Molding of die-cast product and method of
First Claim
1. A system for die-casting products with reduced surface imperfections comprising:
- a source of molten zinc;
a dispenser station having a molten zinc chamber and a piston for loading and dispensing molten zinc from the dispenser station;
a mold cover continually maintaining the molten zinc supported therein in a molten state;
a hot runner for transferring the molten zinc from the dispenser station to the mold cover;
a mold housing mateable with the mold cover to define a mold cavity therein for receiving the molten zinc, the mold cover having a pathway connecting the hot runner to the mold cavity;
an actuating pin located in the pathway of the mold cover for controlling access of the molten zinc to the mold cavity and for following the contraction of the solidification of molten zinc in the mold cavity without intensifying the pressure of the molten zinc in the mold cavity; and
a thermal-insulating barrier located between the mold housing and the mold cover to thermally isolate the temperature difference between the mold housing and the mold cover to enable the zinc in the mold cavity to solidify while the zinc in the mold cover remains in a molten state.
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Abstract
A system and method of preventing surface imperfections of die-cast products with the method comprising the steps of loading a volume of molten zinc from a source of molten zinc into a chamber of a dispenser station, dispensing the molten zinc from the dispenser station through a hot runner and into a mold cavity, continually maintaining the molten zinc in a molten state from the source of molten zinc to the mold cavity, interrupting the flow of the molten zinc to the mold cavity, following the contraction of the molten zinc in the mold cavity as the molten zinc solidifies therein; and removing the solidified die-cast zinc product from the mold cavity.
26 Citations
21 Claims
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1. A system for die-casting products with reduced surface imperfections comprising:
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a source of molten zinc; a dispenser station having a molten zinc chamber and a piston for loading and dispensing molten zinc from the dispenser station; a mold cover continually maintaining the molten zinc supported therein in a molten state; a hot runner for transferring the molten zinc from the dispenser station to the mold cover; a mold housing mateable with the mold cover to define a mold cavity therein for receiving the molten zinc, the mold cover having a pathway connecting the hot runner to the mold cavity; an actuating pin located in the pathway of the mold cover for controlling access of the molten zinc to the mold cavity and for following the contraction of the solidification of molten zinc in the mold cavity without intensifying the pressure of the molten zinc in the mold cavity; and a thermal-insulating barrier located between the mold housing and the mold cover to thermally isolate the temperature difference between the mold housing and the mold cover to enable the zinc in the mold cavity to solidify while the zinc in the mold cover remains in a molten state. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of improving the surface properties and preventing surface imperfections and cracking of die-cast products comprising the steps of:
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loading a volume of molten metal into a chamber of a dispenser station; dispensing the molten metal from the chamber of the dispenser station through a hot runner and into a mold cavity defined by a mold housing and a mold cover; continually maintaining the molten metal in a molten state from the source of molten metal to the mold cavity; interrupting the flow of the molten metal to the mold cavity; following the contraction of the molten metal in the mold cavity by maintaining sufficient pressure on the molten metal as the molten metal solidifies therein without intensifying the pressure of the molten metal to inhibit formation of air bubbles; and removing a solidified die-cast product from the mold cavity of the mold station. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of inhibiting or preventing surface imperfections and cracking of die-cast zinc products comprising the steps of:
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continually maintaining a shot of molten zinc in a molten state from a source of molten zinc to a mold cavity; temporarily closing off an access of the shot of molten zinc to the mold cavity; maintaining sufficient pressure on the shot of molten zinc in the mold cavity without intensifying the pressure of the molten zinc in the mold cavity to inhibit formation of air bubbles therein; and removing a solidified die-cast zinc product from the mold cavity. - View Dependent Claims (18, 19, 20, 21)
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Specification