Metal founding – Means to shape metallic material – Pressure shaping means
Reexamination Certificate
1999-04-13
2001-06-26
Lin, Kuang Y. (Department: 1722)
Metal founding
Means to shape metallic material
Pressure shaping means
C164S098000, C164S133000, C164S342000
Reexamination Certificate
active
06250368
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a casting mold for producing a fiber-reinforced composite article by a die-casting process, i.e., a mold used for a die casting process to produce a fiber-reinforced composite article comprised of a formed product of fiber and a metal matrix.
2. Description of the Prior Art
In a die casting process, the gate speed of molten metal flow is on the order of about 30 to 45 m/sec and hence, the molten metal flow is brought into a turbulent flow within the cavity of the mold. If such a molten metal flow collides against a formed product of fiber, there is a possibility that the formed product of fiber may be deformed or broken, and there is also a possibility that the filling of the molten metal into the formed product of fiber may be impeded by air included into the molten metal flow. In a member including a simple-metal portion integral with the fiber-reinforced article, the air included in the molten metal flow forms air bubbles in the outer surface of the formed product of fiber due to the filtering effect of the fiber formed-product which permits the passing of only the molten metal, and as a result, blow holes are produced in the simple-metal portion.
Accordingly, it is now conventional practice to carry out the casting at a low gate speed of molten metal flow, reduced, for example, to about 0.4 m/sec.
With the conventional process, however, an existing injection device cannot be used, and an exclusive injection device is required, resulting in the problem that the equipment cost is increased, and the efficiency of production of the fiber-reinforced composite article is degraded with the reduction in gate speed of the molten metal flow.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a mold of the above-described type, wherein even if the gate speed of the molten metal is increased to that used in a typical die-casting process, a sound fiber-reinforced composite article can be produced.
To achieve the above object, according to the present invention, there is provided a casting mold for producing a fiber-reinforced composite article which comprises a formed product of fiber and a metal matrix by a die-casting process, the mold comprising a cavity which includes a composite article forming area in which the formed product of fiber is located, a molten metal storing area located adjacent the composite article forming area, the molten metal storing area for storing molten metal to fill into the fiber formed-product, and a molten metal flow slackening area for slackening or reducing the turbulent flow of the molten metal from gates as it is introduced into the molten metal storing area.
With the above construction of the mold, even if the gate speed of the molten metal flow is increased to that of the typical die-casting process, the turbulent flow of the molten metal is reduced in the molten metal flow slackening area. As a result, the flow of the molten metal introduced into the molten metal storing area is brought into a substantially laminar flow state, so that the inclusion of air in the molten metal flow is inhibited. Thus, the molten metal in the molten metal storing area is smoothly poured under pressure into the fiber formed-product. This makes it possible to produce a sound fiber-reinforced composite article free of casting defects.
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Ishizuka Kazuhisa
Shibata Kazuo
Ushio Hideaki
Arent Fox Kintner Plotkin & Kahn
Honda Giken Kabushiki Kaisha
Lin Kuang Y.
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