JP2001246451A - Vacuum melting and injection molding apparatus for active alloy molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an apparatus, with which an injection-molding of an active alloy is continuously executed without releasing a vacuum state in a heating and melting part space with raw material charging at a time and a high quality injection-molded product can be produced in the large quantity and at a low cost. SOLUTION: This apparatus is provided with a vacuum chamber 24 disposed at the lower part of a metallic mold 1 composed of a fixed lower mold 2 and movable upper mold 3, a shield shutter for shutting off/communicating with a cavity of the above metallic mold and a space in a vacuum chamber, an injection sleeve 27 providing an injection plunger 28 in the inner part and arranged so as to be freely advanced/ retreated toward a sprue in the metallic mold, a means 34 for heating and melting a base alloy block A supplied in the injection sleeve and a base alloy supplying means 35 having a base alloy holding magazine 42 disposed at the upper part of a base alloy supplying path 36 connectable to the injection sleeve and forcibly shifting the base alloy block into the injection sleeve. Further, respective vacuum evacuating systems L1, L2 are constituted so as to communicate with the cavity in the metallic mold and the vacuum chamber respectively.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vacuum melting injection molding apparatus for molding an active alloy, and more particularly, to an apparatus capable of high-speed injection casting of a molten active alloy while keeping the molten state clean.

[0002]

2. Description of the Related Art As a method for obtaining an amorphous alloy, which is a typical example of an active alloy, a gas atomizing method, a single roll method, and the like are conventionally widely known. However, these methods only produce powdered or foil-like ribbons, which must be further molded to obtain a product of any desired shape, which is generally compacted, degassed, extruded and cast. Molding and the like are performed. However, along with the deterioration of physical properties in the middle of the process due to the hot working, as a result of a wide variety of processes, the processing cost also increases, and this has been a practical obstacle to the amorphous alloy.

[0003] In addition, a method of melting and casting an active alloy such as an alloy containing a rare earth element or an amorphous alloy is also known. Oxidation sometimes causes various problems such as a decrease in mechanical strength and a decrease in amorphous forming ability. Therefore, recently, there has been proposed a molding method in which an active alloy is heated and melted in a vacuum and injected and filled into a cavity in a mold using an injection sleeve movable toward a mold (Japanese Patent No. 29773).
74 and JP-A-10-296424). In the case of such an injection molding method, it is inevitable that the entire space from the heat melting part to the injection molding part must be kept in a vacuum state during the injection molding, but after the injection molding, the vacuum state of the entire space is temporarily released. However, it is necessary to take out the product and load the raw material into the injection sleeve. That is, since it is necessary to form and release the vacuum state of the entire space each time injection molding is performed, the energy efficiency is poor, and the production efficiency is low due to batch production. Had become.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned prior art, and its basic purpose is to immediately melt an active alloy while heating it in a vacuum or in an inert gas atmosphere. By injection molding into a mold cavity in a vacuum state or an inert gas atmosphere, non-oxidation,
It is an object of the present invention to provide an apparatus capable of manufacturing a high-quality active alloy casting in a non-thermally degraded state and taking out the product without releasing a vacuum state in a space of a heating and melting part. Further, an object of the present invention is to allow the injection molding of the active alloy to be performed continuously without releasing the vacuum state of the space of the heating and melting section by one-time raw material loading, and to produce a high-quality injection molded product at a low cost. An object of the present invention is to provide a device that can be mass-produced.

[0005]

According to a basic aspect of the present invention, there is provided a mold having an injection mechanism for injecting and filling a molten metal into a cavity of the mold. In the injection molding apparatus having the master alloy melting device, an openable / closable vacuum chamber surrounding the master alloy melting device is provided, and a vacuum exhaust system is connected to communicate with the mold cavity and the vacuum chamber, respectively. ,
A vacuum melting and injection molding apparatus for molding an active alloy is provided, wherein a cavity in a mold is configured to be evacuated independently of a vacuum chamber. In one connection mode of the evacuation system communicating with the cavity of the mold, a vacuum housing surrounding the mold so as to be able to be hermetically provided is provided, and the evacuation system is connected to the inside of the vacuum housing, thereby forming the cavity in the mold. It can be configured to be able to evacuate independently of the vacuum chamber. Forming and maintaining independent vacuum states in the heat melting part and the injection molding part, respectively, is preferably
This is performed by providing a shielding shutter between the gate of the mold and the vacuum chamber to block and communicate the cavity of the mold with the space in the vacuum chamber.

In a preferred embodiment in which injection molding can be continuously performed by one-time charging of the raw material, the master alloy melting apparatus includes an injection plunger slidably disposed therein, and a mold. The injection sleeve has an injection sleeve disposed so as to be able to move forward and backward toward the gate, and a heating means for heating and melting the mother alloy mass supplied in the injection sleeve, and the injection sleeve is provided with a mother alloy supply means. . Preferably, the master alloy supply means includes at least one vertical cylindrical master alloy storage magazine for storing a plurality of master alloy blocks, and a master alloy supply path disposed below the mother alloy storage magazine. And forced moving means for moving the mother alloy block dropped from the magazine into the injection sleeve in the supply path, more preferably, a plurality of master alloy storage magazines, and these magazines are arranged on the turntable. Thus, one cassette is constituted.

More specifically, a preferred embodiment of the vacuum melting injection molding apparatus for molding an active alloy according to the present invention is a mold comprising a fixed lower mold having a gate and a movable upper mold that can move up and down; An openable and closable vacuum chamber, a shielding shutter for shutting off and communicating a space in the vacuum chamber with the cavity of the mold; and an injection plunger slidably disposed inside, and the metal mold. An injection sleeve arranged to be able to move back and forth toward the mold gate; heating means for heating and melting the mother alloy block supplied in the injection sleeve; a master alloy supply path connectable to the injection sleeve; A master alloy supply device having a vertical cylindrical master alloy storage magazine disposed at the top of the mother alloy supply path, and a forced movement means for moving the mother alloy block dropped from the magazine into the supply path to the injection sleeve; With the above mold Vacuum exhaust system was connected to Yabiti and vacuum chamber and each communicating, the mold cavity independently of the vacuum chamber is characterized in that the evacuatable configured.

[0008] A shielding shutter,
The upper part of the injection sleeve and the heating means may be provided, or the shielding shutter, the injection sleeve, the heating means and the master alloy supply device may be provided. Further, as a method for making the inside of the mold cavity a vacuum state, a vacuum exhaust system can be connected to the gate side of the mold, but when the movable upper mold is lowered and combined with the fixed lower mold, the mold is closed. It is also possible to provide a vacuum housing surrounding the mold to form a closed space, and connect an evacuation system inside the vacuum housing. More preferably, a vacuum reserve tank is incorporated in the evacuation system.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The first feature of the present invention is to have a mold and a master alloy melting apparatus having an injection mechanism for injecting and filling a molten metal into a cavity of the mold as described above. In the injection molding apparatus, an openable and closable vacuum chamber surrounding the mother alloy melting apparatus is provided, and a vacuum exhaust system is connected so as to communicate with the mold cavity and the vacuum chamber, respectively. It is configured to be able to evacuate independently of the chamber. As described above, since the cavity in the mold can be evacuated independently of the vacuum chamber, it is possible to take out the molded product after injection molding without releasing the vacuum state in the vacuum chamber, thereby improving energy efficiency. Get better. Further, by dividing the space of the heat melting part and the space of the injection molding part by the shielding shutter, the shutter is opened only at the time of molten metal injection, and vacuum injection molding with a short shot cycle can be performed. Especially when a vacuum reserve tank is connected to the mold exhaust system,
Even if the mold is opened for each shot, evacuation and vacuum can be instantaneously performed after the next mold is closed, so that vacuum injection molding can be performed with an extremely short shot cycle.

Next, a second feature of the present invention is that a master alloy supply means is attached to an injection sleeve which moves and abuts toward a gate of the mold and injects the molten metal into the mold cavity. Preferably, at least one vertical cylindrical master alloy storage magazine for accommodating a plurality of master alloy ingots, and a mother alloy supply path disposed below the master alloy storage magazine,
A master alloy supply means having a forced movement means for moving the mother alloy block dropped from the magazine to the injection sleeve in the supply path, particularly preferably a plurality of the mother alloy storage magazines, and these magazines are turntables. Is provided with a mother alloy supply means which is disposed in the cassette and constitutes one cassette. By providing such a master alloy supply means, a large number of mother alloy ingots can be continuously and automatically supplied to the injection sleeve without releasing the vacuum state in the vacuum chamber. Even if the active alloy is easily deteriorated by heat, injection molding can be performed continuously and automatically in a vacuum state. As a result, high-quality injection molded products can be mass-produced at low cost. Hereinafter, other features, functions, and effects of the present invention will be described while describing embodiments of the present invention illustrated in the accompanying drawings.

[0011]

1 to 4 show an embodiment of a vacuum melting injection molding apparatus according to the present invention. In the drawings, reference numeral 1 denotes a mold, which comprises a fixed lower mold 2 and a movable upper mold 3. . The lower mold 2 having the gate 4 is fixed to a main platen 7 having a circular opening 6 at a corresponding position, and a gap between them is sealed by a seal member 8 such as an O-ring. A plurality of tie bars 9 are erected in parallel on the main surface plate 7, and a fixed plate 10 is fixed to the upper end thereof. The number of tie bars 9 is
In the present embodiment, the number is four, but it is needless to say that the number is not limited thereto, and there may be three or two. The movable platen 11 mounted on the tie bar 9 is moved up and down by a mold clamping cylinder 12 mounted on the fixed platen 10. A fixed member 13 and a connecting member 14 (fixed member 1
The movable upper die 3 having the cavity 5 formed on the parting surface with the fixed lower die 2 is fixed via the movable upper die 3. It goes up and down with. In addition, a mold exhaust hole 15 is formed at a predetermined position of the movable platen 11 and the fixed member 13,
A seal member 8 is provided between each of the movable platen 11, the fixed member 13, the connecting member 14, the movable upper die 3, and the fixed lower die 2.
Sealed by

In the mold 1, a plurality of ejector pins 16 are provided so as to be able to protrude into the cavity 5 (in the illustrated example, there are a pair of ejector pins 16; The connecting rods 17 of the ejector pins 16 are inserted into the movable platen 11 and the fixed member 1.
3, and the lower end surface of each ejector pin 16 is configured to coincide with the upper surface of the mold cavity 5 by an urging means and a stopper means (not shown) upward. When the movable platen 11 rises to the top dead center after the end of the injection molding, the upper end surface of the connecting rod 17 is brought into contact with the lower end surface of the cylinder rod 19 of the ejector cylinder 18 mounted on the fixed platen 10 so as to be aligned therewith. By operating the ejector cylinder 18, the cylinder rod 19 pushes down the connecting rod 17, and the ejector pin 16 projects into the cavity 5.

Further, the movable upper die 3 is provided on the lower surface of the movable platen 11.
Is fixed via a seal member 8, while the main vacuum stool 7 is suspended.
A sealing frame 21 is similarly fixed at a corresponding position on the upper surface of the device via a seal member 8, and the movable platen 11 descends to clamp the movable upper die 3 to the fixed lower die 2. When the outer surface of the vacuum housing 20 is
Is slidably in contact with the inner surface of the base member via a seal member 8 so as to form a closed injection molded part space X.

At a predetermined position on the main platen 7, a molded article discharging cylinder 22 having an arm 23 which can approach and retreat to the injection molding section at a predetermined height is attached. On the other hand, a vacuum chamber 24 for sealingly forming the heating / dissolving section space Y is provided below the main platen 7, and is supported by a frame 48. Blocking and communication between the injection molding section space X and the heating / melting section space Y in the vacuum chamber 24 are performed by a shutter shutter 25 which slides on the lower surface of the main platen 7 and moves forward and backward. 26 by closing and opening the opening 6.

In the vacuum chamber 24, a cylindrical injection sleeve 27 is disposed immediately below a position where the gate 4 of the fixed lower die 2 and the opening 6 of the main platen 7 are aligned. An injection plunger 28 is movably disposed, and the injection plunger 28 is operated by an injection cylinder 29 mounted on a lower portion of the vacuum chamber 24. The lower end of the injection sleeve 27 is fixed to a sleeve holding member 30, which is actuated by a sleeve moving cylinder 31, and is guided up and down by a sleeve moving guide pin 32. Therefore, the injection sleeve 27
By operating the sleeve moving cylinder 31 to move the sleeve holding member 30 up and down, it rises toward the gate 4 of the mold 1 and descends to the initial position. A high-frequency induction heating coil 34 is provided around the upper portion of the injection sleeve 27 as heating means. As the heating means,
It is needless to say that the method is not limited to high-frequency induction heating, and other known heating methods such as resistance heating can be employed.

Further, a mother alloy supply device 35 is provided in the vacuum chamber 24 so as to be aligned with the side opening 33 of the injection sleeve 27. This master alloy supply device 35
A master alloy supply path cylinder 36 installed at a height position connectable to the side opening 33 of the injection sleeve 27; a mother alloy cassette 37 disposed on the mother alloy supply path cylinder 36;
A master alloy supply plunger 38 slidably disposed in the supply path cylinder 36 and a mother alloy supply cylinder 39 for operating the same. The mother alloy supply plunger 38 and a mother alloy supply cylinder 39 for operating the same. Is a master alloy block A that has dropped from the master alloy cassette 37 into the master alloy supply path cylinder 36.
As a forced moving means for moving the inside of the injection sleeve 27.

The mother alloy cassette 37 is shown in FIGS.
As shown in FIG. 7, a turntable 41 rotatably mounted on a mounting table 40 fixed to a master alloy supply path cylinder 36.
And a plurality of (in the illustrated example, four, but two, three, or five or more) vertical cylindrical mother alloy storage magazines 42 disposed on the turntable 41. In each of the mother alloy storage magazines 42, a certain number of mother alloy ingots A each having a predetermined size are provided. By fitting the center hole 43 of the turntable 41 of the mother alloy cassette 37 to the rotating shaft of the stepping motor 44, the turntable 41 is rotated stepwise at predetermined time intervals, and each mother alloy storage magazine 42 is sequentially rotated. , On the mother alloy supply path cylinder 36 and on the opening 45 of the mounting table 40.

The mother alloy lump A stored in the master alloy storage magazine 42 in a stepped manner is the lowermost master alloy lump A that has fallen into the master alloy supply path cylinder 36.
8, the opening 45 of the mounting base 40 is supplied by the master alloy supply plunger 38.
Is closed, so that it does not fall into the master alloy supply path cylinder 36, but when the master alloy supply plunger 38 retreats and the opening 45 of the mounting table 40 opens, the mother alloy supply path cylinder It falls into body 36 and prepares for the next supply. In this way, the master alloy blocks A in the master alloy storage magazine 42 are sequentially dropped and supplied one by one to the injection sleeve 27 at predetermined time intervals. When the master alloy storage magazine 42 is empty, the turntable 41 rotates by a predetermined angle, and the next master alloy storage magazine 42 is arranged at the supply position.

The master alloy supply device 35 is provided in the vacuum chamber 2
4 is mounted on a slide-type lid 46, which is slidably mounted on a guide rail 47 so that the entire mother alloy supply device 35 can be pulled out by pulling the lid 46. It has become. Therefore, after the injection molding is completed using the master alloy block A in all the master alloy storage magazines 42, the chamber air valve 53 connected to the vacuum chamber 24 is opened to release the vacuum state (at this time, the vacuum is released). The evacuation system L2 of the chamber 24 is shut off), the lid 46
By pulling out the master alloy cassette 37 and replacing the master alloy cassette 37, the supply state of a large number of master alloy blocks A can be adjusted by one operation. When the lid 46 is set in the vacuum chamber 24, the distal end surface of the mother alloy supply path cylinder 36 comes into contact with the periphery of the side opening 33 of the injection sleeve 27, and
The space between the vacuum chamber 6 and the vacuum chamber 24 is sealed by the seal member 8.

One line L1 of the vacuum pumping system L of the vacuum pump 50 (comprising a diffusion pump and a rotary pump)
The (mold exhaust line) is connected to a mold exhaust hole 15 formed in the movable platen 11 and the fixed member 13, and is connected to the injection molding space X.
It is configured to evacuate until the inside reaches a predetermined degree of vacuum,
The other line L2 is connected to the vacuum chamber 24, and is configured to evacuate the inside of the heating / dissolving section space Y to a predetermined degree of vacuum. A mold air valve 5 for releasing the vacuum state of the injection molding space X is provided in the mold exhaust line L1.
4 and a vacuum reserve tank 51 are also connected so that the injection molding space X can be instantaneously evacuated after the movable upper die 3 is clamped to the fixed lower die 2. An inert gas container 52 is provided in the vacuum chamber 24.
Depending on the type of the mother alloy to be used, heating and melting can be performed in an inert gas atmosphere such as Ar. Reference numerals 55 to 59 are solenoid valves.

Next, an injection molding process using the above-described apparatus will be described. <Mother Alloy Supplying Step> First, after the lid 46 is pulled out and the mother alloy cassette 37 is set in the mother alloy supply device 35 as described above, the lid 46 is closed, and the electromagnetic valve is closed in a state where the chamber air valve 53 is closed. 58 is opened to evacuate the heating / melting unit space Y in the vacuum chamber 24. At this time, the shielding shutter 26 is closed, and the mother alloy supply unit and the heating and melting unit are housed in one vacuum chamber 24. When the mother alloy storage magazine 42 of the mother alloy cassette 37 is set at a predetermined position, the mother alloy supply cylinder 39 operates,
The mother alloy block A that has fallen from the mother alloy storage magazine 42 into the mother alloy supply path cylinder 36 is pushed into the injection sleeve 27 by the master alloy supply plunger 38 as shown in FIG.

<Heat melting step> Next, the injection cylinder 29 is operated, and as shown in FIG. 2, the injection plunger 28 pushes up the mother alloy ingot A to the melting zone. Here, a current is applied to the high-frequency induction heating coil 34 to heat and melt the mother alloy block A. At this time, the movable upper die 3 is clamped to the fixed lower die 2, and the injection molding space X in the vacuum housing 20 is evacuated to be ready for injection molding.

<Injection Molding Step> After the molten metal in the injection sleeve 27 reaches a predetermined temperature (temperature measurement is performed by installing a thermocouple in the injection plunger 28 or using a radiation thermometer as in the embodiment described later). An appropriate method such as use can be adopted.)
The high-frequency induction heating coil 34 is demagnetized, the shutter cylinder 25 operates to open the shielding shutter 26, and the injection molding section space X and the heating and melting section space Y communicate. Immediately at this stage, the sleeve moving cylinder 31 and the injection cylinder 29 are operated synchronously, and the injection sleeve 27 and the injection plunger 28 are raised, so that the upper end of the injection sleeve 27 is around the gate 4 of the mold 1 as shown in FIG. The molten metal pressurized by the injection plunger 28, which rises by a predetermined distance, is injected and filled into the mold cavity 5, and the mold 1 removes heat and solidifies rapidly. At this time, since the mold 1 is exhausted from the ejector portion on the end side of the flow of the molten metal through the mold exhaust hole 15 of the movable platen 11,
Since the flow of the molten metal is charged into the mold cavity 5 along with the flow of exhaust gas, entrainment of air bubbles hardly occurs.

<Molded Article Ejection Step> After the end of injection molding, FIG.
As shown in the figure, the injection sleeve 27 and the injection plunger 28
Recedes to the original position, the shielding shutter 26 is closed,
After closing the solenoid valve 55 and opening the mold air valve 54, the movable platen 11 is raised by the mold clamping cylinder 12, and the mold 1 is opened. When the movable platen 11 reaches the top dead center, the upper end surface of the connecting rod 17 of the ejector pin 16 comes into contact with the lower end surface of the cylinder rod 19 of the ejector cylinder 18. At this stage, the solidified molded product B has been separated from the fixed lower mold 2 together with the movable upper mold 3, so that the ejector cylinder 18 operates to eject the ejector pin 16 downward,
The molded product B is separated from the movable upper mold 3 and dropped on the fixed lower mold 2. Next, the molded product discharge cylinder 22 operates,
After the arm 23 moves forward and grips the molded product B, it retreats, and the molded product B is taken out of the apparatus. At this time, the solenoid valve 5
Reference numerals 6 and 57 are open, and the vacuum reserve tank 51 is connected to the vacuum pump 50. The degree of vacuum in the vacuum reserve tank 51 is increased by utilizing the mold opening process time.

<Shot Cycle> After the molded product is discharged, the mold clamping cylinder 12 operates again to close the mold 1. Next, the mold air valve 54 is closed, the electromagnetic valve 55 is opened, and the injection molding part space X is connected to the vacuum reserve tank 51,
After the preliminary exhaust, the solenoid valve 56 closes (the solenoid valve 57
Is normally open) because it is connected to the vacuum pump 50, the evacuation of the injection molding part space X is completed in a very short time, the state returns to the state shown in FIG. 1, and the next injection cycle is started. On the other hand, in the master alloy supply device 35, the master alloy supply magazine 42
Next mother alloy block A that has fallen into the mother alloy supply path cylinder 36 from the
Is pushed out by the master alloy supply plunger 38 and supplied into the injection sleeve 27, so that the next shot cycle is started.

As described above, the master alloy block A stored in each master alloy storage magazine 42 of the master alloy cassette 37
The shot cycle is automatically and continuously repeated until all of the shots disappear. After all the master alloy blocks A in the master alloy cassette 37 have been exhausted, the solenoid valve 58 is closed, and the chamber air valve 53 is opened.
, And the mother alloy cassette 37 is replaced. After replacement of the cassette, the lid 46 is closed, and the shot cycle as described above is repeated again.

FIG. 6 shows a modification of the embodiment shown in FIGS. In the case of this device, the vacuum chamber 2
4 is configured to house only the heat melting part, that is, a small vacuum chamber 24 that houses the high-frequency induction heating coil 34 disposed above and around the injection sleeve 27 is formed. The injection sleeve 27 is slidably inserted into a sleeve 61 formed at the center of the bottom plate 60, but the other configuration is the same as that of the apparatus shown in FIGS. The space between the sleeve 61 and the injection sleeve 27 is sealed by the seal member 8 so that the vacuum state of the heating / dissolving unit space Y in the vacuum chamber 24 is maintained. As described above, only the shielding shutter 26, the upper part of the injection sleeve 27, and the high-frequency induction heating coil 34 are arranged in the vacuum chamber 24, so that the master alloy cassette 3 as in the previous embodiment is provided.
It is not necessary to release the vacuum state in the vacuum chamber 24 every time 7 is replaced, and automatic continuous injection molding can be performed for a long period of time. In addition, since the space Y for heating and melting in the vacuum chamber 24 to be evacuated is small, energy consumption required for vacuuming is also reduced.

FIG. 7 shows another embodiment of the apparatus of the present invention. In this apparatus, a mold exhaust hole 15 extending from the opening 6 to one side surface is formed in the main platen 7, and the cavity 5 of the mold 1 is evacuated from the pouring gate 4 side of the fixed lower mold 2. The structure is not provided with the vacuum housing as in the above embodiment. As a result, since the space X in the injection molding section to be evacuated is small, the energy consumption required for vacuuming in each injection cycle can be reduced, and the time required for the vacuuming can be shortened. Therefore, it is not necessary to provide a vacuum reserve tank in the mold exhaust line L1 as in the above embodiment, but it may be provided. Reference numeral 62 denotes a radiation thermometer for measuring the temperature of the molten metal.

The movable upper die 3 is fixed to the movable platen 11 via the fixing member 13 and the ejector pin 16 is inserted so as to be able to protrude into the cavity 5 in the same manner as in the previous embodiment. In the case of this embodiment, a seal member 8 such as an O-ring is provided between each ejector pin 16 and the movable upper mold 3 so that a vacuum state in the mold cavity 5 can be maintained.
Sealed by In addition, each ejector pin 16
Is connected to the movable plate 11 and the connecting rod 17 is connected to the movable plate 11.

On the other hand, a guide body 63 for guiding the opening and closing of the shielding shutter 26 is fixed to the lower surface of the main base 7, and the guide body 63 has an opening similar to the opening 6 of the main base 7. Having a part. The space between the main surface plate 7 and the guide body 63 and the shielding shutter 26 that slides in the gap formed therebetween is sealed by the seal member 8, and the space between the injection molding section space X and the heat melting section space Y is formed. It is possible to more reliably cut off between the two. Further, in the present embodiment, the mother alloy storage magazine 42 is configured to be removably incorporated in the master alloy supply path cylinder 36, but a cassette system may be used as in the above embodiment. The injection molding process using the apparatus of the present embodiment is basically the same as that of the apparatus of the above embodiment, and it will be easily understood by those skilled in the art from the above description, so that the description thereof will be omitted.

The preferred embodiment of the apparatus of the present invention has been described above. However, the present invention is not limited to the above-described embodiment, and various design changes are possible. Various combinations of the alloy supply section, the heat melting section, the injection molding section, and the evacuation system may be employed. The device of the present invention is an active alloy that is easily oxidized or thermally degraded, such as Al, Mg, Fe, Ti, Zr, Hf, Y, La,
It can be suitably used for injection molding of an alloy containing at least one active metal element such as Ce, Nd, Sm, and Mm (Misch metal) and having a sum of active atom elements of 50 atomic% or more in the alloy. The present invention is not limited to this, and can be used for injection molding of various alloys.

The apparatus of the present invention is particularly applicable to the following general formulas (1) to (1).
The present invention can be suitably applied to injection molding of an amorphous alloy having a composition represented by any one of (6). Formula _{^{(1): M 1 a M}} 2 b Ln c M 3 d M 4 e M 5 f However, one or two elements M ¹ is selected from Zr and Hf, M ² is Ni, Cu, Fe , Co, Mn, Nb, T
at least one element selected from the group consisting of i, V, Cr, Zn, Al and Ga; Ln is Y, La, Ce, N
at least one element selected from the group consisting of d, Sm, Gd, Tb, Dy, Ho, Yb, and Mm (mish metal which is an aggregate of rare earth elements); M ³ is Be, B,
At least one element selected from the group consisting of C, N and O; M ⁴ is at least one element selected from the group consisting of Ta, W and Mo; M ⁵ is Au, Pt, Pd and A;
at least one element selected from the group consisting of g, a,
b, c, d, e and f are each atomic%, and 25 ≦ a ≦
85, 15 ≦ b ≦ 75, 0 ≦ c ≦ 30, 0 ≦ d ≦ 30,
0 ≦ e ≦ 15 and 0 ≦ f ≦ 15.

The above amorphous alloy has the following general formula (1-a)
To (1-p). General formula (1-a): M ¹ _a M ² _b This amorphous alloy has a large negative enthalpy of mixing and good amorphous forming ability because the M ² element coexists with Zr or Hf. Formula ^{(1-b): M 1} a M 2 b Ln c , as in this amorphous alloy, the thermal stability of the amorphous by adding a rare earth element to the alloy of the formula (1-a) is improves.

The general formula ^{(1-c): M 1} a M 2 b M 3 d general formula ^{(1-d): M 1} a M 2 b Ln c M 3 d like these amorphous alloys, the atomic Element M with small radius
³ By filling the gaps in the amorphous structure with (Be, B, C, N, O), the structure is stabilized and the ability to form an amorphous structure is improved.

The general formula ^{(1-e): M 1} a M 2 b M 4 e general formula ^{(1-f): M 1} a M 2 b Ln c M 4 e general formula ^{(1-g): M 1} a _{^{M 2 b M 3 d M 4}} e general formula ^{(1-h): M 1} a M 2 b Ln c M 3 d M 4 e like these amorphous alloys, refractory metal M ⁴ (Ta,
When (W, Mo) is added, heat resistance and corrosion resistance are improved without affecting the ability to form an amorphous phase.

The general formula ^{(1-i): M 1} a M 2 b M 5 f general formula ^{(1-j): M 1} a M 2 b Ln c M 5 f general formula ^{(1-k): M 1} a _{^{M 2 b M 3 d M 5}} f general formula ^{(1-l): M 1} a M 2 b Ln c M 3 d M 5 f general formula ^{(1-m): M 1} a M 2 b M 4 e M 5 _f general formula ^{(1-n): M 1} a M 2 b Ln c M 4 e M 5 f general formula ^{(1-o): M 1} a M 2 b M 3 d M 4 e M 5 f general formula (1 _{^{-p): M 1 a M 2}} b Ln c M 3 d M 4 e M 5 f these noble metals ^{M 5 (Au, Pt, Pd} , when the amorphous alloy containing Ag), and crystallization occurred Does not become brittle.

The general formula _{(2): Al 100-ghi} Ln g M 6 h M 3 i However, Ln is Y, La, Ce, Nd, Sm, Gd, T
at least one element selected from the group consisting of b, Dy, Ho, Yb, and Mm; M ⁶ is Ti, V, Cr, Mn,
Fe, Co, Ni, Cu, Zr, Nb, Mo, Hf, T
at least one element selected from the group consisting of a and W, M ³ is at least one element selected from the group consisting of Be, B, C, N, and O; g, h, and i are each atomic%; 30 ≦ g ≦ 90, 0 <h ≦ 55, 0 ≦ i ≦ 10
It is.

The above amorphous alloy has the following general formula (2-a)
And (2-b) amorphous alloys. Formula _{(2-a): Al 100} -gh Ln g M 6 h This amorphous alloy, mixing enthalpy is large in negative, amorphous forming ability is good. Formula _{(2-b): Al 100} -ghi Ln g M 6 h M 3 i In this amorphous alloy, small elements M ³ atomic radius
By filling gaps in the amorphous structure with (Be, B, C, N, O), the structure is stabilized, and the ability to form an amorphous structure is improved.

General formula (3): Mg _100-p M ⁷ _{p wherein} M ⁷ is at least one element selected from the group consisting of Cu, Ni, Sn and Zn, and p is atomic% and 5 ≦ p ≦
60. This amorphous alloy has a large negative enthalpy of mixing and a good amorphous forming ability.

General Formula (4): Mg _100-qr M ⁷ _q M ⁸ _r where M ⁷ is at least one element selected from the group consisting of Cu, Ni, Sn and Zn, and M ⁸ is Al, Si and At least one element selected from the group consisting of Ca, q
And r are each atomic%, 1 ≦ q ≦ 35, 1 ≦ r ≦ 2
5 As in this amorphous alloy, the general formula (3)
Element M ⁸ (Al, S
By filling gaps in the amorphous structure with (i, Ca), the structure is stabilized, and the ability to form an amorphous phase is improved.

General formula (5): Mg _100-qs M ⁷ _q M ⁹ _s General formula (6): Mg _100-qrs M ⁷ _q M ⁸ _r M ⁹ _s where M ⁷ is Cu, Ni, Sn and Zn at least one element selected from the group consisting of at least one element M ⁸ is Al, selected from the group consisting of Si and Ca, M
⁹ is at least one element selected from the group consisting of Y, La, Ce, Nd, Sm and Mm, q, r and s are each atomic%, and 1 ≦ q ≦ 35, 1 ≦ r ≦ 25, 3 ≦ s ≦
25. Like these amorphous alloys, by adding a rare earth element to the alloys of the general formulas (3) and (4), the thermal stability of the amorphous is improved.

Among the above-mentioned amorphous alloys, the Zr-TM-Al system and the Hf-TM-Al system (TM: TM) having an extremely wide temperature difference between the glass transition temperature (Tg) and the crystallization temperature (Tx).
Transition metal) amorphous alloys have high strength and high corrosion resistance and have a supercooled liquid region (glass transition region) ΔTx = Tx−
The Tg is 30K or more, particularly the Zr-TM-Al-based amorphous alloy is as wide as 60K or more. In this temperature range, due to viscous flow, very good workability is exhibited even at a low stress of several tens MPa or less. In addition, the amorphous bulk material can be obtained even by a casting method having a cooling rate of about several tens of K / s. These alloys produce an amorphous material and at the same time reproduce the mold shape and dimensions very faithfully, either by die casting from the melt or by viscous flow forming utilizing the glass transition region.

These Zr-TM- used in the present invention
The Al-based and Hf-TM-Al-based amorphous alloys have a very large range of ΔTx, depending on the alloy composition and the measurement method. For example, Zr ₆₀ Al ₁₅ Co _2.5 Ni _7.5
ΔT of Cu ₁₅ alloy (Tg: 652K, Tx: 768K)
x is as wide as 116K. From room temperature to around Tg, the hardness reaches 460 (DPN) in Vickers hardness (Hv), the tensile strength reaches 1,600 MPa, and the bending strength reaches 3,000 MPa. The coefficient of thermal expansion α is 1 × 10 ⁻⁵ from room temperature to around Tg.
/ K, the Young's modulus is 91 GPa, and the elastic limit during compression exceeds 4 to 5%. Further, it has high toughness and shows a Charpy impact value of 60 to 70 kJ / m ² . When the glass transition region is heated while exhibiting such a very high strength characteristic, the flow stress decreases to about 10 MPa. For this reason, it is a feature of the present alloy that it is extremely easy to process and can be formed into minute parts and high-precision parts having low stress and complicated shapes. Moreover, the processed (deformed) surface has extremely high smoothness due to the characteristics as a so-called glass (amorphous), and substantially no steps such as a step in which a slip band appears on the surface as when a crystalline alloy is deformed. have.

In general, when an amorphous alloy is heated to a glass transition region, crystallization starts by holding for a long time, but an alloy having a wide ΔTx such as the present alloy has a stable amorphous phase and a temperature within ΔTx. If no is selected, no crystal is generated until about 2 hours, and there is no need to worry about crystallization in ordinary molding. In addition, the alloy exerts this property even when solidifying from the molten metal. Generally, rapid cooling is required for the production of an amorphous alloy. However, the present alloy can easily obtain a bulk material composed of an amorphous single phase from a molten metal by cooling at a cooling rate of about 10 K / s. The solidified surface is still extremely smooth, and has a transferability that faithfully reproduces even micron-order polishing scratches on the mold surface. Therefore, if this alloy is used as a casting material, if the mold surface has a surface quality that satisfies the required characteristics of the molded product, the casting surface material will reproduce the mold surface characteristics as it is, The adjustment process can be omitted or shortened.

As described above, relatively low hardness, high tensile strength and high bending strength, relatively low Young's modulus, high elasticity limit, high impact resistance, high abrasion resistance, surface smoothness, high precision The feature having both castability is suitable as a material for molded products in various fields such as ferrules, capillaries, sleeves, V-groove substrates, and precision parts such as gears and micromachines of optical connectors. In addition, since amorphous alloys have high-precision castability and workability, and have excellent transferability that can faithfully reproduce the cavity shape of the mold, by appropriately manufacturing the mold, By the die casting method, a molded product satisfying a predetermined shape, dimensional accuracy, and surface quality can be manufactured in a single process with good mass productivity.

The materials used for the production of the molded article made of an amorphous alloy to which the present invention is applied include, in addition to the above-mentioned amorphous alloy, JP-A-10-186176 and JP-A-1
Various known amorphous alloys such as the amorphous alloys described in JP-A No. 0-31923, JP-A-11-104281 and JP-A-11-189855 can be used.

[0047]

As is apparent from the above description, the following effects and advantages can be obtained by the vacuum melting injection molding apparatus for molding an active alloy of the present invention. (1) Since the mold cavity can be evacuated independently of the vacuum chamber, it is possible to take out the molded product after injection molding without releasing the vacuum state in the vacuum chamber, thereby improving energy efficiency. . (2) Further, by dividing the heat melting part space and the injection molding part space by the shielding shutter, the shutter can be opened only when the molten metal is injected, and vacuum injection molding with a short shot cycle can be performed. (3) Especially when a vacuum reserve tank is connected to the mold exhaust system, even if the mold is opened for each shot, the exhaust can be instantaneously evacuated after the next mold is closed, so that an extremely short shot cycle can be achieved. Vacuum injection molding can be performed. (4) A mother alloy supply means using a mother alloy storage magazine is attached to an injection sleeve which moves toward and comes into contact with the mold gate to inject the molten metal into the mold cavity, preferably a cassette type mother alloy. By providing the supply means, a large number of mother alloy ingots can be continuously and automatically supplied to the injection sleeve without releasing the vacuum state in the vacuum chamber. Therefore, the activity is easily oxidized and easily deteriorates due to overheating. Even with an alloy, injection molding can be performed continuously and automatically in a vacuum state. (5) The upper part of the injection sleeve is arranged in the vacuum chamber,
By disposing the master alloy supply means outside the vacuum chamber, the master alloy cassette and the master alloy storage magazine can be replaced without releasing the vacuum state in the vacuum chamber.
Automatic continuous injection molding can be performed over a long period. (6) By providing a vacuum housing that hermetically surrounds the mold, vacuum injection molding can be performed even with an ordinary mold. (7) Since the mold exhaust is performed from the movable platen side, the flow of the molten metal rides on the exhaust flow, and the entrainment of air bubbles is unlikely to occur. As described above, even if the active alloy is easily oxidized or thermally degraded, automatic injection molding can be continuously performed in a vacuum state. As a result, high-quality injection-molded products can be mass-produced at low cost, which is extremely industrially useful. It can be called a device.

[Brief description of the drawings]

FIG. 1 is a schematic partial cross-sectional side view of one embodiment of a vacuum melting injection molding apparatus of the present invention, showing a master alloy supply step.

FIG. 2 is a schematic partial cross-sectional side view of one embodiment of the vacuum melting injection molding apparatus of the present invention, showing a process of moving a master alloy to a heat melting section.

FIG. 3 is a schematic partial sectional side view of one embodiment of the vacuum melting injection molding apparatus of the present invention, showing an injection step.

FIG. 4 is a schematic partial cross-sectional side view of one embodiment of the vacuum melting injection molding apparatus of the present invention, showing a molded article discharging step.

FIG. 5 is a plan view of a master alloy cassette part of a master alloy supply device used in the vacuum melting injection molding apparatus of the present invention.

FIG. 6 is a schematic partial cross-sectional side view of another embodiment of the vacuum melting injection molding apparatus of the present invention.

FIG. 7 is a schematic partial sectional side view of still another embodiment of the vacuum melting injection molding apparatus of the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 mold 2 fixed lower mold 3 movable upper mold 4 gate 5 cavity 11 movable plate 12 mold clamping cylinder 15 mold exhaust hole 16 ejector pin 18 ejector cylinder 20 vacuum housing 22 molded product discharge cylinder 24 vacuum chamber 25 shutter cylinder 26 shielding Shutter 27 Injection sleeve 28 Injection plunger 29 Injection cylinder 31 Sleeve moving cylinder 34 High frequency induction heating coil 35 Mother alloy supply device 36 Mother alloy supply path cylinder 37 Mother alloy cassette 39 Mother alloy supply cylinder 42 Mother alloy storage magazine

Claims (12)

[Claims] Injection having a mold (1) and a master alloy melting device (27, 28, 29, 34) having an injection mechanism for injecting and filling a molten metal into a cavity (5) of the mold. In the forming device, a vacuum chamber (24) that can be opened and closed surrounding the master alloy melting device is provided, and the cavity (5) of the mold (1) and the vacuum chamber (24) are provided.
Evacuation system (L, L1, L2) to communicate with
Wherein the cavity (5) in the mold is evacuated independently of the vacuum chamber (24). 2. A vacuum housing (20) for sealingly surrounding the mold (1), wherein the vacuum housing (2) is provided.
2. The apparatus according to claim 1, wherein an evacuation system (L1) is connected to the inside of (0), and the cavity in the mold (5) can be evacuated independently of the vacuum chamber (24). 3. A shielding shutter (5) between a gate (4) of the mold (1) and a vacuum chamber (24) for blocking and communicating a space in the mold cavity (5) and the vacuum chamber (24). Device according to claim 1 or 2, characterized in that (26) is provided. 4. The master alloy melting device includes an injection plunger (28) slidably disposed therein, and is disposed so as to be able to move forward and backward toward a gate (4) of a mold (1). A heating means (34) for heating and melting the injection sleeve (27) and the mother alloy block (A) supplied into the injection sleeve (27).
Device according to any of the preceding claims, characterized in that the injection sleeve (27) is provided with a master alloy supply means (35). 5. The master alloy supply means (35) includes at least one vertical cylindrical master alloy storage magazine (42) for storing a plurality of master alloy blocks (A), and the master alloy storage magazine. The master alloy supply path (3) disposed below (42)
6) and a forced moving means (38, 39) for moving the mother alloy block (A) dropped from the magazine (42) to the injection sleeve (27) in the supply path (36). The device according to claim 4, characterized in that: 6. A mold (1) comprising a fixed lower mold (2) having a gate (4) and a movable upper mold (3) which can be moved up and down; and is disposed below the mold (1). A vacuum chamber (24) that can be opened and closed; a shielding shutter (26) that blocks and communicates the cavity (5) of the mold (1) with the space in the vacuum chamber (24); The injection plunger (28) and the gate (4) of the mold (1)
Injection sleeve (27) arranged to move forward and backward toward
A heating means (34) for heating and melting the mother alloy block (A) supplied into the injection sleeve (27); a mother alloy supply path (36) connectable to the injection sleeve (27);
A vertically cylindrical mother alloy storage magazine (42) disposed above the mother alloy supply path (36); and a mother alloy block (A) dropped from the magazine (42) into the supply path (36). ) To the injection sleeve (27).
8, 39), and a master alloy supply device (35) having
A vacuum exhaust system (L, L) is connected to the cavity (5) of the mold (1) and the vacuum chamber (24), respectively.
1, L2), and the cavity (5) in the mold.
A vacuum melting and injection molding apparatus for molding an active alloy, characterized in that the apparatus can be evacuated independently of the vacuum chamber (24). 7. Apparatus according to claim 6, wherein the shielding shutter (26), the upper part of the injection sleeve (27) and the heating means (34) are arranged in a vacuum chamber (24). 8. The shielding shutter (26), the injection sleeve (27), the heating means (34) and the master alloy supply device (3).
7. The device according to claim 6, wherein 5) is arranged in a vacuum chamber (24). 9. A vacuum housing (20) surrounding the mold (1) to form a closed space when the movable upper mold (3) is lowered and combined with the fixed lower mold (2). Device according to any one of claims 6 to 8, characterized in that an evacuation system (L1) is connected in the vacuum housing (20). 10. A plurality of said master alloy storage magazines (42) are provided, and these magazines (42) are arranged on a turntable (41) to constitute one cassette (37). Apparatus according to any of claims 5 to 9. 11. The device according to claim 1, further comprising a vacuum reserve tank (51) in the evacuation system (L1). 12. The method according to claim 12, wherein the active alloy is Al, Mg, Fe,
Ti, Zr, Hf, Y, La, Ce, Nd, Sm and M
12. An alloy containing at least one active metal element selected from the group consisting of m (misch metal), wherein the sum of the active metal elements in the alloy is 50 atomic% or more. An apparatus according to claim 1.