RU2674120C1 - Method of manufacture the products in the molding box - Google Patents

Abstract

FIELD: manufacturing technology.

SUBSTANCE: invention relates to a method for manufacturing articles in a flask. Method consists in completing sets of elements for various products. To obtain a series of identical products in a flask from a set of elements, a mold is collected, the cavity in the mold is filled with a flowable, hardening material, article is formed in the form of joining the elements of the article with the material hardened in the mold, the mold is disassembled, the product is separated from the mold elements, and the mold elements from the disassembled mold are used to complete the new set of elements. Fluid, hardening over time material is fed into the mold under pressure or provides its supply by creating in the form of a vacuum.

EFFECT: expansion of technological capabilities in the production of various products.

9 cl, 20 dwg

Description

Known methods of manufacturing products, when the form is filled with a fluid, hardening material over time.

A known method (see patent No. DE 102014224463) for the manufacture of products in a forming device, which consists of three plates forming a shape, each of which includes a half-mold with a cavity in which the product elements are located or form, while one of the plates is located between two others and made with the possibility of rotation.

The cavity formed between two pre-positioned or formed elements of the product is filled with a fluid hardening material over time.

The product is obtained in the form of a combination of product elements and hardened material.

The method allows sufficiently efficient to produce the same flat products.

The disadvantage of this method is that the design of the forming device with a rotating middle plate allows you to produce a strictly limited range of products, while the readjustment of the forming device for a new product requires considerable labor.

The known method is focused on large-scale production, using it for small-scale and individual production is not economically feasible.

Also known is the method according to international application No. WO 2010031710, which allows the manufacture of products in a forming device from several elements, which consists in the fact that each new element of the product is formed and added to the product in a new form by supplying a fluid hardening material over time into a cavity of a new form covering the previous one.

The known method allows to obtain multilayer products, but the forming device used in this case is a complex multi-pass clamping unit, including several molding and injection devices.

The structural device of the forming parts makes the known method of manufacturing products technically difficult.

With this method of production, quick readjustment for the production of other products is almost impossible.

The known method also has significant limitations on the formation of the structure of the resulting product due to the narrow technological capabilities of the forming device.

The closest in technical essence to the claimed method is a method of manufacturing products in a molding device according to patent No. DE 10031696. In this application, this method is taken as a prototype.

In the method according to patent No. DE 10031696 the product is obtained by filling the cavity between the product elements with a fluid hardening material over time, while the product element is prefabricated in the forming device itself.

The product is formed in the form of a connection of the elements of the product with a solidified in the form of material.

The specified method is intended for the manufacture of similar products and is free from the disadvantages associated with the use of complex forming devices.

With relative simplicity, the method, like other analogs, is not intended to produce various series of products with minimal costs for readjustment of the forming device when changing the manufactured product.

In this case, the preliminary manufacture of one of the elements of the product in the same forming device imposes significant restrictions on the production of products of complex geometry.

The purpose of the present invention is to reduce the cost of production and the expansion of technological capabilities in the production of various products obtained by hardening of a fluid, hardening material in the mold over time.

The technical result that ensures the achievement of the purpose of the invention is realized by using a forming device in the form of a mold assembled in a flask of various structural elements.

At the same time, different sets of elements correspond to different products, some of which are used repeatedly in the same flask (form elements), and some are used as elements of manufactured products.

The technical result is achieved due to the fact that complete sets of elements corresponding to different products, each set of elements includes product elements and shape elements, and to form identical products perform the following cycle of operations:

A) a mold is assembled from a set of elements in a flask so that the product elements form a cavity in the form, the mold elements cover the product elements, using mold elements whose outer surface corresponds to the inner surface of the flask;

B) the cavity in the form is filled with a fluid material that hardens with time;

B) the product is formed in the form of a combination of the elements of the product with a hardened material in the form;

D) the form is disassembled, while the product is separated from the elements of the form;

D) form elements from the disassembled form are used to complete the set of elements identical to the set of elements in the operation

At the same time, variants of the method are possible when:

at least one element included in the set of elements is made by the additive method, in particular by the method of volume 3D printing;

for elements included in the set, the female surface of the mold elements fully or partially corresponds to the male surface of the product elements;

using form elements whose outer surface fully or partially corresponds to the inner surface of the flask;

a dry filler is placed in the mold cavity, which is impregnated with a fluid material that hardens over time during the formation of the product; ''

products are formed in the form of composite compounds;

fluid, hardening over time material is supplied under pressure;

the supply of a fluid, time hardening material is ensured by creating in the form of a vacuum.

The proposed method allows in one flask with minimal labor costs for readjustment to receive various products, according to a typical technological scheme.

The implementation of the method is illustrated by the following drawings:

FIG. 1 - composite flask assembly.

FIG. 2, 3, 4 - sets of elements for various products.

FIG. 5, 6, 7 - complete assembly for various products.

FIG. 8, 9, 10 - complete assembly with products.

FIG. 11, 12, 13 - molds with products in disassembled condition.

FIG. 14, 15, 16 - finished products.

FIG. 17 is a flow chart of operations.

FIG. 18 is a form with a dry filler.

FIG. 19, 20 - embodiments of the form.

A method of manufacturing products in a flask can be implemented using a complex of devices including:

A collapsible flask 1 in the form of a hollow device consisting of lower and upper parts and intended for rigid fixation of structural elements forming a form inside the device.

Sets of elements 2, 3, 4, corresponding to various products 5, 6, 7.

The set of elements 2 includes the elements of the product 8 and the elements of the form 9 corresponding to the product 5.

The set of elements 3 includes the elements of the product 8 and the elements of the form 9 corresponding to the product 6.

The set of elements 4 includes the elements of the product 8 and the elements of the form 9 corresponding to the product 7.

Each set of elements 2, 3, 4 in the flask 1 can be assembled in the form of a mold 10 so that the elements of the product 8 form a cavity 11 in the mold 10. Moreover, the elements of the mold 9 cover the elements of the product 8, and the outer surface 12 of the elements of the mold 9 corresponds to the inner surface 13 of the flask 1.

When implementing the method, the cavity 11 in the mold 10 is filled with a fluid, time-hardening material 14, using channels 15 to feed the material 14 into the mold 10.

The channels 15 are made in the flask 1, as well as in the elements of the form 9 and the elements of the product 8.

The channels 15 also serve to remove excess fluid, hardening over time material 14 from the cavity 11 after it is filled.

The flowing, time hardening material 14 is also a binder material, which in the process of implementing the method combines the elements of the product 8 and the hardened material 14 into a single product (5, 6, 7).

Embodiments of the method can be implemented using a dry filler 16, placed in the cavity 11 of the form 10. In the process, the dry filler 16 is impregnated with a fluid, hardening material 14, forming a reinforced layer in the product.

After disassembling the mold 10, a single product (5, 6, 7) leaves the elements of molds 8 and 9 with sprues 17, which are material 14 hardened in the channels 15 (see Figs. 11, 12, 13).

The cavity 11 formed by two elements of the product 8 can be continued in one of the elements of the product 8 in the form of a cavity 18.

This embodiment of the cavity 18 is technologically easy to implement in the manufacture of element 8 by the additive technology method (3D volume printing).

In this embodiment of the method, the dry filler 16 and the material 14 fill the entire cavity 11, including its continuation - the cavity 18 (Fig. 18).

To implement the method, mold elements 9 are used, the outer surface of which 12 corresponds to the inner surface of the flask 13. Correspondence of surfaces 12 and 13 can be full or partial, which is due to the manufacturing technology of mold elements and material saving. In any case, the correspondence of surfaces 12 and 13 (marked by thickened lines in Fig. 1 and Fig. 19) provides a tight closure of all elements of the form, necessary to ensure the tightness of the form 10 when it is filled with fluid, hardening with time material 14.

Similarly, for the same purpose, to ensure the tightness of the mold 10, the female surface of the elements of the mold 9 fully or partially corresponds to the male surface of the product elements 8.

A partial correspondence between the female surface 19 of the elements of the mold 9 and the female surface of the product elements 8 is shown in FIG. 20 (highlighted by a thickened line).

The following describes a specific embodiment of the method for three different products.

A method of manufacturing various products in the flask 1, is that complete sets of elements 2, 3, 4.

These sets of elements are used in the manufacture of products 5, 6, 7 corresponding to these sets.

All elements included in sets 2, 3, 4 are made by 3D volumetric printing.

To form identical products, a series of operations is performed, which is illustrated in FIG. 17.

In this case, identical products 5 are made, in the manufacture of which sets of elements 2 are used.

A method of manufacturing products 5 is implemented in the form of the following cycle of operations:

Operation a

In the flask 1, from the set of elements 2 (product elements 8 and form 9 elements), mold 10 is assembled so that the product elements 8 form a cavity 11 in the form, the elements of form 9 cover the elements of the product 8, using elements of the form 9, the outer surface 12 of which partially corresponds to the inner surface 13 of the flask 1.

For elements included in the set 2, the female surface 19 of the elements of the molds 9 partially corresponds to the male surface of the product elements 8 (outer surface of the product 5).

In this embodiment of the method, a dry filler 16 is placed in the cavity 11.

Operation b

The cavity 11 in the form 10 through the channel 15 in the upper part of the flask 1 is filled with a fluid, time hardening material 14.

Filling with material 14 of form 10 is carried out under pressure. The filling of the mold 10 with the material 14 is stopped after the material 14 leaves the channels 15 in the lower part of the flask 1. When filling the cavity 11 with the material 14, the fluid material 14 completely impregnates the dry filler 16.

Operation B

The product 5 is formed in the form of a combination of the elements of the product 8 with the material 14 solidified in the form 10.

The formation of the product occurs during the exposure of the material 14 in the form 10 under pressure until it is completely cured.

In this case, the dry filler 16 and completely saturated with it and solidified in the cavity 11 material 14 form a composite.

The material 14 solidified in the cavity 11 is at the same time a binder connecting the composite and the elements of the product 8 into a single whole. Thus, the product 5 is a composite permanent connection of the elements of the product 8 (made by 3D 3D printing), connected to a composite inner layer, which is a dry filler 16, impregnated with hardened material 14.

Operation D

Form 10 disassemble:

open the upper and lower parts of the flask 1;

open the elements of form 9;

the product 5 is separated from the elements of the form 9.

The product 5 at this stage leaves the mold 10 with the sprues 17, which are material 14. The sprues 17 hardened in the channels 15. Subsequently, to obtain the finished product 5, the sprues 17 are removed mechanically.

Since the material 14 is a binder material, it is necessary to eliminate the adhesion of the material 14 in the channels 15 with the material of the flask 1 and the material of the elements of the form 9.

To do this, before assembling the mold 10 (operation A), the surface of the holes 15 in the flask 1 and in the elements of the mold 9 is coated with a release agent (release agent), which provides free exit of the gate 17 from the channels 15.

Operation D

Elements of the form 9 from the disassembled form 10 are used to complete the set of elements 2 identical to the set of elements 2 in step A).

Thus, the elements of form 9 made by the additive method (3D printing) can be used repeatedly in the production cycle of products 5.

Elements of products 8 in the production process become inseparable parts of products 5, therefore, to complete sets 2 and ensure an uninterrupted production cycle, products 5 must be manufactured using the additive method (3D printing) and understaffed with them a set of elements 2 in the process.

For the manufacture of products 5, the composition of set 2 also includes dry filler 16, which during the manufacturing process of the product becomes its integral part.

After completing the set of elements 2, the production cycle of identical products 5 is repeated.

Similarly, in accordance with the above cycle, identical products 6 are made from sets 3 and identical products 7 are made from sets 4.

The method allows for technological, quick readjustment of the forming device for the manufacture of a new product.

Since the outer surface of the mold elements for all sets corresponds to the inner surface of the flask, the changeover to the production of a new product is a simple replacement of one set of elements with another.

Compared with known methods, the inventive method significantly expands technological capabilities and reduces the cost of the process, because it allows you to combine mass production of products with a single, using different versions of a simple forming device, assembled in the same flask. This advantage of the method is increased due to the fact that part of the elements included in the sets, or all elements included in the sets, are made by 3D 3D printing.

The 3D printing method is based on the principle of layer-by-layer addition of material, in contrast to traditional methods of forming a part (where the material is removed from the workpiece array), which makes it possible to produce elements of the most complex shapes and configurations.

Thus, to complete the kit for a completely new product, it will be necessary to 3D-print the new consumable elements of the product and new, reusable form elements.

An embodiment of the method combined with the 3D printing method allows the manufacture of elements with internal cavities that cannot be manufactured by any other methods, which significantly increases the technological capabilities of the method.

In particular, it becomes possible to manufacture products containing only one product element with an internal cavity filled with a composite (dry filler impregnated with a binder in the form of a hardened material).

The 3D printing method allows technologically and cheaply to produce mold elements, the outer surface of which fully or partially corresponds to the inner surface of the flask, and the inner (covering) surface of which fully or partially corresponds to the outer (covered) surface of the product.

In order to save time and materials, it is impractical to produce mold elements, the outer surface of which fully corresponds (completely repeats) the inner surface of the flask.

To achieve a technical result, it is enough to use form elements, the outer surface of which partially corresponds to the inner surface of the flask, that is, it repeats it only on a part of the inner surface of the flask in separate places.

Such a design is advisable only in those places where the conjugation of the surfaces of the flask and the mold elements provides the necessary accuracy of closure (with acceptable gaps) of all the components of the mold, and also provides the necessary strength and durability of the forming device as a whole.

Similarly (with the same technical result), the female (inner) surface of the mold elements may partially correspond to the male (external) surface of the product elements.

This embodiment of the form elements significantly reduces the consumption of materials and the cost of their manufacture by 3D printing.

The 3D printing method also makes it possible to technologically and cheaply produce flask elements, mold elements and product elements immediately with internal channels necessary for feeding into the mold cavity and withdrawing from the mold cavity a fluid that hardens with time.

The flask in which the mold is assembled consists of at least two parts. Fasteners may be provided in the flask design to secure parts of the flask.

The flask can be made of any durable material, for example, metal or plastic, and is designed to withstand the supply pressure of a fluid hardening material over time into the mold cavity.

To implement the method, it is possible to manufacture by method of 3D printing the components of the flask, as well as pipelines and connecting elements for feeding / withdrawing into the form of a fluid hardening material over time.

To ensure the flow into the forming device of a fluid, hardening over time material under pressure, a special injection machine is most often used.

Fluid, hardening over time, the material may be a multicomponent mixture comprising a resin and a hardener. If necessary, the mixture may include additives: catalysts, fillers, dyes.

In practice, the method is implemented for the manufacture of four different products, each of which is a plastic-composite composite compound.

The method is implemented using an IM-2 injection machine and an EOS P760 laser 3D printer.

The manufacturing process and the forming device had the following parameters:

The consumption of the mixture at the entrance to the flask: from 5.5 to 9.5 l / min.

Injection machine outlet pressure: 6.5-8.5 bar.

Heated components: up to 120 degrees. FROM.

The exposure time of the product under pressure until the binder is completely cured: 120 min.

Flask: composite of two parts.

Flask material: aluminum.

The dimensions of the flask, mm: 350.0 × 450.0 × 500.0.

The number of form elements is 2.

The number of product elements - 2

The material of the mold elements is EOS PA2200 polyamide (3D printing).

The material of the product elements is carbon-filled polyamide EOSCarbonMide (3D printing).

Dry filler - carbon fabric (twill 2/2-K-1000-200).

As a fluid, hardening over time material (binder), a mixture consisting of two components was used:

Base - L epoxy

Hardener - GL1

As a release agent (release agent) for coating the surface of the channels in the forming device used wax.

The following embodiments of the method are also possible:

The supply of a fluid, time hardening material is ensured by creating in the form of a vacuum (reduced pressure, vacuum). In this case, the fluid material can be fed into the mold through the channels in the lower part of the flask until it is completely filled and the excess fluid material is released through the channels in the upper part of the flask.

All or part of the processes that make up the method are automated using a numerical program method.

In the manufacturing process of the product, the mold is heated.

To seal the forming device, a seal is used at the joints of the parts of the forming device (flask parts, mold elements, product elements).

The forming operations of the product during the implementation of the proposed method is controlled using special sensors built into the forming device, including using temperature and pressure sensors.

Polyamide, glass-filled polyamide, carbon-filled polyamide, polyetheretherketone, non-ferrous and ferrous metals, as well as plastics enriched with metal chips, including aluminum, are used as the material of the elements of the forming device.

The joints between the elements and the surface of the channels of the forming device are coated with a release agent in the form of release waxes, or release agents based on: polyvinyl alcohol; polyvinyl acetate; modified latexes; siloxanes; fluorinated compounds.

Claims (14)

1. A method of manufacturing products in flask, which consists in completing sets of elements corresponding to different products, with each set of elements including product elements and shape elements, and for the formation of identical products perform the following cycle of operations: A) a mold is assembled from a set of elements in a flask so that the product elements form a cavity in the form, the mold elements cover the product elements, using mold elements whose outer surface corresponds to the inner surface of the flask; B) the cavity in the form is filled with a fluid material that hardens with time; B) the product is formed in the form of a combination of the elements of the product with a hardened material in the form; D) the form is disassembled, while the product is separated from the elements of the form; D) the elements of the form from the disassembled form are used to complete the set of elements identical to the set of elements in operation A). 2. The method according to p. 1, which consists in the fact that at least one element included in the set of elements is made by the additive method. 3. The method according to p. 2, which consists in the fact that the element is made by volume 3D printing. 4. The method according to p. 1, which consists in the fact that for included in the set of elements, the female surface of the mold elements fully or partially corresponds to the male surface of the product elements. 5. The method according to p. 1, which consists in the use of form elements, the outer surface of which fully or partially corresponds to the inner surface of the flask. 6. The method according to p. 1, which consists in the fact that a dry filler is placed in the mold cavity, which is impregnated with a fluid material that hardens over time during the formation of the product. 7. The method according to p. 1, which consists in the fact that the products are formed in the form of composite compounds. 8. The method according to p. 1, which consists in the fact that a fluid, hardening over time material is supplied under pressure. 9. The method according to p. 1, which consists in the fact that the supply of fluid, hardening over time material is provided by creating in the form of a vacuum.

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