Die Casting Frame and Feed Channels for Zinc Components
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Solution Overview
Problem
Existing die-casting methods result in non-homogeneous structures due to cooled melt flowing into mold cavities from feed lines, requiring additional processing steps like polishing and separation from multiple surfaces, which complicates and costs the production of decorative components.
Innovation Solution
A device with a mold cavity surrounded by a frame and separate feed channels ensures that only optimally tempered melt fills the cavity, eliminating the need for temperature control channels and simplifying the separation process, while the frame shields the component during electroplating, reducing defects and improving surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cooled melt from feed lines flows into mold cavity, then feed lines can be used to transport melt, but the structure in mold cavity becomes non-homogeneous
Solution Approach 1:
The system is divided into two separate feed channels: a first feed channel for transporting cooled melt to form the frame, and a second feed channel for transporting optimally tempered melt to fill the mold cavity. This segmentation ensures that cooled melt from the first feed channel does not contaminate the mold cavity, maintaining structural homogeneity while still utilizing feed lines for efficient melt transport.
2Productivity
If component is separated from multiple surfaces (web connecting mold cavity and ancillary space, pouring channel), then complete casting can be removed, but production process becomes more complex and time-consuming
Solution Approach 1:
The web connecting the mold cavity and ancillary space is extracted and eliminated from the design. The mold cavity is now only connected to the main casting channel via the second feed channel, which is easily breakable. This allows the component to be removed with a simple break-off action rather than requiring separation from multiple surfaces, significantly simplifying the extraction process.
3Manufacturing precision
If frame surrounds blank at distance of 1 to 10 mm, then electroplating quality improves by shielding blank, but additional material and space are required
Solution Approach 1:
The frame provides localized shielding protection to the blank during electroplating, creating an optimal micro-environment for high-quality coating deposition. The frame is positioned at a specific distance of 1 to 10 mm from the blank, providing just enough protection to prevent coating defects while minimizing material consumption and space requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a more economical and high-quality production process with reduced defects and improved surface finish, allowing for the direct electroplating of components without prior polishing, and enables the efficient casting of small parts without complex temperature control.
Implementation Method 1
the melt that has cooled therein has a main frame web corresponding to the main pouring channel
Implementation Method 2
feed channels of the mold that are separate from one another lead to the mold cavity and to the auxiliary space
Data Source
Figure 1~3
Figure 4~7
Figure 8~9
AI summary
The device for casting a workpiece such as a zinc die cast part, comprises a casting channel (5) for feeding a melt, a mould cavity (3) for the reception of a first part of the melt, an adjoining area (4) for the reception of a second part of the melt, where the adjoining area is formed in frame-shaped manner and completely surrounds the mold cavity, and supply channels (6), which separate from one another from the casting channel formed as a main pouring channel and guides from the casting channel to the mold cavity and to the adjoining area. The device for casting a workpiece such as a zinc die cast part, comprises a casting channel (5) for feeding a melt, a mould cavity (3) for the reception of a first part of the melt, an adjoining area (4) for the reception of a second part of the melt, where the adjoining area is formed in frame-shaped manner and completely surrounds the mold cavity, and supply channels (6), which separate from one another from the casting channel formed as a main pouring channel and guides from the casting channel to the mold cavity and to the adjoining area, where a first supply channel associated to the mold cavity has a small cross-section in comparison to a second supply channel associated to the adjoining area. The frame shaped adjoining area is closely formed and passes in an extension plane of the mold cavity, where the mold cavity and/or the adjoining area is tempered. A molding tool (2) for forming the mold cavity and/or the adjoining area and/or the main pouring channel and/or the first supply channel and/or the second supply channel is formed from a hard metal, and has four sliders. By the molding tool, mold cavities are formed, which are surrounded by the adjoining area in frame-shaped manner, where the first supply channels guide to the number of mold cavities and the second supply channels guide to the adjoining area from a common main pouring channel. Independent claims are included for (1) a semi-finished product for the production of component; (2) a method for the production of a component such as a decorative component; and (3) a decorative component for vehicle locking mechanism.