Pressure Die Casting Mold for Integral Toilet Water Ring and Tank
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Solution Overview
Problem
The production of integral toilets involves laborious and complex handling of three separate pressure die-cast parts, which are subsequently bonded together, resulting in undesirable visible bonding lines.
Innovation Solution
A pressure die casting mold composed of five interconnectable parts, including a base part, two side parts with molded front walls, a rear wall, a cover part, and a wedge element, allowing the water ring and tank to be combined into a single component, reducing the number of visible bonding lines and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If three separate pressure die casting molds are used to produce body, water ring, and tank separately, then each component can be produced independently, but the production process becomes laborious and complex with multiple bonding lines visible
Solution Approach 1:
The patent combines the water ring and tank into a single integrated casting by using a unified pressure die casting mold. The mold includes a base part for the water ring and a wedge element that forms the tank, allowing both components to be produced as one piece. This eliminates the need to produce and bond three separate components, reducing complexity and visible bonding lines.
2Device complexity
If three separate parts are produced and bonded together, then flexibility in production is maintained, but the number of visible bonding lines increases to two
Solution Approach 1:
By integrating the water ring and tank into a single casting, the patent reduces the number of bonding operations from two (body-water ring, water ring-tank) to one (body-integrated component). The unified mold design ensures seamless integration without visible bonding lines between the water ring and tank, eliminating a harmful aesthetic defect.
3Object-generated harmful factors
If a single mold produces both water ring and tank, then the number of bonding lines is reduced, but the mold design becomes more complex requiring five interconnectable parts
Solution Approach 1:
The unified pressure die casting mold is divided into five interconnectable parts: base part, two side parts, rear wall, and cover part. This segmentation allows the complex mold to be assembled and disassembled for maintenance, while the wedge element within the mold creates the integrated water ring and tank casting. The segmented design manages the complexity of producing an integrated component.
Solution Approach 2:
The wedge element acts as an intermediary component within the mold that forms the tank while the base part forms the water ring. This intermediary element enables the creation of the integrated casting by mediating between the mold structure and the final product, allowing complex geometry to be achieved through coordinated action of multiple mold parts.
4Ease of operation
If the tank is produced as a hollow part, then the functional requirement is met, but demolding becomes more difficult
Solution Approach 1:
The mold is segmented into multiple parts including movable side parts and a removable wedge element. This segmentation allows the hollow tank to be demolded by disassembling the mold components, with the wedge element being extracted first to release the tank from the mold cavity, facilitating easy removal of the hollow structure.
Solution Approach 2:
The mold incorporates movable and removable components rather than a fixed structure. The side parts can move, and the wedge element can be extracted, transforming the static mold into a dynamic system that adapts during the demolding process. This dynamic design enables easy removal of the hollow tank without damaging the casting or mold.
Data Source
AI summary
A pressure die casting mold for producing a casting which is part of an integral toilet having a body, a water ring, and a tank, wherein the casting, as an integral component, includes the water ring and the tank which is open on the upper side. The pressure die casting mold is composed of at least five molded parts which are interconnectable in a releasable manner, namely of a base part, two side parts having in each case one half of a front wall, a rear wall, and a cover part. The molded parts delimit a cavity which corresponds to the outer shape of the casting. A wedge element, which at least in portions delimits the inner shape of the water tank, is provided on the base part.