JPH08155588A - Molding formed using special core for molding - Google Patents

Abstract

PURPOSE: To provide a molding formed using a special core for molding capable of efficiently producing a molding of casting, plastic molding, ceramic molding, etc., without any constraint of shape and having excellent quality and wide range of shape. CONSTITUTION: After high pressure molten metal is poured in a hollow part 5 formed in a mold 4, when high pressure molten metal is cooled, by deforming part of the special core for a molding formed into non-uniform thickness, deforming and breaking of molding due to effect of molten metal, etc., is prevented. A molding of relatively large one formed to objective shape with hollow shape/undercut shape, a casting of die casting, etc., of an intake manifold/exhaust manifold, etc., of engine formed with complicated hollow shape/ undercut shape, plastic molding and ceramic molding, etc., are produced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded product molded by using a special molding core, and particularly, it is possible to prevent deformation and damage of the molded product due to the influence of a molding material such as molten metal. , Molded products using special molding cores that can be used to obtain cast products such as die cast products with hollow or undercut shapes, and molded products such as plastic molded products and ceramic molded products. is there.

[0002]

2. Description of the Related Art In casting adopted as a part of machining, a hollow shape and an undercut shape are formed.
Non-disintegrating cores or disintegrating cores are used.

By the way, there is a metal core as the former (non-collapsible core), but it cannot be used except for those that can be directly punched or deformed, and the range of use is limited to that of a specific shape.

As the latter (disintegrating core), there is a sand core in which a binder and a curing agent are mixed and fired, but it is difficult to mold and handle, and it easily collapses, and the pressure resistance during casting and the collapse after casting. Since it is difficult to combine with the property, it becomes glassy after casting and it is difficult to completely remove it.

Therefore, it has been proposed to apply a mold coating agent to the surface of the sand core, but there is a problem that defective products are generated due to the adverse effects such as the formation of porosity and shrinkage due to the permeation of the components, and the problem cannot be solved.

Further, in die casting, the sand core cannot be used due to a defect such as insufficient strength. For example, the formation of a molded product having a hollow shape or an undercut shape such as an engine intake manifold or an exhaust manifold is not possible. There was a problem that casting was impossible.

The sand core is difficult to mold and easily collapses.
It has many drawbacks such as difficulty in handling, and it is difficult to meet the contradictory conditions of pressure resistance during casting and disintegration after casting.Therefore, multiple steps are required from the factor of increasing the number of steps due to sand core characteristics, It had the drawback of being time consuming and expensive.

On the other hand, plastic molding and ceramic molding have various problems similar to the above casting.

For example, the molding core needs to be formed from a specific material having pressure resistance and heat resistance during molding, which causes problems such as difficulty in molding the core and high cost.

Therefore, in order to solve these problems, the present inventor first forms a hollow shape or an undercut shape into a cast product such as die casting, a molded product such as a plastic molded product or a ceramic molded product. In a molding core used for, a molding special core characterized by forming the molding core from a non-sand core, and a molding method using the molding special core, and A molded product molded using the special core has been proposed (Japanese Patent Application Nos. 4-339733 and 4-33).
9734, Japanese Patent Application No. 4-339735, etc.).

By the way, in the case where the molding core is formed from a non-sand core to form a molding special core and the molding product is molded using the molding core, the size of the molding product and Depending on the shape, there is a problem that deformation or damage may occur during molding. After that, the inventor
Continuing research, a special molding core that can solve problems such as relatively large parts such as engine intake manifolds and exhaust manifolds, hollow shapes with complex shapes and undercut shapes can be formed by die casting. We have sought to find a more appropriate molded product molded using

[0012]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems by adopting the following constitution.

That is, by forming a molded product by molding by a specific molding method using a specific molding special core, when the molten metal is poured under pressure into the mold and then the molten metal is cooled. By preventing deformation and damage of the die cast product due to the influence of molten metal, etc., it is possible to obtain a cast product such as a die cast product having a desired shape in which a hollow shape or an undercut shape is formed. To do.

On the other hand, also in the case of plastic molding or ceramic molding, as in the case of casting such as die casting, etc., the molding such as die casting can be performed by using a particular molding special core for a particular molding method. As in the case of the method, after injecting the molding material into the molding die, when cooling the molding material, by preventing the deformation or damage of the molded product due to the influence of the molding material, etc., the hollow shape It is possible to obtain a molded product having a target shape in which the undercut shape and the like are formed.

[0015]

According to the present invention, a molding core is formed of a non-sand core, and a space is formed inside the molding core. Moreover, a molding special core in which a part or the whole of the wall thickness of the molding core is formed to have a non-uniform thickness is used, and the molding special core is made of an upper die and a lower die. It is arranged inside an outer mold such as a mold to form a mold having a hollow part in the shape of a molded product, a molding mold such as a plastic molding mold, a ceramic molding mold, and the like, and the molten metal is pressurized and poured into the molding mold. Formed by injecting a molding material such as a die-cast casting with a desired shape such as a hollow shape or an undercut shape, or a molded article such as a plastic molded article or a ceramic molded article. , A molded product molded using a special molding core It is achieved by.

[0016]

According to the present invention as described above, there are the following actions.

That is, according to the present invention, when the molding material is cooled, a part of the molding special core formed in the non-uniform thickness is deformed, so that the molding product is influenced by the molding material or the like. It can be molded into a molded product having a desired shape in which a hollow shape, an undercut shape or the like is formed by preventing the deformation and damage of the.

That is, according to the present invention, by forming a molded product by molding using a specific molding special core, it is possible to obtain a hollow shape or an undercut shape that cannot be obtained by conventional die casting. Not only facilitates the molding of a molded product having, but also enables casting of all shapes and sizes regardless of shape and size, and further, after pouring the molten metal into the mold under pressure, the molten metal When cooling, the thin-walled part is deformed to create a gap between the die-cast product and the die-cast product, which prevents deformation and damage of the die-cast product due to the influence of the molten metal. It is possible to obtain a cast product such as a die cast cast product having a target shape in which the shape or the undercut shape is formed.

On the other hand, also in the case of plastic molding or ceramic molding, as in the case of casting such as die casting, the molding is performed by using a specific molding special core, which is different from the case of the casting method such as die casting. Similarly, it not only facilitates the formation of hollow shapes and undercut shapes, but also
Furthermore, regardless of shape or size, all shapes and sizes can be molded, and after injecting the molding material into the mold,
By preventing the deformation or damage of the molded product due to the influence of the molding material or the like when the molding material is cooled, it is possible to obtain a molded product having a target shape in which a hollow shape, an undercut shape or the like is formed. it can.

Further, by doing so, it is possible to improve the productivity and expand the range of application, and it is possible to efficiently obtain a molded product of the desired shape with excellent quality.

[0021]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the accompanying drawings.

1 to 3 show a first embodiment of a molded product molded using the special molding core of the present invention.

That is, according to the present invention, the molding core is formed from a non-sand core, a space is formed inside the molding core, and the wall thickness of the molding core is one. A molding special core whose parts or all are formed to have non-uniform thickness is used, and the molding special core is provided inside an outer mold such as a mold including an upper mold and a lower mold. By forming a mold having a cavity having a shape of a molded product, a molding mold such as a plastic molding mold or a ceramic molding mold, and pouring a molding material such as pressurizing molten metal into the molding mold, a hollow shape or A special molding core characterized in that it is formed by molding a cast product such as a die cast product having an undercut shape or the like, or a molded product such as a plastic molded product or a ceramic molded product. It is a molded product that is molded by using.

The molding special core used for molding the molded article of the present invention is made of a non-sand core, and has non-disintegrating property (heat resistance and pressure resistance) at the time of molding and disintegrating property after molding. A combination of both conditions (heat disintegration property, solvent disintegration property, etc.) is required. Further, the non-sand core is required to have a condition that does not exert a bad influence on the molded product such as generation of a large amount of gas during the molding.

Here, the case where a core made of synthetic resin (plastic) is used as the non-sand core will be described. A core (synthetic resin core or plastic core) made of a synthetic resin (plastic) as a non-sand core that is the molding special core (hereinafter referred to as "resin core") 1
Is made of synthetic resin (plastic).

The resin core 1 is made of synthetic resin by a synthetic resin molding method (plastic molding method) such as injection molding, as shown in FIGS.
It is formed in a hollow shape having a hollow portion S.

Further, the resin core 1 is formed such that a part of its wall thickness is non-uniform.

In the resin core 1, a portion having a non-uniform thickness is formed in a local thin portion N.

Further, the local thin-wall forming portion N is formed by thin-walling a predetermined length L into a substantially uniform thickness. For example, in the hollow resin core 1 having the hollow portion S formed therein, when the thickness T of the non-thin portion is 5 mm, the thickness t of the thin portion N is 2 mm. Further, the local thin-walled forming portions N are formed at two locations on the same circumferential surface of the resin core 1.

As described above, the resin core 1 is formed in a hollow shape having the hollow portion S therein, and is formed on the same peripheral surface.
The wall thickness of the portion is formed in a local thin-wall forming portion N with a predetermined length over a predetermined width.

When a molded product such as a cast product, a plastic molded product or a ceramic molded product is molded using such a resin core 1, as shown in FIG. It is possible to form the molding die 4 which is disposed between the upper die 2 and the lower die 3 and has the hollow portion 5 having a shape corresponding to the shape of the molded product 6 to be molded.

Further, when the molding material is poured into the molding die 4 such as by pouring the molten metal under pressure and then the molding material is cooled, a part of the molding special core having the nonuniform thickness is formed. By deforming, the deformation and damage of the molded product due to the influence of the molding material and the like can be prevented, and the molded product can be obtained by molding into a target shape having a hollow shape or an undercut shape.

Further, after molding a cast product such as a die cast product having a desired shape in which the hollow shape or the undercut shape is formed, or a molded product such as a plastic molded product or a ceramic molded product, the molded product is molded into the above mold. A molded product is formed by taking out from a molding mold such as a plastic molding die or a ceramic molding die, and then removing the molding special core by pulling out, residual heat, heating, a solvent or the like from the molding product.

In this way, a molded product such as a cast product, a plastic molded product or a ceramic molded product is formed using the special molding core 1.

In this way, the molding special core remarkably improves the heat resistance and pressure resistance against the molding material such as molten metal, and the core does not undergo thermal deformation or pressure deformation against high temperature and high pressure during molding. Since the initial shape can be maintained, it becomes possible to easily form a cast product such as a die cast product having a hollow shape or an undercut shape and other molded products.

Therefore, the scope of application is greatly expanded, the productivity is dramatically improved, and the quality of the molded product is dramatically improved by preventing the cast product from being adversely affected.

Therefore, by applying the molded product of the present invention, the applicable range can be expanded. Therefore, casting such as die-casting having a hollow shape or an undercut shape of all shapes or sizes, plastic molding, ceramic molding, and the like. The application range can be expanded to the molding method.

Next, a molded product molded using the special molding core of the present invention will be described with reference to the accompanying drawings.

FIG. 3 shows a first embodiment of a molded product molded using the special molding core of the present invention.

That is, the molded product 6 has a hollow shape C inside.
And a die-cast casting product in which an undercut shape U is formed.

This molded product 6 is made of an aluminum material and uses a casting special core 1 which is a special molding core.
As best shown in FIGS. 1 to 3, a special casting core 1 is disposed between an upper mold 2 and a lower mold 3 to form a mold 4 having a cavity 5, A cast product 6 formed into a shape corresponding to the shape of the hollow portion 5 by pouring the molten aluminum while applying pressure to the molten aluminum depending on the material of the cast product 6
Is.

Conventionally, in the die casting, there was a problem that the sand core could not be used due to a defect such as insufficient strength, and it was impossible to form a hollow shape or an undercut shape in the die casting, but molding of a specific constitution was required. By using a special molding core for molding by a specific molding method, it becomes possible to easily mold a die-cast casting product 6 having a hollow shape C and an undercut shape U formed therein by die casting. Of.

Further, since the die cast casting product 6 as the molded product of the present invention is molded by using the special casting core 1 which is a specific molding special core, the casting product 6 which is a molding product.
The occurrence of defects in the molded product such as the occurrence of cast holes due to the elimination of the adverse effect on the cast product 6 is prevented, and the cast product 6 is a molded product of excellent quality.

Furthermore, since the cast product 6 as a molded product is molded with a core having a smooth surface, the inner surface of the molded product, such as a hollow shape or an undercut shape, is formed into a smooth surface without a rough surface. Therefore, the secondary processing for smoothing the inner surface is not necessary, and the occurrence of defects such as wear and damage of the molded product is prevented, and the product has improved performance.

Therefore, the molded product of the present invention is not limited to the die cast product of the above-mentioned embodiment, but may be applied to cast products other than the die cast product, plastic molded products and ceramic molded products. Therefore, the range of application can be expanded, and a molded product with excellent quality can be obtained.

Next, a method of molding the molded article of the present invention by a specific molding method using a molding special core having a specific structure will be described.

That is, as shown in FIG. 1 to FIG. 3, the molded article of the present invention is molded by a specific molding method using a molding special core having a specific structure. It is possible to mold a cast product such as a die cast product having a hollow shape or an undercut shape, or a molded product such as a plastic molded product or a ceramic molded product.

In the present embodiment, by using the above-mentioned non-sand core, casting products such as die cast products having a desired shape in which a hollow shape and an undercut shape are formed, plastic molded products, ceramic molded products, etc. Among the molded products molded using the special core, which is characterized in that the molded product is molded, a cast product molded using the special molding core will be described.

Here, the case of obtaining a die cast product having excellent productivity as one of the cast products and the case of using a synthetic resin core as the non-sand core will be described.

That is, in this embodiment, a die cast product can be obtained by casting in the following steps.

First Step Although not shown in the drawings, a polycarbonate synthetic resin (polycarbonate plastic) having excellent heat resistance and moldability, out of the synthetic resins (plastics), is used in the same manner as described above. And as best shown in FIG.
The hollow resin core 1 having the hollow portion S formed therein is molded.

The resin core 1 is formed such that a part of its wall thickness is non-uniform.

The resin core 1 has a non-uniform thickness portion,
It is formed in the locally formed thin portion N. Further, the resin core 1 is formed by forming the local thin-wall forming portion N to have a predetermined length L and a substantially uniform thickness.

For example, in the hollow resin core 1 having the hollow portion S formed therein, the thickness T of the non-thin portion is 5 mm.
When, the wall thickness t of the thin wall forming portion N is 2 mm. Further, the local thin-walled forming portions N are formed at two locations on the same circumferential surface of the resin core 1.

As described above, the resin core 1 is formed in a hollow shape having the hollow portion S therein, and is formed on the same peripheral surface.
The wall thickness of the portion is formed in a local thin-wall forming portion N with a predetermined length over a predetermined width.

Second Step Subsequently, as shown well in FIG. 1, the resin core 1 is disposed between the upper mold 2 and the lower mold 3 so that a hollow shape or an undercut shape is formed. A mold 4 having a cavity 5 corresponding to the shape of the formed die-cast product is formed.

Third Step Next, as best shown in FIGS. 1 and 2, pressure is applied to the molten metal such as aluminum molten metal in the cavity 5 formed in the mold 4 depending on the material of the cast product. Pouring while adding.

At this time, since the resin core 1 has a large heat capacity, it has high heat resistance and high pressure resistance against the molten metal. Therefore, even if the high-pressure molten metal is poured at the time of molding, the thermal deformation or pressure The initial shape can be retained without deformation. Further, the temperature of the molten metal is about the initial temperature (for example, about 6% for aluminum molten metal) before reaching the cavity 5 of the mold 4.
Since the temperature decreases compared to 60 degrees C), the resin core 1
Due to its own temperature and heat capacity, the initial shape can be maintained without immediate melting even when the molten metal acts.

Therefore, the casting 6 having a shape corresponding to the shape of the cavity 5 is cast in a state where the resin core 1 is maintained in its original shape without being deformed.

Fourth Step Subsequently, as shown in FIGS. 2 and 3, the high-pressure molten metal poured as described above is cooled to form a hollow shape or an undercut shape. A die cast product 6 having a shape is formed. The cooling includes natural cooling and forced cooling, but in the present embodiment, natural cooling is performed.

At this time, as shown in FIGS. 4 and 5, the resin core 1 is formed such that a part of its hollow wall thickness is non-uniform. Further, the resin core 1 has a non-uniform thickness portion formed in a local thin-wall forming portion N, and the thin-wall forming portion N is formed by thinning a predetermined length L into a substantially uniform thickness. Has been done. For example, when the thickness T of the non-thin portion of the resin core 1 is 5 mm, the thickness t of the thin portion N is 2 mm.

The thin-wall forming portion N is formed at two locations on the same peripheral surface of the main body G.

As described above, the resin core 1 is formed in the local thin-walled forming portion N with the wall thicknesses at two locations on the same circumferential surface having a predetermined length over a predetermined width.

Further, after the molten metal is poured into the mold 4 under pressure, when the molten metal is cooled, the thin-walled forming portion N formed to have a substantially uniform thickness is deformed. That is, as well shown in FIG. 6, the arcuate thin-walled forming portion N forming a part of the cylindrical shape is deformed into a substantially M shape (substantially mountain shape), and a cast product 6 that is a molded product A gap is created between the two.

In this way, the arc-shaped thin-walled forming portion N, which is a part of the resin core 1, is deformed into a substantially M-shape, so that the cast product 6 due to the influence of the molten aluminum, which is the casting material, or the like.
Since it is possible to prevent defects such as deformation and damage of the
As shown in FIG. 3, a cast product 6 having a desired shape having a hollow shape, an undercut shape, etc.
Can be cast.

Fifth Step Subsequently, as well shown in FIGS. 2 and 3, a die-cast casting 6 having a target shape in which the hollow shape C, the undercut shape U and the like formed above are formed is cast. Take out from 4.

Sixth Step Next, although not shown, the resin core 1 remaining inside the cast product 6 is removed to complete the casting, thereby forming the molded product of the first embodiment of the present invention. The die-cast casting 6 is molded.

At this time, the resin core 1 contributes to the formation of the intended casting 6 by maintaining its shape during casting, and after casting, the casting is performed by the residual heat or heating of the casting 6. Melt and cast alone or in combination with drawing 6
It is removed from and eliminated so that no residue remains.

In this case, in this embodiment, the removal of the resin core 1 is carried out by using the residual heat alone or the residual heat and the extraction together, or the residual heat and the heating together, or the residual heat and the heating and extraction. Are used together, or both heating and drawing are performed together, or only heating is performed.

Further, the resin core 1 can be removed by using a solvent, particularly an organic solvent, without being limited to these, and the solvent removal can be carried out in combination with residual heat or withdrawal, as in the above. And heating, or residual heat, heating and drawing, or heating and drawing, or the solvent alone.

As described above, in the case of die casting, which is the first embodiment of the molded product molded by using the special molding core of the present invention, the resin core 1 should retain its shape during casting. This contributes to the formation of the intended cast product 6, and after casting, the cast product 6 is melted and removed by residual heat or heating, and can be removed without leaving a residual component.

Seventh Step Further, although not shown in the drawing, unnecessary parts such as burrs of the cast product 6 are removed, and a die-cast cast product of a target shape in which a finished hollow shape C, an undercut shape U, etc. are formed. You can get a product that is

At this time, the resin core 1 is removed and disappears from the molded product, but depending on the shape and size, the whole or a part can be extracted and reused as the material of the resin core 1, thus reducing the material cost. Can be planned.

As described above, according to the first embodiment, the hollow core and the undercut, which cannot be formed by the conventional die-casting, can be obtained by molding by the specific molding method using the specific molding special core. Not only is it easy to form shapes, but it is also possible to form relatively large parts such as engine intake manifolds and exhaust manifolds, hollow shapes with complicated shapes, and undercut shapes by die casting. Regardless of the shape and size of the product, it is possible to cast the molten metal into the mold and then cool the molten metal. By preventing the generation, it is possible to obtain a cast product such as a die-cast cast product having a target shape in which a hollow shape or an undercut shape is formed. Therefore, as compared with the conventional sand core casting method, (1) core coating mold, (2) core drying, (3)
Sand removal of castings, (4) sand heat treatment (sand baking) of castings,
(5) The number of man-hours can be reduced by eliminating the need for the five steps of sand drop inspection of cast products.

Next, the operation of this embodiment will be described.

As described above, the molded product molded by using the molding special core of this embodiment has the following effects.

That is, according to the present embodiment, the molten metal such as aluminum molten metal is poured into the cavity 5 formed in the mold 4 while applying pressure to the molten metal, and then the high pressure is poured. When the molten metal is cooled, the cast product 6 having the target shape is formed. When the molding material is cooled, a part of the special molding core having the nonuniform thickness is deformed. By preventing deformation and damage of the molded product due to the influence of the molding material and the like, it is possible to obtain a molded product having a desired shape in which the hollow shape C, the undercut shape U and the like are formed.

In this case, when the molten metal poured under pressure is cooled, the thin-walled forming portion N formed to have a substantially uniform thickness is deformed into a substantially M-shape and a gap is formed between the thin-walled formed portion 6 and the cast product 6 which is a molded product. In this state, the cast product 6 is prevented from being deformed or damaged due to the influence of the molten aluminum, which is the casting material, and the cast product 6 of the desired shape having the hollow shape C, the undercut shape U, etc. is formed. Can be cast.

As described above, according to this embodiment, the hollow core C and the undercut shape, which cannot be formed by the conventional die casting, are formed by molding the specific molding core by the specific molding method. Not only it becomes possible to easily cast a die cast product having U, but also a relatively large one such as an engine intake manifold and an exhaust manifold, and a die cast product having a complicated hollow shape C and an undercut shape U. It is possible to cast die cast products of all shapes and sizes regardless of shape and size. Moreover, after the molten metal is pressurized and poured into the mold, the hollow shape C and the undercut shape can be prevented by preventing defects such as deformation and damage of the die cast product due to the influence of the molten metal when cooling the molten metal. It is possible to obtain a cast product such as a die cast product having a target shape in which U and the like are formed.

Further, by doing so, it is possible to improve the productivity and expand the range of application, and it is possible to efficiently obtain a molded product of the desired shape with excellent quality.

The molding special core used for molding the molded product of the present invention is not limited to the above-mentioned embodiment, and many modifications are conceivable, and those having different structures, shapes and sizes are considered. Of course, it can be done.

For example, FIG. 7 is a cross-sectional view showing a second embodiment of a molding special core used for molding the molded product of the present invention. The hollow resin core 1 has a small size. The local thin portion N having a substantially uniform thickness is formed only at one location on the same circumferential surface of the resin core 1.

FIG. 8 is a cross-sectional view showing a third embodiment of a molding special core used for molding the molded product of the present invention. The hollow resin core 1 has a large size. Therefore, the local thin-walled forming portions N having a substantially uniform thickness are formed at four locations on the same circumferential surface of the resin core 1.

Further, FIG. 9 is a cross-sectional view showing a fourth embodiment of a special molding core used for molding the molded article of the present invention. The hollow resin core 1 has a non-uniform thickness. The thin-wall forming portion N is formed by gradually forming the entire wall thickness to be non-uniform so as to be formed to have a uniform thickness. According to the present embodiment, as shown in FIG. 10, when the molten metal is cooled, the thin-walled forming portion N is deformed into a substantially M shape (generally mountain shape), and the thin product forming portion N There is a gap between them,
It is possible to prevent the cast product 6 from being deformed or damaged, and it is possible to cast the die cast cast product 6 having a target shape in which the hollow shape C, the undercut shape U and the like are formed. FIG. 11 is a transverse cross-sectional view showing a fifth embodiment of a special molding core used for molding the molded product of the present invention, in which the hollow resin core 1 is locally thinned to have a substantially uniform thickness. The portions N are formed at two locations on the same peripheral surface of the resin core 1 so as to face each other. As described above, the resin core 1 is formed in a hollow shape having the hollow portion S therein and is formed in the thin-walled forming portion N with a predetermined length over a predetermined width. The thin-walled forming portion N is deformed so that a gap is formed between the thin-wall forming portion N and the cast product 6, and defects such as deformation and breakage of the cast product 6 can be prevented, and a target shape in which a hollow shape C, an undercut shape U, and the like are formed. It is possible to cast a die cast product 6 of excellent quality.

At this time, the molding special core used for molding the molded article of the present invention is not limited to the above-mentioned embodiment, but the shape, size and forming position of the thin wall forming portion N may be various. Also, it can be applied to various shapes using various molding special cores such as various shapes and sizes of cores themselves, and can improve quality of molded products. The present invention is not limited to the above, and many modified examples are possible.

For example, the number of the thin-wall forming portions N is not limited to one, two or four in the above-mentioned embodiment, but it is needless to say that the number may be three, five or more, which is the other number. Is. The shape of the thin-walled forming portion N is not limited to the shape having the uniform thickness in the above-described embodiment, and it is needless to say that the thin-wall forming portion N can be formed in the shape having other non-uniform thickness. further,
The shape of the thin-wall forming portion N is not limited to the shape in which a part of the wall thickness of the above-described embodiment is formed to be substantially uniform, and it goes without saying that a part of the wall thickness can be formed to have a non-uniform thickness.

Next, a sixth embodiment of the special molding core used in the molded article of the present invention will be described.

That is, FIGS. 3 and 13 to 14 show a sixth embodiment of a special molding core used for molding the molded article of the present invention, in which molding is performed using the special molding core. Among the molded products such as the molded product having the hollow shape C and the undercut shape U obtained in 1. and the desired shape, the plastic molded product, the ceramic molded product, and the like, the die cast product will be described.

At this time, in each of the above-described embodiments, a die-cast product is obtained by using the resin core 1 having the hollow portion S. In this embodiment, the following non-sand core is used. By using it, a die cast product having a desired shape can be obtained. .

As shown in FIGS. 13 and 14, the casting special core 1 which is the non-sand core has a hollow main body G in which a filling space S which is a hollow portion is formed. The filling body H is filled in the filling space S. The hollow main body G having the filling space S is formed of a polycarbonate synthetic resin which is a thermoplastic synthetic resin. In addition, the filling body H is formed of shirasu, which is a gravel of a mountain, which is a collapsible material, and is filled in the filling space S of the main body G.

Then, in the same manner as the casting method such as the die casting method of the first embodiment, the special casting core 1 can be used to obtain the die casting product of the present embodiment.
The same effect as the first embodiment can be obtained.

In this case, as well shown in FIG. 12, by cooling the poured high-pressure molten metal, the cast product 6 having the target shape shown in FIG. 3 is formed.

The cooling includes natural cooling and forced cooling. In this embodiment, natural cooling is used.

At this time, the casting special core 1 as the molding special core used for molding the molded article of the present invention is filled in the filling space S as well shown in FIG. 13 and FIG. Two wall thicknesses on the same circumferential surface of the hollow main body G filled with the body H are formed in a local thin-wall forming portion N over a predetermined width, and the thin-wall forming portion N has a predetermined length. Is formed by thinning the thickness L substantially uniformly (for example, when the wall thickness T of the non-thin wall forming portion of the hollow body G is 5 mm, the wall thickness t of the thin wall forming portion N is 2 mm). ).

Then, after the molten metal is poured into the mold 4 under pressure, when the molten metal is cooled, the thin-walled forming portion N formed to have the substantially uniform thickness is deformed. That is, as well shown in FIG. 6, the arcuate thin-walled forming portion N forming a part of the cylindrical shape is deformed into a substantially M shape (substantially mountain shape), and a cast product 6 that is a molded product is obtained. A gap is created between the two.

As described above, the arc-shaped thin-walled forming portion N which is a part of the casting special core 1 is deformed into a substantially M-shape,
As shown in FIG. 3, the hollow shape C and the undercut shape U are prevented by preventing defects such as deformation and damage of the cast product 6 due to the influence of the aluminum melt, which is the casting material.
It is possible to cast a cast product 6 in which a target shape in which the above are formed is excellent in quality.

The present invention as described above can be applied not only to the die casting in the above embodiment but also to the sand type gravity casting method, the die gravity casting method, the low pressure casting method and the precision casting method, and other casting methods. In addition to obtaining the same excellent effects as the above-mentioned respective examples, it can also be applied to plastic molding, ceramic molding and other molding methods, the same excellent effects as the above-mentioned respective examples can be obtained, and the desired shape with excellent quality The molded product can be obtained efficiently.

The molded article of the present invention is not limited to the above-described embodiments, and many modifications can be considered, and the same effects as those of the above-described embodiments can be obtained.

Next, the operation of the above embodiment will be described.

Also in the case of this embodiment, as in the case of the first embodiment, aluminum molten metal or the like is pressurized and poured into the cavity 5 formed in the mold 4 according to the material of the cast product, and then the molten metal is cooled. As a result, the casting 6 having the desired shape is formed, but when the molten metal is cooled, the thin-walled forming portion N is deformed into a substantially M shape, and a gap is created between the casting 6 and the casting 6. It is possible to prevent defects such as deformation and damage of the cast product 6 due to the influence of molten metal and the like, and contribute to casting of the cast product 6 having the target shape in which the hollow shape C, the undercut shape U, and the like are formed.

In addition to the above, according to the above embodiment, the following remarkable effects can be further obtained.

That is, according to the above-mentioned embodiment, since the casting special core 1 uses the core filled with the filling body, the core has pressure resistance, heat resistance, etc. in the state where the filling body is filled. The conditions such as pressure resistance and heat resistance required for the core can be relaxed and the selection range of the core material can be expanded, and the filler and the amount can be selected. so,
The pressure resistance and heat resistance of the core can be adjusted. Further, since the heat resistant main body G is integrally formed on the surface of the filling body H, the heat capacity is large, the heat resistance and pressure resistance are high, and the initial shape can be maintained without thermal deformation or pressure deformation. further,
Since the main body G is completely removed and disappeared due to residual heat of the cast product 6 and only the filling body H remains, it is easy to discharge the filling body H from the casting product 6 and the special casting core 1 is completely removed from the casting product 6. It can be removed and prevent defects such as wear and damage of the product,
It improves the quality and yield of castings, saves time and money, and improves productivity.

Therefore, the cast product 6 having a shape corresponding to the shape of the hollow portion 5 is efficiently cast.

As described above, according to the present embodiment, by molding with a specific molding method using a specific molding special core, it is possible to obtain a hollow shape or an undercut shape which is impossible by conventional die casting. Not only is it easy to form, but it is possible to form relatively large objects such as engine intake manifolds and exhaust manifolds, hollow shapes with complex shapes, and undercut shapes by die casting, regardless of shape or size. It is possible to perform casting such as die casting of all shapes and sizes.

Therefore, since the surface of the special molding core to be used is smoother than the rough surface of the conventional sand core, the molded products molded according to the above-mentioned examples have a hollow shape or an undercut shape. The inner surface is formed as a smooth surface without a rough surface, eliminating the need for secondary processing such as machining for inner surface smoothing, and preventing defects in the molded product such as wear and damage to the molded product. It is possible to improve the performance of the product using the product.

Although the above-mentioned embodiments have all been described with respect to die casting, the molded product molded by using the special molding core of the present invention is not limited to die casting, but sand sand gravity casting method and die gravity casting method. Of course, it can be applied to the low pressure casting method, the precision casting method, and other casting methods. Further, the molded product molded by using the molding special core of the present invention is not limited to the above-mentioned casting method, and can be applied to other molding methods such as plastic molding and ceramic molding, and is similar to the above-mentioned die casting casting and other casting methods. Excellent effects can be obtained, and a molded product having a desired shape with excellent quality can be efficiently obtained.

As described above, according to the method of the present invention, molded products having a wide range of shapes can be efficiently molded without being restricted by the shape, and a cast product, a plastic molded product or a ceramic product having a hollow shape or an undercut shape is formed. It is possible to obtain molded products such as molded products.

Moreover, molding of all shapes and sizes is possible without being restricted by the shape or size, the range of application is greatly expanded, the degree of freedom in design is improved, and the product performance is improved.
Further, the productivity can be improved and the cost can be reduced by reducing the weight.

Next, with reference to the attached drawings, a method for forming the special molding core used in the second embodiment will be described.

13 and 14 show a method of forming a special molding core for use in the second embodiment of the present invention. The special molding core 1 can be formed by various methods.

That is, the first is a method of forming the filling body H first, and then forming the main body G on the surface (outer surface) of the filling body H, and the second is the method of forming the main body G first and then the main body G. It is a method of forming by filling a collapsible material such as gravel of river, sea, or mountain into the inside of.

First, a first embodiment of the method for forming the molding special core 1 used in the method of the present invention will be described with reference to the drawings. That is, FIGS. 13 and 14 show a first embodiment of a method for forming a molding special core used in the second embodiment of the present invention.

First, shirasu, which is a mountain gravel as an inorganic material, is hardened with glue to form a filling body H having a predetermined shape. Subsequently, a polycarbonate synthetic resin, which is a heat-resistant synthetic resin, is formed on the surface of the filling body H with a predetermined thickness to form a main body G made of a heat-resistant main body. In this way, the molding special core 1 having a predetermined shape in which the heat-resistant main body G is formed on the surface of the filling body H can be formed.

If the special molding core 1 is used for molding, the strength is improved, the breakage is less likely to occur, and the handling is easier, so that molding is possible regardless of the shape or size, and the application range is expanded and the productivity is improved. Therefore, it is possible to efficiently obtain a molded product having excellent quality.

Next, a second embodiment of the method for forming the special molding core 1 used in the method of the present invention will be described with reference to the drawings. That is, FIG. 13 and FIG. 14 show a second embodiment of the method for forming the molding special core used in the second embodiment of the present invention.

First, a polycarbonate synthetic resin is formed in a predetermined shape with a predetermined thickness, so that the filling space S is filled inside.
The main body G is formed of a heat-resistant main body having a hollow shape. Next, the filling space S of the main body G is filled with shirasu, which is a mountain gravel, and hardened with glue to form a filling body H having a predetermined shape. In this way, it is possible to form the special molding core 1 having a predetermined shape in which the filling body H is filled and formed in the filling space S of the body G.

If the special molding core 1 is used for molding, the strength is improved, the breakage is less likely to occur, and the handling is easier. Therefore, molding is possible regardless of the shape or size, and the range of application and the productivity are improved. Therefore, it is possible to efficiently obtain a molded product having excellent quality.

FIG. 15 shows an engine intake manifold, which is a molded product of the second embodiment according to the present invention, and a molding core used for molding the intake manifold.

Intake manifold I of the engine
Has a problem that a hollow shape or an undercut shape having a complicated shape is formed and is relatively large, which may cause deformation or breakage during conventional molding. However, according to the present invention, these It is possible to solve the problems such as the formation of an intake manifold of an engine, which is a die-cast casting product in which a relatively large or complicated hollow shape or undercut shape is formed. It is possible to obtain a molded product molded by using a special molding core.

FIG. 16 shows an engine exhaust manifold which is a molded product of the third embodiment according to the present invention, and a molding special core used for molding the exhaust manifold. Exhaust manifold E of the engine
In the same manner as in the above embodiment, a hollow shape or an undercut shape having a complicated shape is formed and is relatively large, and there is a problem that deformation or damage may occur during conventional molding, According to the present invention, these problems can be solved, and a molded product can be formed using a special molding core that can solve problems such as die casting.

The present invention is not limited to such cast products such as die cast products, but rather moldings such as plastic molded products and ceramic molded products having relatively large or complicated hollow or undercut shapes. Of course, it can be applied to products.

The molding special core, the filling body and the main body used in the method of the present invention are not limited to the examples, but can be applied to various materials, shapes and sizes, and many variations are conceivable. ,
It is possible to obtain the same effect as that of each of the above embodiments.

Further, the molding using the special molding core of the present invention is not limited to the molding method of the embodiment, but can be applied to molded products of various materials, shapes and sizes. To improve the quality of molded products by adding specific processes, etc.
The present invention is not limited to the molding method of the embodiment, and many modifications can be considered.

Further, the filling body constituting the molding special core is required to have a non-disintegrating property in a state where the surface of the main body is covered at the time of molding and a disintegrating property after molding.

Fillers satisfying these conditions include, for example, fillers made of an inorganic material such as river, sea, or mountain gravel, or another collapsible material. Among them, as the inorganic material, there are river gravel, sea gravel, and mountain gravel, as well as raw foundry sand itself that does not contain a binder, a hardening agent, etc., or a powdery, granular, or lumpy ceramic ( There are new ceramics and old ceramics). Further, the filling body may be made of gravel, foundry sand, ceramics or the like alone, or may be a mixture thereof with a powdery, granular or lumpy metal. Examples of the metal include iron such as iron oxide, aluminum such as aluminum oxide, and other metals.

Further, the main body may be formed on the entire surface of the filling body as in the embodiment, or may be formed on most (or part) of the surface of the filling body depending on the shape of the molded product.

The main body has non-disintegration properties (heat resistance and pressure resistance) at the time of molding and disintegration properties (heat disintegration property, solvent disintegration property, etc.) after molding, and the filler is enclosed inside. It is required to protect and further completely prevent gas generation from the molding special core even if gas is generated in the filling body, and not to adversely affect the molded product. A material similar to the resin core as the sand core is suitable.

The resin core as the non-sand core which is the special molding core used in the present invention and the material of the main body which constitutes the non-sand core are non-disintegrating (heat resistance) during molding. And pressure resistance) and disintegration property after molding (heat disintegration property, solvent disintegration property, etc.) are required, and it is required not to give adverse effects to the molded product such as gas generation during molding.

Materials satisfying the above conditions include synthetic resins (plastics) and other materials. Among them, the synthetic resins include the following.

That is, the synthetic resin includes, for example, a thermosetting synthetic resin (thermosetting plastic) and a thermoplastic synthetic resin (thermoplastic), and both of the above conditions are satisfied. It is possible to obtain a molded product that sufficiently satisfies

Further, among the thermoplastic synthetic resins, the most suitable one is the polycarbonate synthetic resin of the embodiment, which satisfies the above conditions and sufficiently satisfies the intended purpose. Can be obtained. Next to this, there are fluororesins (polyfluorethylene resins) such as tetrafluoroethylene resin, polyimide resins, polyamideimide resins and polysulfone resins,
Since all of the above conditions are satisfied, it is possible to obtain a cast product or other molded product that satisfies the intended purpose.

Next to this, there are polyamide resin (nylon resin) and polypropylene resin,
Since all of the above conditions are fulfilled, a molded product satisfying the initial purpose can be obtained. Further, other examples include polyethylene resin and polyester resin (Tetron resin), which have both of the above conditions and can provide a molded product satisfying the initial purpose.

Further, as the synthetic resin, as long as the above conditions are satisfied, it is needless to say that a thermoplastic synthetic resin, a thermosetting synthetic resin and other synthetic resins other than those in the examples and the above list can be used. The same effect as that of the embodiment can be obtained.

Further, it goes without saying that other materials can be used as well as the synthetic resin material as long as the above conditions are satisfied.

Other materials satisfying the above conditions include heat-resistant synthetic rubber, rubber such as silicon rubber and fluorine rubber. For example, heat-resistant rubber such as silicon rubber can be mentioned. Any of the above conditions can be satisfied. However, it is possible to obtain the same effect as that of the above embodiment.

Further, as the material, other than the above synthetic resins and rubbers, low-melting metals such as tin, lead and antimony and ceramics, as long as they satisfy the above conditions,
In addition to other single materials, FRR (fiber reinforced rubber), FRP (fiber reinforced plastic) and GFR
P (glass fiber reinforced plastic) and other composite materials can be used, various materials can be used, and the same effects as those in the above-described embodiment can be obtained.

The resin core as the non-sand core, which is a special molding core for satisfying the disintegration property (heat disintegration property, solvent disintegration property, etc.) after molding, and the main body constituting the non-sand core Basically, it is dissolved and removed by residual heat of the molded product, but depending on the size and shape of the core and the molded product, it is difficult to dissolve and remove with only the residual heat of the molded product. And can be removed from a molded product such as a cast product.

In this case, the removal of the resin core and the main body is not limited to the method of completely dissolving and removing the resin core inside the molded product, but if the resin core or the like can be removed from the molded product, the surface of the resin core or the like is dissolved. It is possible to take out from the molded product in the state of being melted, or in a state in which a part or most of the resin core or the like is melted or in a state of semi-molten.

At this time, the remaining portion of the resin core or the like that has been extracted can be reused without discarding, cost reduction can be achieved, and pollution problems can be solved.

When the special core for molding or the main body is insufficiently or difficultly or impossiblely removed by residual heat or drawing, the heating can be performed alone or by using the heating in combination with the residual heat or drawing. At this time, as a heating removal method, heating by a burner,
Heating in a heating tank, heating with high-temperature and high-pressure steam, heating with shot blasting to blast (jet) other shots such as metal powder such as alumina powder, heating with microwaves or electromagnetic induction heating,
There are other heating methods, and in any case, the non-sand core after molding can be completely removed by heating.

Further, depending on the shape of the molding special core or the shape of the molded product, in addition to residual heat, heating or drawing, a solvent, particularly an organic solvent, alone or in combination with residual heat, heating or drawing is used for molding. The special core or body can be removed from the molded product. This solvent removal method, there is a solvent spray removal or removal by immersion in a solvent tank, or removal by using a microwave immersed in a solvent tank, other solvent removal methods, in any case after molding The non-sand core can be completely removed by the solvent. As the solvent, when the molding special core or the main body is a polycarbonate synthetic resin, normal alkylbenzene (trade name "Nonion" or the like) is sufficiently satisfactory in terms of function and cost, and there is no problem in actual use. In addition to these, as the solvent of the polycarbonate synthetic resin, there are the following. For example, tetrachloroethane, methylene chloride, chloroform, 1,1,2 trichloroethane, etc. were able to obtain the same effect.

The solvent of the present invention is not limited to the solvent of the examples as long as it can dissolve the molding special core and the main body, and it goes without saying that various solvents can be used. Alternatively, the same effect as that of the embodiment can be exhibited by performing it independently.

Further, the removal of the molding special core or the main body of the present invention is performed by using the residual heat alone or by using the residual heat and the heating in combination, or by the heating alone or by a solvent such as an organic solvent. Not limited to those, if it is possible to effectively remove the molding special core or the main body, it goes without saying that other removal methods can be used, and many modified examples are possible,
The same effect as that of each embodiment can be obtained.

The molded product of the present invention is not limited to the die cast casting of the above-mentioned embodiment, but a specific step can be added to the die cast casting to further improve the quality of the cast product. A modified example of is conceivable.

Further, the present invention is not limited to the die casting of the above-mentioned embodiment, but can be naturally applied to the sand type gravity casting method, the die gravity casting method, the low pressure casting method and the precision casting method, and other casting methods. Many modifications are conceivable, and the same effect as the above embodiment can be obtained.

In this case, the effect of the present invention is particularly great in the above gravity casting method.

That is, in the gravity casting method, since the molten metal residence time is long, the core-to-molten metal contact time is long, and the molten metal temperature is relatively high, the core must have both pressure resistance and heat resistance. However, by using the molding special core used in the present invention, the heat capacity becomes large as compared with the conventional sand core and the synthetic resin core etc. of the present inventor's prior application. The core temperature rises little, the heat resistance and pressure resistance are improved, the initial shape is maintained without thermal deformation or pressure deformation, and it is possible to contribute to the formation of the desired molded article of a wide range of excellent quality.

That is, even when a cast product is obtained by the gravity casting method using the special molding core used in the present invention, the intended cast product can be obtained in the same manner as in the above embodiment.

In this case, the temperature of the molten metal depends on the cavity 5 of the mold 4.
Until the temperature reaches the initial temperature (for example, about 750 degrees C for molten aluminum), the core has a large heat capacity in combination with improved heat resistance and pressure resistance. The temperature rise of the core at the time is relatively small, the initial shape can be maintained without melting without thermal deformation or pressure deformation, and it can contribute to the formation of a wide variety of high-quality molded products, and casting products can be obtained efficiently. To be

[0150] The cast product prevents defects such as porosity and shrinkage, greatly reduces the number of steps as compared with the conventional sand core, and is a cast product excellent in appearance quality and functional quality.

Further, the special molding core used in the method of the present invention is not limited to the special molding core of the embodiment, and many modifications are conceivable. Further, a molding method other than casting is a plastic molding method. It can also be applied to a molding special core used in a ceramic molding method, can solve various problems as in casting, and can exhibit the same excellent effects as in the embodiment.

Further, the special molding core used in the present invention is not limited to the above-mentioned embodiment, and it can be applied to various shapes having various special molding cores to improve the quality of molded products. However, the present invention is not limited to the above-described embodiment, and many modifications can be considered.

[0153]

As described above, the molded product of the present invention is excellent in quality by improving the productivity and expanding the range of application by molding by a specific molding method using a specific molding special core. The idea is to obtain the desired product, and it has the following excellent effects.

That is, in order to obtain the molded product of the present invention, a special molding core whose thickness is partially or wholly formed to have a non-uniform thickness is used. By deforming the thin-walled part of the child, it is possible to prevent defects such as deformation and damage of the molded product due to the influence of the pressurizing material, and to mold the molded product of the desired shape such as hollow shape and undercut shape. . In the conventional molding of castings and the like, there was a problem such as deformation and damage of the molded product due to the influence of the pressure material at the time of molding, but according to the present invention, these problems can be prevented, and conventional die casting casting and the like molding It is possible to easily mold a molded product having a hollow shape or an undercut shape, which is impossible, a molded product having a large shape, or a complicated shape. As a result, molding of all shapes and sizes is possible, the scope of application and the degree of freedom in design are greatly expanded, productivity and product performance can be dramatically improved, and cost can be reduced by weight reduction, etc. There is an advantage that quality can be improved.

In addition to the above, the following effects can be obtained when, for example, a die cast product is obtained. (1) A casting is formed by cooling the high-pressure molten metal poured into the cavity of the mold, but when the molten metal is cooled, the thin-walled forming portion is deformed to create a gap with the casting. so,
There is an advantage that a casting product having a desired shape in which a hollow shape, an undercut shape or the like is formed can be cast by preventing defects such as deformation and damage of the casting product due to the influence of molten metal. (2) In addition to facilitating the formation of hollow shapes and undercut shapes, which are not possible with conventional die casting, it is also possible to use relatively large or complicated shapes such as engine intake manifolds and exhaust manifolds. Shape can be formed by die-casting.Each shape and size can be cast regardless of shape and size, and defects such as deformation and damage of the cast product that occur when cooling the molten metal after pressure pouring. Therefore, there is an advantage that a cast product such as a die cast cast product having a target shape such as a hollow shape or an undercut shape can be obtained. (3) The core used in the present invention satisfies both conditions of non-disintegration during molding and disintegration after molding, and the surface of the core is smoother than the rough surface of a conventional sand core. Therefore, the inner surface such as a hollow shape or an undercut shape is formed to be a smooth surface, and secondary processing such as internal surface smoothing machining is unnecessary.
There is an advantage that the performance of the product using the molded product can be improved by preventing the occurrence of defects in the molded product such as wear and damage. (4) By using a special core, core molding is facilitated, molding equipment is simplified, the number of processes is reduced, the core is not easily broken, and it is easy to handle. While reducing the time and cost,
There is an advantage that a cast product such as a die cast product having a target shape can be obtained. (5) Prevents the penetration of the main component into the molded product, prevents the occurrence of defects such as blowholes due to the adverse effect prevention, shrinkage and molten metal insertion, and prevents defective products, improving yield and productivity, and die casting of the target shape. There is an advantage that a cast product such as a cast product can be obtained. (6) The core used in the present invention has the advantage that it can be reused by reworking, the material cost can be reduced and pollution can be prevented, and a die cast product having a target shape can be obtained. (7) When a core filled with a filling material is used in the present invention, the core is required to have conditions such as pressure resistance and heat resistance in a state where the filling material is filled inside. Conditions such as pressure resistance and heat resistance required are relaxed, and the selection range of core materials can be expanded.In addition, the pressure resistance and heat resistance of the core can be adjusted by selecting the filling material to achieve the desired shape. There is an advantage that a cast product such as a die cast product can be obtained. (8) When a core filled with a filling material is used in the present invention, the hollow body is removed and lost by residual heat or heating and only the filling material remains, so that the filling material can be easily discharged. It can be completely removed, and defects such as wear and damage of the product can be prevented,
There is an advantage that a cast product such as a die cast product having a target shape can be obtained.

The molded product of the present invention is not limited to the die cast casting of the above-mentioned embodiment, but can be molded by gravity casting or other casting methods, as well as plastic molding, ceramic molding or other molding methods. The same excellent effects as other casting methods can be obtained, molding of all shapes and sizes can be performed without being constrained by shape, the range of application and design flexibility are greatly expanded, and molded products with a wide range of shapes Can be efficiently molded, productivity can be improved, cost can be significantly reduced by weight reduction, etc., and a molded product excellent in quality with a hollow shape or an undercut shape can be efficiently obtained.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a molding die used for molding a molded article according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a state in which a molded product is molded by injecting a molding material into a mold used for molding the molded product of the first embodiment according to the present invention.

FIG. 3 is a cross-sectional view showing a molded product of the first embodiment according to the present invention.

FIG. 4 is a vertical cross-sectional view showing a special molding core used for molding the molded product of the first embodiment according to the present invention.

FIG. 5 is a transverse sectional view showing the molding special core.

FIG. 6 is a cross-sectional view showing a deformed state of the special molding core during molding.

FIG. 7 is a cross-sectional view showing a second embodiment of a special molding core for use in molding the molded article of the first embodiment according to the present invention.

FIG. 8 is a cross-sectional view showing a third embodiment of a special molding core for use in molding the molded article of the first embodiment according to the present invention.

FIG. 9 is a transverse cross-sectional view showing a fourth embodiment of a special molding core for use in molding the molded product of the first embodiment according to the present invention.

FIG. 10 is a cross-sectional view showing a deformed state of the special molding core during molding.

FIG. 11 is a transverse cross-sectional view showing a fifth embodiment of a special molding core for use in molding the molded article of the first embodiment according to the present invention.

FIG. 12 is a vertical cross-sectional view showing a sixth embodiment of a special molding core for use in molding the molded product of the first embodiment according to the present invention.

FIG. 13 is a cross-sectional view showing the molding special core.

FIG. 14 is a cross-sectional view corresponding to FIG. 2 using the same molding special core.

FIG. 15 is a sectional view showing an intake manifold and a special molding core according to a second embodiment of the present invention.

FIG. 16 is a cross-sectional view showing an exhaust manifold and a molding special core which are molded products of a third embodiment according to the present invention.

[Explanation of symbols]

1 Special core for molding (Special core for casting) (Special core for plastic molding) (Special core for ceramic molding) 2 Upper mold (mold) (outer mold) 3 Lower mold (mold) (outer mold) ) 4 Mold (mold) (Plastic mold) (Ceramic mold) 5 Cavity (Casted product shape) (Plastic molded product shape) (Ceramic molded product shape) 6 Molded product (Casted product) (Plastic molded product) ( Ceramic molded product) S Hollow part (filling space) G Main body (heat resistant main body) H Filler N Local thin-wall forming part L Length of thin-wall forming part t Thickness of thin-wall forming part T Thickness of non-thin-wall forming part C Hollow shape U Undercut shape E Exhaust manifold I Intake manifold

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B28B 7/34 F // B29C 33/50 9543-4F 45/44 7639-4F

Claims (27)

[Claims] 1. A molding core is formed of a non-sand core, a space is formed inside the molding core, and a part or all of the wall thickness of the molding core is formed. The shape of a molded product is obtained by using a special molding core having a non-uniform thickness and arranging the molding special core inside an outer mold such as a mold including an upper mold and a lower mold. By forming a mold having a hollow portion, a mold such as a plastic mold or a ceramic mold, and injecting a molding material such as pouring molten metal into the mold, a hollow shape or an undercut shape can be obtained. Was formed by molding a molded product such as a die-cast molded product or a molded product such as a plastic molded product or a ceramic molded product having a desired shape formed by molding using a special molding core. Molding. 2. A molding material, etc., which is obtained by injecting a molding material into the molding die such as pouring molten metal under pressure, and then deforming a part of the molding special core when the molding material is cooled. The special core for molding according to claim 1, wherein the special core for molding is formed by preventing deformation and damage of the molded product due to the influence of, and by molding into a target shape having a hollow shape or an undercut shape. Molded product molded using. 3. A molded product such as a die cast product having a desired shape in which the hollow shape or the undercut shape is formed, or a molded product such as a plastic molded product or a ceramic molded product, and the molded product is then molded into the mold. 2. A molded core is taken out from a molding die such as a plastic molding die or a ceramic molding die, and then the special core for molding is removed from the molded article by drawing, residual heat, heating, a solvent, or the like. Alternatively, a molded product molded using the special molding core according to claim 2. 4. The special core for molding is removed by drawing, residual heat, heating, a solvent or the like alone or in combination, and formed.
A molded product molded using the special molding core described above. 5. A molding special core in which the entire thickness of the molding core is formed to have a non-uniform thickness, and is formed by molding using the molding special core. A molded product molded using the special molding core according to any one of claims 1 to 4. 6. A molding core, wherein a part or most of the wall thickness of the molding core is formed to have a non-uniform thickness,
A molded article formed by using the special molding core according to any one of claims 1 to 4, which is formed by molding using the special molding core. 7. A molding special core in which part of the wall thickness of the molding core is locally thin, and is formed by molding using the molding special core. A molded product molded using the molding special core according to claim 6. 8. The localized thin-walled forming portion is a special molding core having a predetermined length that is thinned substantially uniformly, and is formed by molding the molding special core. A molded product molded using the special molding core according to claim 7. 9. The local thin-wall forming portion is a special molding core having a predetermined length that is unevenly formed thin, and is formed by molding using the special molding core. A molded product molded using the special molding core according to claim 7. 10. The localized thin-walled forming portion is a special molding core at one location, and is formed by molding using the special molding core. A molded article molded using the special molding core according to any one of claims 7 to 9. 11. The local thin-walled forming portion is a special molding core at a plurality of locations, and is formed by molding using the special molding core. A molded article molded using the special molding core according to any one of claims 7 to 9. 12. The molding material comprising a non-sand core that satisfies both conditions of non-disintegration during molding (heat resistance) and disintegration after molding (heat disintegration property, solvent disintegration property, etc.). It is a special core and is formed by molding using the special core for molding, using the special core for molding according to any one of claims 1 to 11. Molded product. 13. The non-sand core is a special molding core made of a heat-resistant material, and is formed by molding using the special molding core. 1
A molded product molded using the molding special core described in 2. 14. The heat resistant material is a molding special core made of heat resistant rubber such as silicone rubber, and is formed by molding using the molding special core. A molded article molded using the special molding core according to claim 13. 15. The heat-resistant material is a molding special core made of synthetic resin (plastic), and is formed by molding using the molding special core. A molded product molded using the molding special core according to Item 13. 16. The synthetic resin (plastic) is a special molding core made of a thermosetting synthetic resin (thermosetting plastic), and is formed by molding using the special molding core. A molded product molded using the molding special core according to claim 15. 17. The synthetic resin (plastic) is a molding special core made of a thermoplastic synthetic resin (thermoplastic), and is formed by molding using the molding special core. A molded product molded using the special molding core according to claim 15. 18. A molding special core made of a polycarbonate synthetic resin (polycarbonate plastic), wherein the thermoplastic synthetic resin (thermoplastic plastic) is formed by molding using the molding special core. A molded article molded using the molding special core according to claim 17. 19. The non-sand core comprises a main body having a space formed therein, and a filling body filled inside the main body, and moreover, a part or all of the thickness of the main body is The special molding core according to any one of claims 1 to 18, which is formed by molding using a special molding core having a non-uniform thickness. Molded product 20. The filling body is a molding special core made of a heat-resistant material such as powder, granules, or lumps, and is formed by molding using the molding special core. A molded product molded using the special molding core according to claim 19. 21. The heat resistant material is a molding special core made of an inorganic material such as gravel of river, sea or mountain, and is formed by molding the molding special core. A molded product molded using the special molding core according to claim 20. 22. A molding special core made of ceramics, wherein the inorganic material is formed by molding using the molding special core.
A molded product molded using the molding special core described in 1. 23. The molding material according to claim 21, wherein the inorganic material is a molding special core made of foundry sand, and the molding is performed by using the molding special core. A molded product molded using a special molding core. 24. A molding special core in which the filler is mixed with powdery, granular, or lumpy metal, and is formed by molding using the molding special core. A molded product molded using the special molding core according to any one of claims 19 to 23. 25. The molded product according to claim 1, wherein the molded product is a cast product such as a die cast product having a hollow shape, a molded product such as a plastic molded product or a ceramic molded product. A molded product molded using the molding core according to any one of 1. 26. The molding product according to claim 1, wherein the molding product is a casting product such as a die-cast casting product having an undercut shape, or a molding product such as a plastic molding product or a ceramic molding product. A molded article molded using the molding special core according to any one of 24. 27. The molded product is a relatively large product such as an engine intake manifold or an exhaust manifold of an engine, a cast product such as a die cast product having a complicated hollow shape or an undercut shape, a plastic molded product, or a ceramic. A molded product molded using the molding special core according to any one of claims 1 to 24, which is a molded product such as a molded product.