0002] It is known that a curable molding compound can be made into any desired shape by curing it in a shape using a molding tool, that is, by solidifying or amalgamating it. In this way, parts of a desired shape can be manufactured from the original amorphous molding compound. This may also be referred to as primary molding of parts.

[0003] Casting is a typical method in primary molding. In this case, the molding compound is filled into the molding tool, solidifies in the molding tool, and can then be removed from the molding tool. For example, there are various casting methods in which the type of molding tool, the molding compound, and / or the method of filling the molding compound into the molding tool are different.

[0004] One drawback of conventional casting methods is that the desired components, especially the size of the components, cannot necessarily be manufactured with the desired quality. This applies in particular to components having thin-walled regions. In the context of the present disclosure, a thin-walled region can generally be understood as a region having a material thickness of up to 3 mm or up to 5 mm. In such thin-walled regions, there is a risk of so-called cold laps occurring in the casting process. This can be understood to mean that, for example, while the molding compound is still being filled, a part of the molding compound cures prematurely before reaching the intended positioning within the molding tool.

[0005] As a result, the minimum wall thickness generally depends on the method used for manufacturing the cast product and the material of the molding compound, but does not depend on the function of the component. The closer it approaches the minimum possible wall thickness specific to the method, the greater the process-related rejection reaction.

[0006] Furthermore, various metal alloys with inherently advantageous properties cannot be processed into thin-walled products. For example, forged aluminum alloys, steel, etc. Even with plastics, problems occur when filling thin-walled regions with the molding compound, especially when using highly viscous molding compounds. Additionally, not all polymers can be reliably processed (e.g., Teflon (registered trademark)). In ceramic pressure casting, problems occur in the form of premature moisture removal and solidification, and the achievable material structures are often not very dense. Due to its low fluidity, concrete can only be used as a molding compound for thick-walled parts. Also, when combined with reinforcing rods, it is often difficult to fill and mold the concrete.

[0007] As a result, the design of potential components for manufacturing has been limited until now, or for example, complex additional measures are required to limit the risk of cold laps. These additional measures include, for example, specially designed gate systems that maintain a high proportion of fluid molding compound near the thin-walled regions. Insulated and / or heated molds can also be used. The die-casting method can also be used. However, the achievable part sizes are limited, and when filling the molding compound under pressure, turbulent flow and air inclusions may occur in the melt, which may reduce the quality of the metal structure. Cores for producing hollow structures cannot be used in die-casting.

Summary of the Invention

Problems to be Solved by the Invention

[0008] Therefore, an object of the present invention is to improve the manufacturing of components from curable molding compounds, particularly components having thin-walled regions, especially with regard to cost, labor, and / or quality.

[0009] This object is achieved by the subject matter of the appended independent claims. Advantageous embodiments are given in the dependent claims and in this specification.

Means for Solving the Problems

[0010] Accordingly, a method for molding a curable molding compound has been proposed, the method comprising placing (i.e., arranging) a fluid, in particular a curable molding compound in a fluid or molten state, in a cavity delimited by a first molding part and at least one second molding part of a molding tool, generating at least a first relative movement between the first molding part and the second molding part such that the cavity becomes smaller, in particular when the molding compound is still fluid at this stage, curing the molding compound, which may in particular include elapsing a predetermined period during which the molding parts are not moved and / or a predetermined period during which the cavity does not change.

[0011] This procedure differs from known casting methods in that, when the molding compound has not yet cured, the size of the cavity filled with the molding compound changes, in particular it becomes smaller. The cavity in the prior art does not change in this way after the fluid molding compound has been injected and remains the same until the molding compound has solidified. Thereafter, the molding tool is opened so that the finished component can be removed. That is, the cavity is enlarged and dissolved.

[0012] On the other hand, according to the present invention, it has been recognized that, by the proposed procedure, after the cavity or at least one molding part has been filled, the molding parts can be heated by the molding compound (see below). In particular when forming thin-walled regions of the type disclosed herein, the cavity becomes smaller and the wall thickness or volume of the cavity, and thus also the still-fluid molding compound contained therein, locally shrinks. However, the molding parts in this state have already been heated to some extent by the previously absorbed molding compound and thus extract only limited heat from the molding compound. This means that these parts of the molding compound located in the thin-walled regions of the cavity cure more slowly, thereby reducing the risk of cold laps.

[0013] Furthermore, despite the risk of cold laps (even when molding compounds such as concrete at room temperature), the disclosed relative movement can achieve the formation of highly reliable and high-quality thin-wall regions. According to the present invention, for example, the molding compound can enter the thin-wall region in a laminar flow and / or uniform manner that avoids casting defects, rather than in a way with a lot of turbulent flow, in contrast to conventional die-casting methods.

[0014] Reducing the cavity as a result of the first relative movement can include reducing the volume of the cavity. Thus, the cavity and the molding compound contained therein can achieve a so-called target shape. Additionally or alternatively, the distance between at least one pair of opposing regions of the molded part can be reduced by the first relative movement (e.g., when viewed along the movement axis of the first relative movement). This can also be accompanied by a reduction in the size of the cavity, particularly the dimensions of the cavity corresponding to this distance.

[0015] The cavity can define the shape of the manufacturing component parts. The molded parts together can define, or in other words, limit, at least 80% or at least 90% of the volume and / or surface area of the cavity. Each of the molded parts can define or limit at least 15% or at least 25% of the volume and / or surface area of the cavity. The movable parts that define the scope of the cavity are not provided except for the molded parts. Otherwise, these movable parts can only define a relatively small proportion of the surface area and / or volume of the cavity. For example, these movable parts can only be provided for the locally limited pressing of the molding compound into the cavity that is originally defined in scope by the first and second molded parts. The movement of such additional parts cannot be included in the first and second relative movements of the molded parts disclosed herein.

[0016] Containing the molding compound in the cavity - Filling a molding compound into a cavity defined by first and second molding parts, that is to say, filling the molding compound into a molding tool when the first and second molding parts are already arranged such that the cavity is formed (at least in an enlarged initial state or as a pre-cavity). This can include.

[0017] Alternatively, this can include accommodating the molding compound in the cavity. - Filling the molding compound into the molding tool in an open state and arranging the first and second molding parts relative to each other to form a cavity containing the (already filled) molding compound.

[0018] In the open state, the first and second molding parts can be lifted relative to each other such that, in particular, they do not together define the extent of the wall region of the cavity and / or the molding parts do not generally contact each other. Thus, in this case, the molding compound can be filled into only one of the molding parts, for example, into a recess present therein. Then, the molding parts can be arranged relative to each other to form the cavity, and the already filled molding compound is contained between them and the cavity.

[0019] One further development provides that the first relative movement occurs only when the entire molding compound is contained in the cavity. For example, when a predetermined volume of molding compound is required to manufacture a particular component. Only when this completely fills the molding tool and is consequently contained in the cavity can the cavity be reduced by the first relative movement (in particular, by defining a thin-walled region). This increases the degree to which the molding parts are heated by the incorporated molding compound.

[0020] In principle, it is possible to fill the molding compound into the molding tool such that (especially exclusively) a laminar flow occurs within the molding compound. For this purpose, for example, an appropriate filling rate of the molding compound can be selected.

[0021] According to one variant, the molding compound is filled into the molding tool by gravity die casting. Alternatively, the molding compound can be filled into the molding tool by die casting or low-pressure casting. In this context, the pressure applied for filling can be at least partially maintained or (e.g., by more than 10%) increased when generating the first relative movement. Thereby, the turbulent flow in the molding compound can be reduced.

[0022] On the other hand, in order to avoid turbulent flow, the pressure applied to the molding compound during and / or as a result of the first relative movement (in particular, regardless of the method used to fill the molding compound) must not be increased by more than 25% or more than 10%, or can remain essentially constant. It can be assumed that at least atmospheric pressure or a predetermined negative pressure acts on the molding compound before the first relative movement occurs.

[0023] Even after the completion of the first relative movement, a fluid connection from the inside to the outside of the cavity (in other words, to the region outside the cavity) may exist. For example, the fluid connection to the overflow region of the molding compound displaced from the cavity and / or the fluid connection to the outside of the cavity can be maintained via a vent hole. Thereby, the pressure increase in the molding compound is limited.

[0024] The first relative movement can move the molding compound substantially under a laminar flow state, and in particular, can push it into the thin-walled region in the laminar flow direction. To do this, for example, the force and / or the moving speed of the first relative movement can be appropriately selected. In particular, the first relative movement can be substantially force-free. This means that the force generating this relative movement is limited such that the movement can be achieved thereby (e.g., by overcoming inertial force or frictional force), but any force significantly exceeding this (e.g., by more than 20%) and / or permanently increasing the pressure of the molding compound, which would be required for this, does not affect the molding compound.

[0025] Generally, pressure casting cannot occur before, and / or during, and / or after the first relative movement. The molding compound may be subjected to a pressure exceeding 0.2 MPa or a pressure exceeding 1 MPa in at least one of the above states, and preferably in any state, it is not subjected to a pressure exceeding 0.2 MPa or a pressure exceeding 1 MPa.

[0026] After the first relative movement and, optionally, after curing the molding compound, one embodiment is applying a closing force to at least one of the first and second molded parts to cause the inflow force to press the molded parts against each other to provide.

[0027] There may be a need to wait for a predetermined time, for example, at least 2 seconds, preferably 60 seconds or less, between the first relative movement and the application of the closing force, or generally, there may be no need to wait until the molding compound begins to solidify. The cavity can be in a reduced state achieved as a result of the first relative movement during this time. This may be done by applying an appropriate holding force or without force. The closing force may correspond to a subsequent increase (especially a re-increase) in the force applied to at least one of the molded components.

[0028] This additional closing force enables the molding compound to be brought to its final shape with improved accuracy. Furthermore, this indicates that it can improve the material structure, for example, by achieving a preferred particle size in a metal molding compound.

[0029] Optionally, a closing force can be used to generate further relative movement between the first and second molded parts, thereby reducing the size of the cavity, and in particular, the size is further reduced based on the state after the first relative movement. This reduction in size can be made smaller than in the case of the first relative movement. For example, the reduction in size can be less than 50% or less than 10% of the size during the first relative movement. This takes into account the fact that the molding compound cannot be as fluid as during the first relative movement, but is, for example, at least partially already solidified. After the further relative movement, the cavity and the molding compound contained therein may reach the final target shape.

[0030] Additionally or alternatively, the closing force can be generated only when the molding compound is no longer fluid in at least some regions. This can mean that the molding compound is at least partially and / or in some regions already cured. The molding compound may be completely cured.

[0031] Thus, the at least partially cured molding compound can be formed by the closing force, and in particular finally, can be formed to produce the shape and / or the final material structure of the final component.

[0032] According to a further aspect, the closing force is at least 10% greater than the force applied to generate the first relative movement. Thereby, the molding compound can be molded particularly reliably and accurately by the closing force. The closing force and the force applied to generate the first relative movement can be generated by the same moving device, which can simplify the methods and devices used for this purpose.

[0033] The molding tool can form a lost mold (a mold that is destroyed as a result of the casting process) or a permanent mold. Especially in the case of a lost mold, due to the abnormal relative movement of the molded parts so far, thin-walled regions cannot be manufactured with the reliability achievable by the present invention.

[0034] According to one variant, one of the molding parts is a lost mold part and the corresponding other of the molding parts is a permanent mold part. This can be provided in particular in any of the variants disclosed herein, in which further relative movement takes place while generating a closing force. Since the lost mold part allows the part to be removed by destroying this molding part, the degree of freedom in molding is increased. In particular, with regard to the placement of the overflow area or the collecting cavity, the degree of freedom is increased. These can be arranged, for example, outside the parting plane of the molding part and in particular completely inside the lost mold part. However, since it is only necessary to newly manufacture only one of the molding parts (i.e., the lost mold part) before each casting process, the labor can be limited by providing additional molding parts as permanent mold parts.

[0035] One further development of the method is discharging a part of the molding compound from the cavity during the first relative movement (and / or, as a result of applying, for example, the closing force described above, during a further relative movement), i.e., discharging that part of the molding compound extruded from the cavity that becomes smaller in size is also provided.

[0036] This enables a significant movement path within the range of relative movement and a significant reduction in cavity size. The cavity can initially be defined with a corresponding large volume so as to be able to accommodate a large volume of molding compound in order to effectively heat the molding part.

[0037] In this context, the discharging can include at least one of the following. -Discharging a molding compound portion into at least one collection cavity defined by at least one of the molding components. The collection cavity may, for example, be at least partially unfilled beforehand and / or may not be able to define a component that is retained by the component to be manufactured (i.e., the molding compound that solidifies therein can subsequently be removed from the component). The collection cavity may also be referred to as an overflow. Alternatively or additionally, a common overflow region can be provided within the molding tool. -Discharging a portion of the molding compound through a filling channel used to fill the molding compound. This can include, for example, pushing back a portion of the molding compound into a molding compound reservoir connected to the filling channel and / or a melt generator connected to the filling channel and / or a gate system connected to the filling channel. -Discharging the molding compound through a (fluid) channel formed or opened by destroying a defined region of the molding tool. For example, at least one of the molding component or the molding tool may generally include at least one predetermined breaking point that breaks in a defined manner as a result of the pressure exerted by the molding compound. This predetermined breaking point can be broken and opened, thus forming a predetermined region of the molding tool that is destroyed. This predetermined region and / or the predetermined breaking point can be, for example, a wall region of a lost mold where the material thickness is locally reduced. This wall region can separate the cavity from the discharge channel and can be penetrated by the molding compound, thereby forming a fluid connection between the cavity and the discharge channel. The pressure effect of the molding compound can be increased beyond a threshold as a result of a first relative movement of the molding component or any further relative movement, whereby the predetermined breaking point is destroyed.

[0038] In further development, at least one core is arranged in a cavity embedded in a molding compound. At least one of the molding parts, in particular a molding part that is actively moved during the first relative movement or any further relative movement, can be movable relative to the core. The core may generally be stationary. For example, the core can be positioned in the cavity via a rod or bar, whereby at least one (in particular actively moved) molding part is movable relative to the core. In this context, the molding part may be penetrated by a rod or web. For example, these can project into the cavity via recesses in the molding part.

[0039] The invention also relates to an apparatus for molding a curable molding compound, in particular - a molding tool comprising a first molding part that integrally defines a cavity in which a curable molding compound can be received, and at least one second molding part, - a moving device configured to generate a relative movement between the first molding part and the second molding part, - a control device configured to control the moving device when generating at least a first relative movement that reduces the size of the cavity between the first molding part and the second molding part when the cavity is at least partially filled with the curable molding compound.

[0040] The apparatus can be configured to carry out the method according to any of the variants disclosed herein. In particular, the control device can be set to initiate any necessary measures and / or carry out any necessary activation.

[0041] Further optional features and specific embodiments of the general features of the methods and apparatuses disclosed herein are described below. These features and embodiments can be provided in any number and combination.

[0042] For example, according to one general aspect, the molding tool and / or the molded part can comprise at least one of plastic, wood, ceramic, glass, glass-ceramic, concrete, cement, plaster, composites and / or composite materials, sand / binder mixtures, molding sand, metal, steel, in particular hot-work steel.

[0043] The molding tool and / or its components can be non-heated or heatable (i.e., temperature-controlled). The latter can be achieved by at least one of hot air preheating, radiant heating, convective heating, heat conduction, electrical heating via resistance heating, electrical heating via induction, electrical heating via current heating, near-contour heating / cooling via a heating / cooling loop, temperature control by water, temperature control by oil, temperature control by a fluid metal, a variant of heating via a chemical reaction.

[0044] The number of molded parts is not limited to two. That is, the molding tool is not necessarily limited to the two mold halves formed by the molded parts. Instead, more molded parts may be provided. Generally, the molded parts can include mold inclination and / or mold rounding.

[0045] The forming tool can include at least one of a ram, a die, a hold-down clamp, a slide, an undercut molded part and / or an undercut tool component, a mandrel, a core, as at least one of the forming parts or as an additional tool component.

[0046] The forming tool can have any number of at least one of the following features: injection channels, ventilation ducts, overflow areas, ejector pins, guides or guide structures, temperature sensors, pressure sensors, material detectors, hot runners, seals, valves for controlling the flow rate of the molding compound, overflow or return guide structures for controlling predetermined breaking points and / or diaphragms, temperature sensors, pressure sensors, material detectors, hot runners, seals, valves, overflow or return resistances (e.g., including geometric flow resistance, cross-sectional transitions, porous structures, specially induced cold traps, extended flow paths, roughing), which features can also be referred to as auxiliary parts of the tool.

[0047] The acting direction of the molded part can be linear and / or can include only one direction of movement. Alternatively, several acting directions and / or complex movements can be carried out in several successive acting directions.

[0048] The molding compound can include at least one of the following materials: thermoplastics, thermosets, fiber-reinforced composites, ceramic casting compounds, gypsum, concrete, especially ultra-high-performance concrete (UHPC), polymer concrete, metals such as magnesium, aluminum, copper, zinc, tin, iron, nickel, lead, titanium and their alloys, forged aluminum alloys, cast iron, steel materials.

[0049] The feeding of the material, in other words, the filling of the molding compound, can be carried out according to one of the following variants. The molded part can be completely immersed in the fluid molding compound and closed there; gravity casting into an open forming tool can be carried out; one of the molded parts can include filling channels, especially molded parts formed as rams, which move into a molded part formed as a die; a lateral hot channel can be provided; the molding compound can be supplied vertically from below using the low-pressure principle, through one of the molded parts and especially through a molded part designed as a die; the molding compound can be contained in the cavity and then heated, especially melted there.

[0050] Additionally or alternatively, any of the auxiliaries of grease or lubricant, release agent, coating for chemical protection, coating for adapting heat transfer, coating for changing surface layer composition / grain crystal form can be used alone or in any combination.

Brief Description of the Drawings

[0051] Examples of embodiments of the present invention will be described below with reference to the attached schematic diagrams. Features that are the same or act in the same manner may be provided with the same reference numerals throughout all the drawings.

[0052]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Mode for Carrying Out the Invention

[0053] FIG. 1 shows an apparatus 10 including a molding tool 12. The molding tool 12 has two molding parts 100, 101. One molding part 100 is designed as a ram, and the other molding part 101 is designed as a die. The molding tool 12 can be designed as a lost mold made of, for example, sand, or as a die.

[0054] The molded part 101 is fixed. The molded part 100 is movable. For this purpose, the molded part 100 is mechanically coupled to the actuator of the moving device 18, in particular a hydraulic cylinder, in the generally indicated moving direction 18.

[0055] The device 10 also comprises a control device 16, such as a computer and / or at least one processor. The control device 16 is configured to control the moving direction 18 via a wired or wireless data connection, indicated by a dashed line, such that the molded part 100 is moved as required.

[0056] The control device 16 and the moving direction 18 are only shown in state a, but also exist in other states b - d. The control device 16 and the moving direction 18 also exist in the device 10, although not shown as in FIGS. 2 - 6.

[0057] The molded part 101 has a recess 20 in which the molded part 100 can move. The space between this recess 20 and the opposite face of the component 100 that can be moved into the recess 20 forms a cavity 14 for accommodating a molding compound (not shown).

[0058] FIG. 1 shows consecutive operating states a - d, each operating state corresponding to a method step of a method executed by the device 10.

[0059] In state a, the molding tool 12 is shown in the open state. The molded part 100 has clearly moved out of the recess 20 of the molded part 101, and the cavity 14 is not completely sealed, or rather, not completely defined, by the molded parts 100, 101. In this state, the cavity 14 can be described as open, dissolved, or not yet fully formed.

[0060] For example, in gravity casting, a molding compound (not shown) is filled into the recess 20 in a fluid state, particularly in a molten state. The molding compound is heated to a temperature above room temperature, for example, 100 °C or higher. The molding compound includes any of the material examples disclosed herein and may particularly be a molten metal.

[0061] In state b, the molded part 100 has partially descended into the recess 20 of the molded part 101 in the moving direction 18. As a result, the cavity 14 is formed and / or is completely sealed by the molded parts 100, 101 and is completely defined therebetween. This can be described as forming an enlarged pre-cavity. A molding compound (not shown) completely fills the cavity 14, thereby heating the molded parts 100, 101. Features known to those skilled in the art, such as vents, that allow the molding compound to be sealed by the molded parts 100, 101 are not shown.

[0062] The molded part 100 further descends to reach state c. It should be noted that starting from state a, the descent of the molded part 100 can occur as part of a continuous first relative movement. This first continuous relative movement includes state b as an intermediate stage and can end at state d where the target shape is reached. In this case, state c represents an intermediate stage, which can also be described as achieving a pre-geometry.

[0063] However, the first relative movement (particularly the continuous relative movement) of the type disclosed herein can occur only at the time of state b. For example, after reaching state b, it is possible to wait for a predetermined time while the molded parts 100, 101 are heated.

[0064] In state c, the cavity 14 becomes significantly smaller than in state b, i.e., the volume of the cavity 14 is reduced. This size reduction is also achieved by forming thin-walled regions as the distance between the opposing regions and surfaces of the molded parts 100, 101 decreases. These thin-walled regions can have a material thickness of 5 mm or less or 3 mm or less. In other words, such a thin material thickness can be formed or predetermined by the cavity.

[0065] In state c, the molding compound, which is still a fluid, penetrates into the thin-walled regions without forming cold laps and completely fills them. This is done under laminar flow conditions, which, for example, significantly improve the quality of the cast product compared to turbulent die casting.

[0066] During the transition from state b to state c, the excess molding compound flows back into the filling channels (not shown). As described above, the size of the cavity 14 is reduced while the molding compound is still a fluid, and finally, it reaches state d (i.e., the target shape can be achieved) where this can be continued before the molding compound solidifies.

[0067] In summary, starting from state b (pre-cavity), passing through state c (pre-shape), state d (target shape) can be achieved by continuous relative movement, and then the molding compound may be cured.

[0068] Alternatively, starting from state c, after a predetermined time has elapsed, it is possible to approach state d. During this time, the molding compound has at least partially and / or in specific regions started to cure and is no longer completely fluid. Next, a closing force is generated by the movement direction 18, which further pushes the molded part 100 into the recess 20 of the molded part 101, reaching state d. The molding compound that has already partially or completely solidified is thereby formed into the final component's geometry. In such a case, the molding tool 12 is advantageously designed as a permanent mold to withstand the closing force.

[0069] Finally, in order to remove the component formed from the cured molding compound from the molding tool 12, the molding tool 12 can be changed to state a or an even more open state (not shown).

[0070] FIG. 2 shows a modification of the first embodiment, in which a filling channel 201 is formed in the first molded part 101 and the gravity casting method is performed. State a in FIG. 2 substantially corresponds to state b (pre-cavity) in FIG. 1 and shows the initial filling of the molten molding compound 200 through the filling channel 201. As a result, the molded parts 100, 101 are heated by the molding compound 200.

[0071] State b in FIG. 2 corresponds to the target shape according to state d in FIG. 1 and is achieved by relatively moving the molded part 100 into the molded part 101 (see the movement arrow in state b). The cavity 14 defined between these molded parts 100, 101 becomes smaller and forms a thin-walled region. The still fluid molding compound penetrates along the heated adjacent surfaces of the molded parts 101, 100 under laminar flow conditions and no casting defects occur.

[0072] FIG. 3 shows a process similar to that in FIG. 2, but for the case of low-pressure casting. In this case, the molding compound 200 is filled vertically from below into the cavity 14 between the molded parts 100, 101 through the filling channel 300 according to a low-pressure casting method known per se. In other words, the molding compound 200 is pressured to rise into the cavity 14 (see the flow direction 301). The molded parts 100, 101 can form a permanent mold and can be manufactured, for example, from hot-work steel.

[0073] In state a (pre-cavity), in order to achieve heating of the molded parts 100, 101, the molding compound fills at least partially, in particular completely, the cavity 14. Next, the molded part 100 is lowered with respect to the molded part 101 (see the movement arrow for state b corresponding to the target shape). Thereafter, the cavity 14 becomes smaller, forming a thin-walled region, and is still filled with the fluid molding compound 200. The excess molding compound 200 is pushed back from the cavity 14 into the filling channel 300 (see the flow direction 302).

[0074] Optionally, similar to state d in FIG. 1, after the molding compound has cured, the solidified component parts can be further formed by an additional closing force, further reducing the size of the cavity 14. In this case, the filling channel 300 can be closed, for example, by a valve (not shown) before the closing force is applied.

[0075] FIG. 4 shows a process similar to that of FIG. 3, but for the case of a die-casting method in which the molding compound 200 is supplied laterally. More precisely, in state a (expanded pre-cavity), the molding compound 200 is filled in layers into the cavity 14 between the molded parts 100, 101 by the slide 400, heating the molded parts 100, 101.

[0076] In state b (target shape), due to the movement of the molded part 100 into the molded part 101 (see the movement arrow), the cavity 14 becomes smaller. The excess molding compound is extruded from the cavity 14 by pushing back the slide 401.

[0077] FIG. 5 shows an apparatus 10 in which the fixed molded part 101 comprises at least one collecting cavity 500 (formed, for example, as a circumferential ring). The collecting cavity 500 can also be referred to as an overflow.

[0078] In state a (pre-cavity), the molding compound is filled through filling channel 504 using a low-pressure method similar to that shown in FIG. 4 and increases within cavity 14 (see the flow direction indicated by the arrow). Thereafter, the molding compound heats the molded parts 100, 101. In state b (pre-geometry), molded part 100 descends into molded part 101, pushing out the excess molding compound from cavity 14 (see the flow direction indicated by the lower arrow). As indicated by the inclined hatching or filling, the molding compound 501 begins to solidify, becoming viscous and / or curing. After the corresponding curing time has elapsed, a closing force is applied to reach state d (target shape), whereby molded part 100 further descends and cavity 14 is further reduced. Then, the molding compound 501 enters collection cavity 500, where it forms the excess component region 502, which can then be removed.

[0079] In the state of FIG. d, filling channel 504 can be closed by a valve (not shown) and / or filling channel 504 can be closed by the solidified molding compound.

[0080] FIG. 6 shows a variant having an additional core 600 for defining a hollow structure within the manufactured component. Molded part 100 has a recess into which rod 601 is inserted. Rod 601 functions as a holding and positioning device for positioning core 600 within cavity 14.

[0081] In state a, the molding compound 200 is refilled into cavity 14 through filling channel 300 using a low-pressure method (see flow direction 301). The molding compound 200 embeds, i.e., encapsulates, the core 600.

[0082] The core 600 initially has a predetermined gap 610 with respect to the molding part 100, especially when viewed along the moving axis of the molding part 100. This gap enables adjustment of the degree of movement of the core 600 with respect to the molding parts 100, 101. To achieve state b), the molding part 100 descends (see the movement arrow) into the molding part 101 with respect to the initially fixed rod 601. Only after bridging the gap 610 is the moving force transmitted from the molding part 101 to the core 600, allowing the core to descend together with the molding part 100.

[0083] When state b is reached, the cavity 14 is miniaturized and the target shape with a thin-walled region is achieved. As indicated by the flow arrow 302, the excess molding compound can be extruded from the cavity 14 through the filling channel 300.

[0084] In the following table, the state of the molding compound is input as a function of the positions of the molding parts 100, 101 for an embodiment of the method according to the invention. The "open" state corresponds to the state shown in FIG. 1a. The "pre-cavity" state corresponds to the state having an initially enlarged cavity as in FIG. 1b.

[0085] The "pre-shape" state corresponds to a cavity that has already been reduced in size compared to the "pre-cavity", but not yet completely reduced, for example, as in the case of FIG. 1c. The "target shape" state corresponds to the maximum reduced volume of the cavity (see FIG. 1d as an example).

[0086] The following states of the molding compound can be achieved, for example, by selecting appropriate time intervals between the individual movement states of the molding tool, and / or by selecting the molding compound, and / or by selecting its filling temperature.

[0087] When injecting into a sand mold (optionally including a core package moved as in FIG. 6), one embodiment shows the following sequence, where "X" indicates the state of the molding compound in each state of the molding tool. TIFF2025516812000002.tif46150

[0088] In another exemplary process corresponding to a type of thixoforming process for forming a pulp-like mass, the following method is used. For example, for example, a low-pressure method is used such that the molding compound is not filled until the pre-cavity is formed. TIFF2025516812000003.tif35150

[0089] In another exemplary process where the molding compound solidifies as soon as the pre-shape exists and then is formed into the target shape by applying an additional closing force, the following process occurs. This can also be called casting forging. TIFF2025516812000004.tif35150

Description of Reference Signs

[0090] List of Reference Signs 10 Device 12 Molding Tool 14 Cavity 16 Control Device 18 Moving Device 20 Recess 100 Molded Part 101 Molded Part 201 Filling Channel 202 Molding Compound 300 Filling Channel 301 - 302 Flow Direction 500 Collection Cavity 501 Solidified Molding Compound 502 Excess Component Region 504 Filling Channel 600 Core 601 Rod 610 Gap

Claims

1. A method for molding a curable molding compound, The curable molding compound in a fluid state is contained within a cavity defined by a first molding part and at least one second molding part of the molding tool, After a predetermined time has elapsed for heating the molded part with the molding compound, at least a first relative movement is caused between the first molded part and the second molded part, thereby forming a thin-walled region having a material thickness of 5 mm or less or 3 mm or less, while reducing the size of the cavity. A method for curing the aforementioned molded compound.

2. The method according to claim 1, wherein the first relative movement occurs such that the molded compound enters the thin-walled region in a substantially laminar flow.

3. The method according to claim 1 or 2, wherein the first relative movement occurs while the molded compound is still in a fluid state.

4. Including the aforementioned molding compound means Filling the cavity defined by the first and second molded parts with the molded compound, or The method according to claim 1 or 2, comprising filling the molding tool with the molding compound in an open state, and arranging the first molding part and the second molding part relative to each other to form the cavity containing the molding compound.

5. The method according to claim 1 or 2, wherein the first relative movement occurs only when the entire molded compound is contained in the cavity.

6. The method according to claim 1 or 2, wherein the molding compound is filled into a molding tool by pressure casting or low-pressure casting, and the pressure applied for the filling is at least partially maintained or increased when the first relative movement occurs.

7. The method according to claim 1 or 2, wherein when the first relative movement occurs, the pressure acting on the molded compound increases by 25% or less or 10% or less.

8. The method according to claim 1 or 2, wherein the heating time for the molded part is at least 2 seconds.

9. Following the first relative movement, The method according to claim 1 or 2, wherein a closing force is applied to at least one of the first and second molded parts to press the molded parts together.

10. The method according to claim 9, wherein further relative movement between the first and second molded parts is generated by the closing force, thereby reducing the cavity.

11. The method according to claim 9, wherein the closing force is generated only when the molded compound is no longer fluid, at least regionally.

12. The method according to claim 9, wherein the closing force is at least 10% higher than the force applied to generate the first relative motion.

13. The molding tool is used to form a lost mold or a permanent mold, according to the method of claim 1 or 2.

14. The method according to claim 1 or 2, wherein one of the molded parts is a lost-wax molded part and the other of the molded parts is a permanently molded part.

15. moreover, The method according to claim 1 or 2, wherein a portion of the molding compound is discharged from the cavity during the first relative movement.

16. The aforementioned discharge is Discharge of the molded compound portion into at least one collection cavity, the range of which is defined by at least one of the molded parts, Discharge of the molded compound portion through the filling channel used to fill the molded compound, Discharge of the molded compound through channels formed or opened by destroying a predetermined area of ​​the mold, The method according to claim 15, comprising at least one of the above.

17. The method according to claim 1 or 2, wherein at least one core is located within the cavity and embedded within the molded compound.

18. An apparatus for molding a curable molding compound, A molding tool comprising a first molding part that integrally defines the range of a cavity in which a curable molding compound can be contained, and at least one second molding part, A moving device configured to generate relative movement between the first molded part and the second molded part, The system comprises a control device configured to control the moving device to generate at least a first relative motion between the first and second molded parts that reduces the size of the cavity after the cavity is at least partially filled with the curable molding compound and a predetermined time has elapsed for heating the molded parts with the molding compound, The control device is further configured to control the first moving device so as to reduce the size of the cavity by the first relative motion while forming a thin-walled region having a material thickness of 5 mm or less or 3 mm or less.

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