阅读说明：本技术 用于压铸金属的设备和方法 (Apparatus and method for die casting metal ) 是由 C·施塔克 D·伯威龙 于 2020-11-23 设计创作，主要内容包括：本发明涉及一种用于压铸金属的设备,该设备具有：用于容纳金属熔液的铸造室；铸造腔,其带有用于使金属熔液以限定的形状硬化的铸造腔；铸造通道,铸造通道将铸造室与铸造腔连接起来,因而金属熔液能从铸造室通过铸造通道导入到铸造腔中,以便在铸造腔那里以限定的形状硬化；和布置在铸造通道中的用于沿着铸造通道输送金属熔液的熔液泵,以便将金属熔液从铸造室通过铸造通道导入到铸造腔中。(The invention relates to a device for die casting metal, comprising: a casting chamber for containing molten metal; a casting chamber with a casting chamber for hardening the molten metal in a defined shape; a casting channel connecting the casting chamber with the casting cavity, so that a metal melt can be introduced from the casting chamber through the casting channel into the casting cavity for hardening there in a defined shape; and a melt pump arranged in the casting channel for conveying the molten metal along the casting channel in order to introduce the molten metal from the casting chamber through the casting channel into the casting cavity.)

1. An apparatus (10) for die casting metal, comprising:

a casting chamber (100) for receiving a molten metal (110),

a casting mould (301) having a casting chamber (300) for hardening a molten metal (110) in a defined shape, and

a casting channel (200) which connects the casting chamber (100) to the casting chamber (300) in such a way that the molten metal (110) can be introduced from the casting chamber (100) through the casting channel (200) into the casting chamber (300) in order to harden there in a defined shape, and

a melt pump (250) arranged in the casting channel (200) for conveying the molten metal (110) along the casting channel (200) in order to introduce the molten metal (110) from the casting chamber (100) through the casting channel (200) into the casting chamber (300).

2. Device (10) for die casting metal according to the preceding claim,

wherein the melt pump (250) comprises a suction opening (252) and a discharge opening (254), and

wherein the intake opening (252) of the melt pump (250) is connected to a first casting channel section (202) leading to the casting chamber (100), and the outlet opening (254) of the melt pump (250) is connected to a second casting channel section (204) leading to the casting chamber (300), in order to intake the molten metal (110) through the first casting channel section (202) and to discharge it again through the second casting channel section (204).

3. Device (10) for diecasting metal according to any one of the preceding claims,

wherein the melt pump (250) comprises an elastic element (260) for conveying the molten metal (110) by deformation of the elastic element (260),

wherein the flexible element (260) preferably comprises or consists of an elastomer, in particular a perfluoroelastomer and/or a silicone rubber.

4. The device (10) for die casting metal according to any one of the preceding claims, wherein the melt pump (250) comprises a pump chamber (265), in particular a pump chamber connected to the suction opening (252) and the discharge opening (254), which is designed in a leak-free, in particular air-tight, in particular hermetically sealed manner, in particular in order to avoid oxygen contact of the melt (110).

5. Device (10) for diecasting metal according to any one of the preceding claims,

the melt pump (250) comprises a suction valve (256), in particular a suction valve, which is arranged at the suction opening (252) or in the first casting channel section (202) and is provided for opening when the melt (110) is sucked in and/or for

Wherein the melt pump (250) comprises a discharge valve (258), in particular a discharge valve, which is arranged at the discharge opening (254) or in the second casting channel section (204) and which is provided to be opened when the melt (110) is discharged.

6. Device (10) for diecasting metal according to any one of the preceding claims,

wherein the melt pump (250) is designed as a diaphragm pump with a membrane (270), and

wherein the membrane (270) preferably forms the elastic element (260).

7. Device (10) for diecasting metal according to any one of the preceding claims,

wherein the melt pump (250) is designed as a hose pump with a hose (280), and

wherein the hose (280) preferably forms the elastic element (260).

8. Device (10) for diecasting metal according to any one of the preceding claims,

wherein the melt pump (250) is provided for conveying a melt of metal up to 300 ℃, in particular up to 290 ℃, in particular up to 280 ℃, in particular up to 270 ℃, in particular up to 260 ℃, in particular up to 250 ℃, in particular up to 232 ℃, in particular up to 138 ℃, in particular up to 117 ℃, and/or

Wherein the melt pump (250) is provided for operating at up to 500 ℃, in particular up to 400 ℃, in particular up to 330 ℃, in particular up to 300 ℃, in particular up to 290 ℃, in particular up to 280 ℃, in particular up to 270 ℃, in particular up to 260 ℃, in particular up to 250 ℃, and/or

Wherein the elastic element (260), in particular the membrane (270) and/or the hose (280), is provided for operation up to 500 ℃, in particular up to 400 ℃, in particular up to 330 ℃, in particular up to 300 ℃, in particular up to 290 ℃, in particular up to 280 ℃, in particular up to 270 ℃, in particular up to 260 ℃, in particular up to 250 ℃, and/or

Wherein the pump chamber (270), and preferably the suction valve (256) and/or the discharge valve (258), is provided for operation up to 500 ℃, in particular up to 400 ℃, in particular up to 330 ℃, in particular up to 300 ℃, in particular up to 290 ℃, in particular up to 280 ℃, in particular up to 270 ℃, in particular up to 260 ℃, in particular up to 250 ℃.

9. Method for die casting metal, in particular by means of a device (10) according to one of claims 1 to 8,

wherein a molten metal (110) is introduced into the casting chamber (100), and

wherein the molten metal (110) is pumped out of the casting chamber (100) from the casting channel (200) and

wherein the molten metal (110), preferably also from the casting channel (200), is discharged in the direction of the casting chamber (300).

10. Method for die casting metal according to claim 9,

wherein the molten metal (110) is sucked by deforming the elastic element (260), in particular the membrane (270) and/or the hose (280), and/or

Wherein the molten metal (110) is discharged by deforming the elastic element (260), in particular the membrane (270) and/or the hose (280).

11. Method for diecasting metal according to claim 9 or 10,

the molten metal (110) is pumped and/or discharged in a leak-free, in particular air-tight manner.

12. Method for diecasting metal according to any of claims 9 to 11,

wherein, when the molten metal (110) is pumped, a pump valve (256) is opened, and/or

Wherein a discharge valve (258) is opened when the molten metal (110) is discharged.

13. Method for diecasting metal according to any of claims 9 to 12,

wherein a component is inserted into the casting chamber before the molten metal (110) is introduced into the casting chamber, and

wherein the component is at least partially encapsulated by a molten metal.

14. The method for plastic injection molding and metal die casting according to claim 13,

wherein the component is at least partially encapsulated with plastic before being introduced into the casting cavity, such that a plastic injection-molded component is formed on the component, and

wherein the plastic injection-molding compound formed on the component is at least partially encapsulated with a molten metal in such a way that a metal casting compound is formed on the plastic injection-molding compound, and

optionally, after at least partial potting of the plastic injection molding compound formed on the component with the metal melt, the metal casting compound is at least partially encapsulated again with plastic, so that a further plastic injection molding compound is formed on the metal casting compound.

15. The method for plastic injection molding and metal transfer molding according to claim 14,

wherein the component placed into the casting cavity is an electrical connector, wherein the electrical connector comprises:

one or more line components belonging to at least one line or at least one plug connector,

one or more shielding cans or shielding housings belonging to at least one line or at least one plug connector, and

wherein the line components of the electrical connector are at least partially encapsulated with plastic in order to form a plastic injection molding compound designed as an intermediate insulator, which protects the line components during encapsulation with a molten metal, and

the plastic injection-molded component, which is designed as an intermediate insulator, is at least partially encapsulated with a molten metal in order to form a metal cast component, which is designed as a shielding housing and which either connects a plurality of shielding shells to one another or connects at least one shielding shell to at least one shielding housing or a plurality of shielding housings to one another or forms part of a shielding housing.

16. A combined injection molding and casting mold (312) having an injection cavity (300 ') for hardening the injected plastic and a separate casting cavity (300) for hardening the molten metal and preferably having a further separate injection cavity (300') for hardening the injected plastic, wherein the dimensions of the cavities are preferably increased such that one component of a batch of components can be encapsulated with plastic in the injection cavity, then encapsulated with metal in the casting cavity and optionally finally encapsulated again with plastic in the further injection cavity.

Technical Field

The invention relates to a device for die casting metal, comprising: a casting chamber for containing molten metal; a casting cavity for hardening the molten metal in a defined shape; and a casting passage connecting the casting chamber with the casting cavity. The invention also relates to a method for die casting metal.

Background

Die casting is a casting process in which liquid metal is introduced under pressure into a casting cavity in order to solidify or harden there in the shape defined by the casting cavity. Before the molten metal enters the casting chamber, also referred to as the casting cavity, the molten metal is initially introduced into a casting chamber connected to the casting chamber and is pressurized there, for example, by a pressure piston. Due to the pressure acting on the melt stored in the casting chamber, the melt enters the casting chamber through the casting channel, so that the desired metal cast is formed there after hardening. In the case of hot-chamber die casting, the melt in the casting chamber is additionally kept warm, as a result of which the method can be automated and accelerated better. In low-pressure casting, a casting chamber for receiving the molten metal is usually arranged below the casting chamber and the pressurization of the molten metal is carried out by compressed air, so that the molten metal rises into the casting chamber against gravity.

DE102012010923a1 relates, for example, to a conveying device for molten metal in a metal casting machine. The conveying device has a holding container for the molten metal and a conveying channel, in which the molten metal is conveyed to the mold cavity. It is provided here that the conveying channel comprises a cylinder bore in which a piston is arranged in an axially displaceable manner.

DE102012009790a1 relates to a method in which a liquid metal component is introduced into a mold cavity by means of a nozzle. It is provided that the transition region between the nozzle and the mold cavity is cooled after the metal component has entered the mold cavity in such a way that the metal in the gate region solidifies. In a subsequent method step, the gate region is heated again, so that the metal present in the gate region liquefies again.

A disadvantage of the known injection molding methods is that slag is formed in the melt over time, which can lead to fluctuations in the mold filling or can be mixed into the casting channel. This problem is further exacerbated by the use of pressure pistons which move in the melt. The melt is also typically aggressive to the materials used, for example, in the melting crucible and piston. Furthermore, due to these problems, it may become difficult to reliably seal portions that are movable relative to each other. Even in low-pressure casting in which the melt is pressurized with compressed air, there is a problem of slag formation in principle. In addition, low pressure casting has the disadvantage that it is difficult to meter and control the solution flow.

Disclosure of Invention

The object of the present invention is therefore to provide a device and a method for die casting, in which the formation of slag is avoided or reduced and which at the same time ensure good metering and control of the melt when it is introduced into the casting chamber.

Die casting or low-pressure casting according to DIN8580 involves forming or preliminary forming from a liquid state, for example a molten metal. In contrast, the plastic is formed from a plastic state, for example by injection molding or injection compression molding.

Against this background, it is an aspect of the object of the invention to design a metal injection molding process as a plastic injection molding process with process safety and low maintenance costs, in order to provide a multicomponent method with a plastic injection molding component and a metal injection molding component, which method forms an efficient composite process. In this respect, as already explained, the aim is to reduce or avoid the formation of slag and to improve the metering and control of the melt flow in order to keep the maintenance effort for the die casting to a minimum. On the other hand, metal diecasting without sprues and without overflows should also be carried out in order to avoid separating sprues and overflows before or after the injection molding process steps and thus to accelerate and simplify the compounding process.

The object of the invention is achieved by the solution of the independent claims. Advantageous embodiments of the invention are defined in the dependent claims.

The invention relates to a device for die casting metal, comprising: a casting chamber for containing molten metal; a die casting die having a casting cavity for hardening the molten metal in a defined shape; and a casting channel connecting the casting chamber to the casting cavity in such a way that a metal melt can be introduced from the casting chamber through the casting channel into the casting cavity to harden there in a defined shape.

According to the invention, the device comprises a melt pump arranged in the casting channel for conveying the metal melt along the casting channel in order to introduce the metal melt from the casting chamber through the casting channel into the casting cavity. The melt pump thus forms in particular part of a casting channel for connecting the casting chamber to the casting chamber. In other words, the casting channel extends in particular at least partially through the melt pump.

It is therefore possible within the scope of the invention to actively generate a negative pressure and/or an overpressure for the supply of the melt in the casting channel. In particular, active pressurization of the melt in the casting chamber from the outside, for example by means of a piston, can thus be dispensed with. Movable parts of the solution, such as pistons, can thus be successfully omitted in an advantageous manner, whereby slag formation is reduced or avoided. In addition, the metering and control of the melt flow can be improved. For example, metering and control are optimized in relation to low-pressure casting by means of active compressed air supply, since the pumping process acts directly on the molten metal, which, due to its incompressibility, continues to convey the pressure caused by the pumping process without loss.

In conventional die casting or hot-chamber die casting methods with a pressure piston acting on the melt in the casting chamber, high maintenance costs are incurred as a result of oxidation between the solder used and the casting piston. As the operating time progresses, a large amount of oxide dust is generated at the interface between the piston rod and the natural slag layer on the dip soldering bath, which in turn leads to blockages in the melt channel between the casting unit and the mold cavity. There are different piston geometries, extensive series of tests of piston materials, and loading the surface of the dip soldering bath with nitrogen gas do not satisfactorily reduce dust formation. These problems are reduced or almost avoided with the device according to the invention with a melt pump.

The use of a melt pump provides a solution for treating the melt without the need for mechanical moving parts between the surface of the dip soldering bath (Lotbad) and the ambient air. The melt pump allows in particular the delivery of melts having a low viscosity or a low-pressure and gentle delivery process. Furthermore, with a melt pump, contact of the solder (melt) with the ambient air can be avoided with a corresponding system design.

The following alloys are particularly considered as molten metals: indium tin eutectic 52In (melting point of 48Sn about 117 ℃), bismuth tin eutectic 58Bi (melting point of 42Sn about 138 ℃), tin solder Sn (melting point: about 180 ℃ to 232 ℃), and other lower or higher melting point alloys. In particular, the casting chamber (hot chamber device) and/or the casting channel can be heated at least to the melting point of the alloy up to approximately 70 ℃. Preferably, all the materials that are in contact with the melt are resistant to the melt (dealloying) in order to avoid the materials used (e.g., metals) dissolving in the melt, enriching the melt with foreign substances and/or necessitating replacement of components. With the invention, in particular, metal components in the melt (for example pistons) can be avoided, whereby this disadvantageous effect can be avoided.

The melt pump provided according to the invention preferably has a suction opening and a discharge opening, wherein the suction opening of the melt pump is connected to a first casting channel section leading to the casting chamber and the discharge opening of the melt pump is connected to a second casting channel section leading to the casting chamber, in order to suck in the molten metal through the first casting channel section and to discharge the molten metal again through the second casting channel section.

As described, the melt pump is arranged according to the invention in the casting channel. The melt pump is arranged in particular not only at the end of the casting channel. More precisely, the melt pump is preferably located between the casting chamber and the casting mold. The melt pump is preferably arranged in the casting channel in such a way that the length of the first casting channel section is at least 1% of the length of the casting channel, in particular at least 10% of the length of the casting channel, in particular at least 20% of the length of the casting channel. Preferably, the corresponding description also applies to the second casting channel section. The melt pump is preferably arranged outside the melt, particularly preferably outside the casting chamber.

The melt pump preferably comprises an elastic element in order to convey the metal melt by deformation of the elastic element, wherein the flexible element preferably comprises or consists of an elastomer, in particular a perfluoroelastomer and/or silicone rubber.

The melt pump preferably further comprises a pump chamber, in particular a pump chamber connected to the suction opening and the discharge opening, which is designed in a leak-free, in particular air-tight, in particular hermetically sealed manner, in particular in order to avoid oxygen contact with the melt. In other words, the pump chamber is preferably constructed leaktight, sealed and/or gas-tight, apart from the suction opening or the discharge opening.

In one embodiment of the invention, the melt pump has a suction valve, in particular a suction valve arranged at the suction opening or in the first casting channel section, which is provided to be opened when the melt is sucked in. In addition, the suction valve may be closed at the time of discharge. Furthermore, the melt pump may also comprise a tapping valve, in particular a tapping valve arranged at the tapping opening or in the second casting channel section, which is provided to be opened when tapping the melt. The outlet valve can furthermore preferably be closed during suction.

In one embodiment of the invention, the melt pump is designed as a diaphragm pump. In other words, a film is included, which can be deflected to cause the transport process of the melt. The membrane thus forms in particular the elastic element described previously. Further, when a diaphragm pump is used, a suction valve and a discharge valve are particularly preferable.

In a further embodiment of the invention, the melt pump is designed as a hose pump. In other words, a hose is included, which, by means of external mechanical deformation, effects the melt supply process. The hose here forms in particular the elastic element described above.

Since the metal melt to be conveyed can have a relatively high process temperature, the hose pump or its material is advantageously correspondingly resistant to high temperatures. The material used for the film or the hose, in particular the flexible material, is preferably sufficiently resistant to high temperatures in order to withstand the melt temperatures mentioned above permanently. The perfluoroelastomers described above can be used, for example, at operating temperatures up to 330 ℃. The silicone rubber may then be used at operating temperatures of up to 250 ℃ to about 300 ℃. But other elastomers are possible depending on the melt temperature.

The melt pump is therefore preferably provided for conveying molten metal up to 300 ℃, in particular up to 290 ℃, in particular up to 280 ℃, in particular up to 270 ℃, in particular up to 260 ℃, in particular up to 250 ℃, in particular up to 232 ℃, in particular up to 138 ℃, in particular up to 117 ℃.

Furthermore, the melt pump is preferably also provided for operating at up to 500 ℃, in particular up to 400 ℃, in particular up to 330 ℃, in particular up to 300 ℃, in particular up to 290 ℃, in particular up to 280 ℃, in particular up to 270 ℃, in particular up to 260 ℃, in particular up to 250 ℃.

The elastic element, in particular the membrane and/or the hose, is especially provided for operation at up to 500 ℃, in particular at up to 400 ℃, in particular at up to 330 ℃, in particular at up to 300 ℃, in particular at up to 290 ℃, in particular at up to 280 ℃, in particular at up to 270 ℃, in particular at up to 260 ℃, in particular at up to 250 ℃.

However, the pump chamber and preferably the suction valve and/or the discharge valve are preferably provided for operation at up to 500 ℃, in particular up to 400 ℃, in particular up to 330 ℃, in particular up to 300 ℃, in particular up to 290 ℃, in particular up to 280 ℃, in particular up to 270 ℃, in particular up to 260 ℃, in particular up to 250 ℃.

In a preferred embodiment of the invention, the casting chamber is designed without an overflow, i.e. does not comprise an overflow provided for the molten metal to flow into it. The cavity can thereby be filled in an advantageous manner without sprue and without overflow, so that metal diecasting can be simplified and accelerated, and therefore low maintenance costs and process safety can be achieved, similar to plastic injection molding.

The casting cavity may have an outlet for venting or pumping out gases present in the casting cavity. The outlet is preferably designed such that the molten metal to be introduced into the casting chamber cannot flow into the outlet.

One possibility for ensuring that the molten metal to be introduced into the casting chamber cannot flow into the outlet consists in defining the cross-sectional area of said outlet. The cross-sectional area is preferably between 0.0001 and 10 square millimeters, particularly preferably between 0.001 and 1 square millimeter. For example in the form of a gap or a drilled hole, may for example have a diameter of about 0.05mm to 1 mm. Furthermore, a plurality of outlets is also possible, which may in particular be connected in parallel. The outlet may also be formed by a porous region of the casting cavity, for example a porous mold insert.

Alternatively or additionally, it can be provided that the device comprises a cooling device for cooling the outlet, so that the molten metal hardens at the outlet, so that the molten metal to be introduced into the casting chamber does not flow into the outlet. In other words, active cooling can be provided in the region of the outlet or of the porous insert in order to ensure rapid solidification of the melt. Additionally, materials with good thermal conductivity, for example materials with a high copper content, can be used for this purpose. However, if the penetration of the melt into the outlet is still minimal, it is also possible to provide an ejector which is arranged in the outlet in order to clean the outlet from the residues of the penetrating melt after each shot.

Furthermore, a vacuum pump, in particular a vacuum pump, can be provided, which is connected to the outlet of the casting chamber in order to pump out the gas present in the casting chamber via the outlet. The (negative) pressure may in particular lie in the range between-1.1 and-0.7 bar, for example approximately-0.9 bar.

The device for die casting metal, in particular to avoid or reduce slag formation, also comprises an outer vessel for containing a fluid, in particular a gas, in order to ensure oxygen insulation of the melt surface located in the casting chamber. The outer vessel may house or be formed by a casting chamber. In particular, it can be provided that the fluid covering the melt surface actively pressurizes the outer melt surface in order to form an oxygen barrier.

In addition to the device described above, the invention also relates to a method for die casting metal, in particular by means of a device for die casting metal, comprising a casting chamber, a casting mold with a casting cavity, and a casting channel connecting the casting chamber to the casting cavity, preferably as explained above.

In the method according to the invention, the molten metal is introduced into the casting chamber and is drawn out of the casting chamber from the casting channel, in particular by actively inducing a pressure change in the molten metal in the casting channel. The molten metal is preferably also discharged from the casting channel in the direction of the casting chamber, as a result of which, in turn, a pressure change in the molten metal can be actively induced in the casting channel. Active in the casting channel means that the point of triggering the pressure change is not outside the casting channel, i.e. the pressure change is not merely transmitted into the casting channel.

The melt is preferably pumped and/or discharged from outside the melt, particularly preferably from outside the casting chamber.

Furthermore, the method for die casting metal also comprises the further features explained above in the context of the device for die casting metal.

The molten metal is therefore sucked and/or discharged, for example, in particular by deformation of the elastic element, in particular the membrane and/or the hose. Furthermore, the molten metal is preferably pumped and/or discharged in a leak-free, in particular air-tight manner. The suction valve can also be opened when the molten metal is being sucked in and/or the discharge valve can also be opened when the molten metal is being discharged.

The method according to the invention can be used in particular in a multi-component method (composite process) with at least one plastic injection molding component and at least one metal injection molding component. In this case, the term diecasting, in particular with reference to molten metal, is clearly distinguished from the term injection molding, in particular with reference to plastic, according to DIN 8580.

In principle, in the method according to the invention, provision may first be made for the component to be inserted into the casting chamber before the molten metal is introduced into the casting chamber, so that the component is completely or at least partially encapsulated with the molten metal. In other words, a method for casting an encapsulating element is also specified within the scope of the disclosure.

In a step prior to the injection molding, the component can be at least partially encapsulated with plastic, so that a plastic injection molding compound is formed on the component before the component is inserted into the casting cavity. The plastic injection molding compound formed on the component can then be encapsulated at least partially with a molten metal in the context of injection molding, so that a metal casting compound is formed on the plastic injection molding compound.

Alternatively, the further, in particular external, plastic injection molding component can be formed on the metal casting component by at least partially encapsulating the metal casting component with plastic again after at least partially encapsulating the plastic injection molding component formed on the component with the molten metal.

In a specific application, the component inserted into the casting chamber can be an electrical connector, wherein the electrical connector comprises one or more line components belonging to at least one line or at least one plug connector and one or more shielding cans or shielding housings belonging to at least one line or at least one plug connector. Further details of the electrical connector refer to DE102015102703a1, which uses the same glossary of terms and is hereby incorporated by reference.

In a specific application of the method for such a connector, it can be provided that the line elements of the electrical connector can be at least partially encapsulated with plastic in order to form a plastic injection molding compound designed as an intermediate insulator, which protects the line elements during encapsulation with the molten metal.

Furthermore, it can be provided that the plastic injection-molded component forming the intermediate insulating body is encapsulated at least partially with a molten metal in order to form a metal cast component forming the shielding housing, which metal cast component either connects a plurality of shielding shells to one another or connects at least one shielding shell to at least one shielding housing or a plurality of shielding housings to one another or forms part of a shielding housing.

Furthermore, it can be provided that the metal casting compound designed as a shielding housing is in turn at least partially encapsulated with plastic, so that an outer plastic injection molding compound is formed on the metal casting compound.

Drawings

The invention is explained in more detail below with the aid of the figures. In the figure:

FIG. 1 is a first embodiment of an apparatus for die casting metal;

FIG. 2 is a second embodiment of an apparatus for die casting metal;

FIG. 3 is a method step of a composite process with injection molding and die casting;

fig. 4 is a combined injection molding-die casting mold.

Detailed Description

Fig. 1 shows a first embodiment of a die casting installation 10, also referred to as a casting assembly, with: a casting chamber 100; a two-part casting mold 301 with a casting chamber 300 located therein and a casting channel 200 in which a melt pump 250 is arranged. A molten metal 110, in particular a low-melting metal alloy, is located in the heated casting chamber 100 (hot chamber).

The melt pump 250 is in this case designed as a diaphragm pump. By depressurizing the film 270, a negative pressure is generated in the pump chamber 265 that forms a part of the casting passage 200, and thus the molten metal 110 is pumped from the casting chamber 100 (fig. 1 a). In contrast, an overpressure is generated in the pump chamber 265 and thus in the casting channel 200 by pressurizing the diaphragm 270, so that the molten metal 110 is conveyed in the direction of the casting chamber 300 (fig. 1 b). The membrane 270 may be depressurized or pressurized by means of a suitable actuator (not shown).

The melt pump 250 installed in the casting channel 200 is connected on the one hand via a suction opening 252 to the casting channel section 202 leading to the casting chamber 100, in order to be able to suck melt from the casting chamber 100. On the other hand, the pump 250 is connected to the casting channel section 204 leading to the casting chamber 300 via the outlet opening 254, in order to be able to introduce the melt into the casting chamber 300.

When the membrane 270 is depressurized in the first step (fig. 1a), the suction valve 256 arranged at the suction opening 252 may be opened and the discharge valve 258 at the discharge opening 254 is simultaneously closed. In this way, a backflow of melt from the casting channel section 204 to the casting chamber 300 is avoided, so that no ambient air enters the casting channel and oxidation is avoided. The suction valve 256 can be opened and/or the discharge valve 256 can be closed by the generated vacuum itself. Alternatively the valve may be opened or closed electrically.

When the membrane 270 is pressurized in the second step (fig. 1b), the suction valve 256 may be closed and/or the discharge valve 258 may be opened in the opposite manner. The melt 110 is conveyed from the pump to the chamber 300 or the mold by pressurizing the film 270.

The connection to the casting channel section 202 of the casting chamber 100 is preferably made at or near the bottom of the casting chamber 100 in order to draw cleaner solder (Lot) from deeper layers into the system, thereby also reducing or avoiding the ingress of oxide particles.

Fig. 2 shows a second embodiment of the die casting device 10, which in turn has a casting chamber 100, a casting channel 200 with a melt pump 250 and a casting cavity 300.

In contrast to the first embodiment, the melt pump 250 located in the casting channel 200 is now embodied as a hose pump or peristaltic pump. The pump chamber 265 is therefore formed by a deformable hose 280 which furthermore forms part of the casting channel 200 and connects the casting channel section 202 leading to the casting chamber with the casting channel section 204 leading to the casting cavity 300.

The operation of the pump is effected by rotation of the cam shaft 290 by which the hose is "peristaltic" between the cam shaft and the pump housing. This peristaltic movement causes a more or less strongly pulsating supply flow of the melt 110 from the casting chamber 100 to the casting chamber 300.

In the same way as a diaphragm pump, a closed, air-free process can also be achieved with this system, so that oxidation products in the melt system are advantageously avoided. A suction pump and a discharge valve can optionally be provided in this system configuration. But the valve may also be omitted. In addition, an almost continuous conveying process can be achieved with such a system, with which also extremely large filling volumes can be achieved very simply.

Fig. 3 shows a three-stage composite process, which includes injection molding of plastic and die casting of metal, wherein the terms injection molding and die casting are defined in accordance with DIN8580 and are distinguished from one another.

In a first step (a), an injection mold 301 'with an injection cavity 300' is provided and plastic is injected into the injection mold 301 'through an injection line 200'. This results in a component having a plastic injection molding compound, which is then inserted into the casting chamber 300 of the injection molding tool 301 and encapsulated with metal in a second step (b) in such a way that the molten metal is introduced through the casting channel 200, in particular as described above, so that the metal casting compound is formed. This results in a two-component which can optionally be inserted again into the injection cavity 300 "of a further injection molding tool 301" in order to be encapsulated again by plastic.

Fig. 4 shows a two-part combined injection molding/diecasting mold 312, with which the previously described steps can also be carried out. The combined injection molding-die casting mold 312 includes a first injection cavity 300 'for hardening injected plastic, a separate casting cavity 300' for hardening molten metal, and a separate second injection cavity 300 "for hardening injected plastic.

The multi-component injection-casting-injection process in the composite system may be used, for example, to manufacture shielding structures for electrical connectors. The electrical connector is first injection-molded in plastic, then subsequently encapsulated with metal in order to produce the shielding structure, and then subsequently encapsulated again with plastic. With the inventive die casting method or the inventive die casting installation, a metal casting process can therefore be designed with process safety and low maintenance costs, as can a plastic injection molding process or two plastic injection molding processes. As already explained above, this enables in particular a sprue-free and overflow-free injection molding, so that there is no need to separate the sprue and the overflow before the subsequent injection molding process. The casting is inexpensive to maintain since the formation of slag in the molten metal is avoided, fluctuations in the mold filling during the casting process are advantageously avoided and mixing into the casting channel is avoided.

It will be appreciated by a person skilled in the art that the embodiments described hereinbefore are exemplary and that the invention is not limited thereto, but can be varied in a multitude of ways without departing from the scope of protection of the claims. It is also known that the features described define important parts of the invention individually, irrespective of whether they are disclosed in the description, the claims, the drawings or otherwise, even if they are described together with other features.