JP5723078B2 - Dual plunger rod for controlled transfer in injection molding system - Google Patents

Description

  The present disclosure relates generally to an injection molding system for melting a material and molding an article from the molten material.

  Some conventional casting or molding equipment includes a single plunger rod for moving material into a mold and pressing it using a strong force. However, when casting or casting high aspect ratio parts using amorphous alloys in such systems, the mold quench rate is insufficient (eg, on one side of the material). The cooling on the other side (e.g. the plunger side is not sufficiently quenched), the molded part tends to be heterogeneous and / or crystallized. Increasing the speed or force of a single plunger rod does not reduce this problem.

  In addition, in a horizontal injection system, the molten material must be held in the melt zone so as not to mix too much or to cool too quickly.

  The solution proposed by the embodiments herein to improve the molded article or part uses a bulk solidified amorphous alloy.

  One aspect of the present disclosure provides an injection molding system having a melting zone configured to receive molten meltable material therein and a dual plunger rod assembly. The dual plunger rod assembly includes a first plunger rod and a second plunger rod, at least the first plunger rod being configured to move the molten material from the melting zone into the mold. The dual plunger rod assembly and melting zone are provided on one line. The first and second plunger rods are configured to move along a longitudinal axis, whereby at least the first plunger rod moves the molten material longitudinally from the melting zone into the mold.

  Another aspect is to move relative to each other with a melting zone configured to melt the meltable material received therein and a mold configured to receive the material melted therein for molding. An injection molding system is provided that includes a first plunger rod and a second plunger rod configured as described above. The first plunger rod and the second plunger rod are configured to move the molten material from the melting zone into the mold.

  Yet another aspect provides a method of molding an article from a meltable material using an injection molding system. The system includes a melting zone configured to melt a meltable material received therein, and a plunger rod assembly having a first plunger rod and a second plunger rod, the assembly melting the molten material. It is configured to move from the zone into the mold. The method includes melting a meltable material in a melting zone and moving the molten material from the melting zone into a mold, wherein the first plunger rod and the second plunger rod are the molten material. Is configured to accommodate molten material therebetween while moving toward the mold.

FIG. 3 is a temperature-viscosity diagram of an exemplary bulk solidified amorphous alloy.

1 is a schematic diagram of a time-temperature-transformation (TTT) diagram for an exemplary bulk solidified amorphous alloy. FIG.

1 is an injection molding system with a dual plunger rod assembly according to one embodiment of the present disclosure.

FIG. 4 illustrates the movement of the dual plunger rod assembly relative to the melt zone, mold, and each other in the injection molding system of FIG. 3 according to one embodiment. FIG. 4 illustrates the movement of the dual plunger rod assembly relative to the melt zone, mold, and each other in the injection molding system of FIG. 3 according to one embodiment. FIG. 4 illustrates the movement of the dual plunger rod assembly relative to the melt zone, mold, and each other in the injection molding system of FIG. 3 according to one embodiment.

FIG. 4 is a detailed view that assists in injecting molten material transferred inward by a first plunger rod into a mold cavity using a second plunger rod, according to one embodiment.

FIG. 4 is a detailed view of removing an article molded with a second plunger rod from a mold according to one embodiment.

  All publications, patents, and patent applications cited herein are hereby incorporated by reference in their entirety.

  The articles “a” and “an” are used herein to refer to one or more (ie, at least one) grammatical objects of the article. By way of example, “a polymer resin” means one polymer resin or more than one polymer resin. Any ranges set forth herein are inclusive. The terms “substantially” and “about” as used throughout this specification are used to describe and explain minor variations. For example, the terms are ± 2% or less, ± 1% or less, ± 0.5% or less, ± 0.2% or less, ± 0.1% or less, ± 0.05% or less, etc. Of ± 5% or less.

  Bulk solidified amorphous alloys, or bulk metallic glass (“BMG”), is a recently developed class of metallic materials. These alloys can be solidified and cooled at a relatively moderate rate, and they maintain an amorphous, amorphous (ie, glassy) state at room temperature. Amorphous alloys have many superior properties than their crystalline counterparts. However, if the cooling rate is not sufficiently high, crystals may form within the alloy during cooling, thus losing the benefits of the amorphous state. For example, one important challenge associated with the manufacture of bulk amorphous alloy parts is the partial crystallization of those parts, either by slow cooling or by impurities in the alloy raw material. Within BMG parts, a high degree of amorphization (and conversely, a low degree of crystallinity) is desirable, so there is a need to develop a method for casting BMG parts with a controlled amount of amorphization. There is.

  FIG. 1 (obtained from US Pat. No. 7,575,040) is an exemplary bulk from the VIT-001 series of the Zr--Ti--Ni--Cu--Be family manufactured by Liquidmetal Technology. The viscosity-temperature graph of a solidified amorphous alloy is shown. It should be noted that there is no clear liquid / solid transformation for bulk solidifying amorphous metals during the formation of amorphous solids. This molten alloy becomes increasingly viscous with increasing supercooling until it approaches a solid form near the glass transition temperature. Thus, the temperature of the solidification front for a bulk solidified amorphous alloy can be near the glass transition temperature, where it actually acts as a solid to remove the quenched amorphous sheet product.

  FIG. 2 (obtained from US Pat. No. 7,575,040) shows a time-temperature-transformation (TTT) cooling curve, or TTT diagram, of an exemplary bulk solidified amorphous alloy. Bulk solidified amorphous metals, like conventional metals, do not undergo liquid / solid crystallization transformations upon cooling. Instead, the highly flowable amorphous form of the metal found at high temperatures (near the “melting temperature” Tm) becomes more viscous as the temperature decreases (to near the glass transition temperature Tg) In particular, it exhibits the external physical properties of a conventional solid.

  For bulk solidified amorphous metals, the “melting temperature” Tm can be defined as the thermodynamic liquid phase temperature of the corresponding crystal phase, even though there is no liquid / crystallization transformation. Under this regime, the viscosity at the melting temperature of the bulk solidified amorphous alloy can range from about 0.1 poise to about 10,000 poise, and in some cases, less than 0.01 poise. . This lower viscosity at the “melting temperature” results in faster and complete filling of complex parts of the shell / mold with bulk solidified amorphous metal to form BMG parts. In addition, the cooling rate of the molten metal to form the BMG part is such that the time-temperature profile during cooling does not cross the nose shaped region that bounds the crystallization region in the TTT diagram of FIG. There must be. In FIG. 2, T nose is the critical crystallization temperature Tx where crystallization occurs most rapidly and occurs on the shortest time scale.

The supercooled liquid region, i.e., the temperature region from Tg to Tx, demonstrates extreme stability against crystallization of the bulk solidified alloy. Within this temperature range, the bulk solidified alloy can exist as a highly viscous liquid. The viscosity of the bulk solidified alloy in this supercooled liquid region ranges from 10 ¹² Pa · s at the glass transition temperature to 10 ⁵ Pa · s at the high temperature limit of the supercooled liquid region, which is the crystallization temperature. Can vary between. A liquid having such a viscosity can experience substantial plastic strain under pressure. Embodiments herein utilize the large plastic formability within this supercooled liquid region as a forming and separating method.

  It is necessary to clarify Tx. Technically, the nose shaped curve shown in the TTT diagram describes Tx as a function of temperature and time. Therefore, Tx is reached when it hits this TTT curve, regardless of the trajectory followed during heating or cooling of the metal alloy. In FIG. 2, Tx is shown as a dashed line because Tx can vary from proximal Tm to proximal Tg.

  The schematic TTT diagram of FIG. 2 shows a die casting processing method in which the time-temperature trajectory (shown as (1) as an exemplary trajectory) does not hit the TTT curve and is greater than or equal to Tm and less than Tg. During die casting, this shaping is performed at the same time as the rapid cooling to avoid the trajectory hitting the TTT curve. Time-temperature trajectory (shown as exemplary trajectories (2), (3) and (4)) does not hit the TTT curve, and processing related to superplastic forming (SPF) from Tg or less to less than Tm Method. In SPF, amorphous BMG is reheated into the supercooled liquid region and the available processing window can be much larger than die casting, resulting in better process controllability. The SPF process does not require rapid cooling to avoid crystallization during cooling. Also, as shown by exemplary trajectories (2), (3), and (4), SPF is performed with the highest temperature during SPF being above or below T nose and up to about Tm can do. In the case of avoiding hitting the TTT curve while raising the temperature of the piece of amorphous alloy, Tx is not reached even when heated to “Tg to Tm”.

The typical differential scanning calorimeter (DSC) heating curve of bulk solidified amorphous alloys, obtained at a heating rate of 20 ° C./min, largely describes the specific trajectory across the TTT data. There will be a Tg of temperature, a Tx where the DSC heating ramp intersects the onset of TTT crystallization, and finally a melting peak where the same trajectory intersects the temperature range for melting. Avoid TTT curves completely when heating bulk solidified amorphous alloys at a rapid heating rate as shown by the up-tilted portions of trajectories (2), (3), and (4) in FIG. And DSC data show a glass transition upon heating but no Tx. Another way of thinking about this is that the trajectories (2), (3), and (4) are within the TTT curve nose (and further above) to the temperature of the Tg line, as long as they do not hit the crystallization curve. It can fit in any place. That simply means that as the processing temperature increases, the horizontal flats in the trajectory can become much shorter.
phase

As used herein, the term “phase” can refer to what can be found in a thermodynamic phase diagram. A phase is a region of space (eg, a thermodynamic system) throughout which all physical properties of the material are essentially uniform. Examples of physical properties include density, refractive index, chemical composition, and lattice periodicity. A simple description of a phase is a region of material that is chemically uniform, physically different, and / or mechanically separable. For example, in a system consisting of ice and water in a glass jar, the ice cube is one phase, water is the second phase, and humid air above the water is the third phase. Jar glass is another separate phase. The phase may refer to a solid solution such as a solution of two components, three components, four components or more, or a compound such as an intermetallic compound. As another example, the amorphous phase can be distinguished from the crystalline phase.
Metals, transition metals, and non-metals

  The term “metal” refers to an electropositive chemical element. As used herein, the term “element” generally refers to an element that can be found in the periodic table. Physically, a ground state metal atom includes a partially filled band with an empty state close to the occupied state. The term “transition metal” is the third in the periodic table that has an incomplete internal electron shell and serves as a transition link between the most electropositive and the least electropositive in a set of elements. It is one of the metal elements within the range of Group 12 to Group 12. Transition metals are characterized by multiple valences, colored compounds, and the ability to form stable complex ions. The term “nonmetal” refers to a chemical element that does not have the ability to lose electrons and form a cation.

  Depending on the application, any suitable non-metallic elements, or combinations thereof, can be used. An alloy (or “alloy composition”) may include a plurality of non-metallic elements, such as at least two, at least three, at least four or more non-metallic elements. The nonmetallic element can be any element found within Groups 13-17 in the periodic table. For example, the nonmetallic elements are F, Cl, Br, I, At, O, S, Se, Te, Po, N, P, As, Sb, Bi, C, Si, Ge, Sn, Pb, and B. It can be any one of them. In some cases, non-metallic elements may also refer to certain semimetals within Group 13 to Group 17 (eg, B, Si, Ge, As, Sb, Te, and Po). In one embodiment, the non-metallic element can include B, Si, C, P, or a combination thereof. Thus, for example, the alloy can include borides or carbides, or both.

  Transition metal elements are scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, hafnium, tantalum, tungsten , Rhenium, osmium, iridium, platinum, gold, mercury, rutherfordium, dobnium, seaborgium, bolium, hassium, mitonium, ununnilium, ununnium, and ununbium. In one embodiment, the transition metal element-containing BMG is Sc, Y, La, Ac, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, It may have at least one of Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, Zn, Cd, and Hg. Depending on the application, any suitable transition metal element, or combinations thereof, can be used. The alloy composition may include a plurality of transition metal elements, such as at least 2, at least 3, at least 4 or more transition metal elements.

  An alloy or alloy “sample” or “specimen” alloy described herein may have any shape or size. For example, the alloy can have a particulate shape, which can have a shape such as a sphere, ellipse, wire, rod, sheet, flake, or irregular shape. The microparticles can have any size. For example, the microparticles can be about 5 micrometers to about 80 micrometers, such as about 10 micrometers to about 60 micrometers, such as about 15 micrometers to about 50 micrometers, such as about 15 micrometers to about 45 micrometers, etc. It may have an average diameter of about 1 micrometer to about 100 micrometers, such as about 25 micrometers to about 35 micrometers, such as about 20 micrometers to about 40 micrometers. For example, in one embodiment, the average diameter of the microparticles is from about 25 micrometers to about 44 micrometers. In some embodiments, smaller particles, such as those in the nanometer range, or larger particles, such as those larger than 100 micrometers, can be used.

The alloy sample or specimen can also be of much larger dimensions. For example, it can be a bulk structural component such as an ingot, a housing / casing of an electronic device, or even a part of a structural component having dimensions in the millimeter, centimeter, or meter range.
Solid solution

The term “solid solution” refers to the solid form of the solution. The term “solution” refers to a mixture of two or more substances that can be a solid, liquid, gas, or a combination thereof. This mixture can be homogeneous or heterogeneous. The term “mixture” is a composition of two or more substances that can be combined with each other and generally separated. In general, the two or more substances are not combined with each other.
alloy

  In some embodiments, the alloy compositions described herein can be fully alloyed. In one embodiment, an “alloy” refers to a homogenous mixture or solid solution of two or more metals in which one atom replaces another atom or occupies an interstitial position between atoms. For example, brass is an alloy that is an alloy of zinc and copper, as opposed to a composite material, which is partially or completely of one or more elements in a metal matrix, such as one or more compounds in the metal matrix. A solid solution. The term alloy herein may refer to both a fully solid solution alloy that may exhibit a single solid phase microstructure and a partial solution that may exhibit two or more phases. The alloy compositions described herein can refer to those comprising an alloy or those comprising an alloy-containing composite material.

Thus, a fully alloyed alloy can have a homogeneous distribution of its constituents, whether in solid solution phase, compound phase, or both. As used herein, the term “fully alloyed” can describe slight variations within tolerances. For example, the term includes at least 90% alloying, such as at least 95% alloying, such as at least 99% alloying, such as at least 99.5% alloying, such as at least 99.9% alloying. Can point. Percentages herein can refer to either volume percentages or weight percentages, depending on the context. These percentages can be balanced by impurities that can be in terms of compositions or phases that are not part of the alloy.
Amorphous or amorphous solid

  An “amorphous” or “amorphous solid” is a solid that lacks the lattice periodicity characteristic of crystals. As used herein, “amorphous solid” includes “glass”, which is an amorphous solid that softens and transforms into a liquid state upon heating through the glass transition. In general, amorphous materials lack the long-range order characteristic of crystals, but these amorphous materials can possess some short-range order on the atomic length scale due to the nature of chemical bonds. A distinction between an amorphous solid and a crystalline solid can be made based on lattice periodicity determined by structural property evaluation techniques such as X-ray diffraction and transmission electron microscopy.

  The terms “order” and “disorder” indicate the presence or absence of any symmetry or correlation within a multiparticulate system. The terms “long-range order” and “short-range order” distinguish order within a material based on a length scale.

  The most rigorous form of order in a solid is lattice periodicity, and a specific pattern (atom arrangement in a unit cell) is repeated many times to form a translational uniform space filling of the space. This lattice periodicity is a defining characteristic of crystals. The possible symmetries are grouped into 14 Bravey lattices and 230 space groups.

  Lattice periodicity suggests long-range order. If only one unit cell is known, its translational symmetry makes it possible to accurately predict all atomic arrangements at an arbitrary distance. The converse is generally true, except in the case of, for example, quasicrystals that have a completely deterministic filling but do not possess lattice periodicity.

Long-range order characterizes a physical system in which remote parts of the same sample exhibit correlated behavior. This long-range order can be expressed as a correlation function, that is, the next spin-spin correlation function.

  In the above function, s is a spin quantum number and x is a distance function in a specific system. This function is equal to the identity element when x = x ′ and decreases as the distance | x−x ′ | Typically, this function decays exponentially to zero over long distances and the system is considered disordered. However, if this correlation function decays to a constant value with a large | x−x ′ |, it can be stated that the system possesses long-range order. If this function decays to zero as a power of distance, it can be called quasi-long-range order. Note that what constitutes a large value of | x-x '| is relative.

  A system can be extended to exhibit a quenching disorder, such as a spin glass, if some parameters that define its behavior are random variables that do not evolve over time (ie, they are quenched or frozen). it can. This quenching disorder is the opposite of the annealing disorder in which the random variable itself can develop. Embodiments herein include systems that include a quenching disorder.

  The alloys described herein can be crystalline, partially crystalline, amorphous, or substantially amorphous. For example, an alloy sample / specimen can include at least some degree of crystallinity, and the grains / crystals have a size in the nanometer and / or micrometer range. Alternatively, the alloy can be substantially amorphous, such as completely amorphous. In one embodiment, the alloy composition is substantially crystalline, such as fully crystalline, and at least not substantially amorphous.

In one embodiment, the presence of one or more crystals in another amorphous alloy can be interpreted as a “crystalline phase” in that alloy. The degree of crystallinity of an alloy (or in some embodiments, “crystallinity” for short) can refer to the amount of crystalline phase present in the alloy. The degree can refer, for example, to the fraction of crystals present in the alloy. This fraction can refer to a volume fraction or a weight fraction, depending on the context. A measure of how “amorphous” an amorphous alloy can be is the degree of amorphization. The degree of amorphization can be measured from the viewpoint of the degree of crystallinity. For example, in one embodiment, an alloy having a low degree of crystallinity can be described as having a high degree of amorphousness. In one embodiment, for example, an alloy having 60% by volume crystalline phase may have 40% by volume amorphous phase.
Amorphous alloy or amorphous metal

  “Amorphous alloy” means an amorphous content greater than 50% by volume, preferably greater than 90% by volume, more preferably greater than 95% by volume, most preferably greater than 99% by volume to almost 100% by volume. % Is an alloy with an amorphous content. As noted above, it should be noted that alloys with a high degree of amorphization have an equally low degree of crystallinity. An “amorphous metal” is an amorphous metal material having a disordered atomic scale structure. In contrast to most metals, which are crystalline and thus have a highly ordered atomic arrangement, amorphous alloys are amorphous. The material in which such a disordered structure is created directly from the liquid state during cooling may be referred to as “glass”. Thus, amorphous metals are commonly referred to as “metallic glass” or “glass metal”. In one embodiment, bulk metallic glass (“BMG”) can refer to an alloy whose microstructure is at least partially amorphous. However, in addition to extreme rapid cooling, there are several ways to create amorphous metals, including physical vapor deposition, solid phase reaction, ion irradiation, melt spinning, and mechanical alloying. Amorphous alloys can be a single class of materials regardless of how they are prepared.

  Amorphous metal can be produced through various quenching methods. For example, amorphous metal can be created by sputtering molten metal onto a rotating metal disk. A quench of about several million degrees per second can be too fast for crystals to form, so that the metal is “fixed” in the glassy state. Amorphous metals / alloys can also be created with critical cooling rates that are slow enough to allow the formation of thick layer amorphous structures, such as bulk metallic glass.

  The terms “bulk metallic glass” (“BMG”), bulk amorphous alloy (“BAA”), and bulk solidified amorphous alloy are used interchangeably herein. These terms refer to an amorphous alloy having a minimum dimension in the range of at least millimeters. For example, the dimension is at least about 0, such as at least about 1 mm, at least about 2 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 8 mm, at least about 10 mm, at least about 12 mm, etc. .5 mm. Depending on the geometry, the dimensions can refer to diameter, radius, thickness, width, length, etc. The BMG may also be a metallic glass having at least one dimension in the centimeter range, such as at least about 1.0 cm, such as at least about 2.0 cm, such as at least about 5.0 cm, such as at least about 10.0 cm. You can also. In some embodiments, the BMG may have at least one dimension in the range of at least meters. BMG can take on any of the shapes or forms described above associated with metallic glass. Accordingly, the BMG described herein may differ from thin films made by conventional deposition techniques in one important aspect in some embodiments, the former BMG being the latter The size can be much larger than that of the thin film.

  The amorphous metal can be an alloy rather than a pure metal. This alloy can contain atoms of significantly different sizes, resulting in a low free volume in the molten state (and therefore has a viscosity that is orders of magnitude higher than other metals and alloys). . This viscosity prevents atoms from moving sufficiently to form an ordered lattice. This material structure can provide low shrinkage during cooling and resistance to plastic deformation. This absence of grain boundaries, which in some cases is a weakness of crystalline materials, can result in better resistance to wear and corrosion, for example. In one embodiment, although technically glass, amorphous metals can also be much stronger and less brittle than oxide glasses and ceramics.

  The thermal conductivity of amorphous materials can be lower than the thermal conductivity of their crystalline counterparts. In order to achieve the formation of an amorphous structure even during slower cooling, an alloy is made with three or more components, resulting in a composite crystal unit with higher potential energy and lower probability of formation. be able to. The formation of an amorphous alloy is dependent on several factors: the composition of the alloy constituents, the atomic radii of the constituents (preferably more than 12% to achieve high compaction density and low free volume). As well as the negative mixing heat of the combination of components that prevents crystal nucleation and extends the time that the molten metal remains supercooled. However, since the formation of an amorphous alloy is based on a wide variety of variables, it may be difficult to determine in advance whether the alloy composition forms an amorphous alloy.

  For example, amorphous alloys of boron, silicon, phosphorus, and other glass formers with magnetic metals (iron, cobalt, nickel) can be magnetic with low coercivity and high electrical resistance. This high resistance results in low loss due to eddy currents when exposed to an alternating magnetic field, which is a characteristic useful as a magnetic core for a transformer, for example.

  Amorphous alloys can have a variety of potentially useful properties. Specifically, amorphous alloys tend to be stronger than crystalline alloys of similar chemical composition, and they can withstand greater reversible (“elastic”) deformation than crystalline alloys. Amorphous metals derive their strength directly from their amorphous structure, which can have no defects (such as dislocations) that limit the strength of the crystalline alloy. For example, one state-of-the-art amorphous metal, known as Vitreloy ™, has a tensile strength approximately twice that of high-grade titanium. In some embodiments, the metallic glass at room temperature is not ductile and breaks suddenly when tension is applied, which is not evident in imminent failure, so in applications where reliability is important, Limit applicability of the material. Therefore, to overcome this challenge, a metal matrix composite having a metallic glass matrix containing ductile crystalline metal dendritic particles or fibers can be used. Alternatively, BMGs that are low in elements that tend to cause failure (eg, Ni) can be used. For example, by using BMG that does not contain Ni, the ductility of the BMG can be improved.

  Another useful property of bulk amorphous alloys is that they are intrinsic glasses, in other words they can soften and flow with heating. This allows easy processing such as injection molding as well as polymer. As a result, amorphous alloys can be used to make sports equipment, medical devices, electronic components and equipment, and thin films. Amorphous metal thin films can be deposited as protective coatings via high speed oxygen fuel technology.

  The material can have an amorphous phase, a crystalline phase, or both. These amorphous and crystalline phases can have the same chemical composition and differ only in microstructure (ie, one is amorphous and the other is crystalline). Microstructure in one embodiment refers to the structure of the material as revealed by a microscope with a magnification of 25 × or greater. Alternatively, these two phases can have different chemical compositions and microstructures. For example, the composition can be partially amorphous, substantially amorphous, or fully amorphous.

  As described above, the degree of amorphization (and conversely, the degree of crystallinity) can be measured by the fraction of crystals present in the alloy. The degree can refer to the volume fraction or weight fraction of the crystalline phase present in the alloy. A partially amorphous composition includes at least about 10%, such as at least about 20%, such as at least about 40%, such as at least about 60%, such as at least about 80%, such as at least about 90%. , Which can refer to a composition at least about 5% by volume of which is in an amorphous phase. The terms “substantially” and “about” are defined elsewhere in this specification. Thus, a composition that is at least substantially amorphous includes at least about 99.8 vol%, such as at least about 95 vol%, such as at least about 98 vol%, such as at least about 99 vol%, such as at least about 99.5 vol%. %, Such as at least about 99.9% by volume, at least about 90% by volume of which is amorphous. In one embodiment, the substantially amorphous composition may have some accompanying small amount of crystalline phase present inside.

  In one embodiment, the amorphous alloy composition can be homogeneous with respect to the amorphous phase. A substance with a uniform composition is homogeneous. This is in contrast to materials that are heterogeneous. The term “composition” refers to the chemical composition and / or microstructure in a substance. A material is homogeneous when the volume of the material is divided in half and both halves have substantially the same composition. For example, a particulate suspension is homogeneous when the volume of the particulate suspension is divided in half and both halves have substantially the same volume of particles. However, it may be possible to see individual particles under a microscope. Another example of a homogeneous material is air, where the various components in the air are equally floating, but the particles, gases, and liquids in the air can be analyzed separately or separated from the air. You can also.

  A composition that is homogeneous with respect to an amorphous alloy can refer to one having an amorphous phase that is distributed substantially uniformly throughout its microstructure. In other words, the composition macroscopically comprises an amorphous alloy that is distributed substantially uniformly throughout the composition. In an alternative embodiment, the composition can be of a composite material having an amorphous phase with a non-amorphous phase therein. This non-amorphous phase can be a single crystal or multiple crystals. The crystals can be in the form of particulates of any shape, such as spherical, oval, wire, rod, sheet, flake, or irregular shape. In one embodiment, the crystals can have a dendritic morphology. For example, an at least partially amorphous composite composition may have a crystalline phase in the form of dendrites dispersed in an amorphous phase matrix, and this dispersion may be uniform or non-uniform. In one embodiment, the amorphous phase and the crystalline phase can have the same chemical composition or different chemical compositions, and the phases can have substantially the same chemical composition. In another embodiment, the crystalline phase can be more ductile than the BMG phase.

  The methods described herein may be applicable to any type of amorphous alloy. Similarly, the amorphous alloy described herein as a component of the composition or article can be of any type. The amorphous alloy may include elements of Zr, Hf, Ti, Cu, Ni, Pt, Pd, Fe, Mg, Au, La, Ag, Al, Mo, Nb, Be, or combinations thereof. That is, the alloy may include any combination of these elements in its chemical formula or chemical composition. These elements can be present in various weight or volume percentages. For example, an iron “base” alloy can refer to an alloy having a significant weight percentage of iron present therein, such as at least about 50 wt%, such as at least about 40 wt%. , At least about 60%, such as at least about 80%, such as at least about 20%. Alternatively, in one embodiment, the percentages described above can be volume percentages instead of weight percentages. Thus, the amorphous alloy can be a zirconium base, a titanium base, a platinum base, a palladium base, a gold base, a silver base, a copper base, an iron base, a nickel base, an aluminum base, a molybdenum base, and the like. The alloy may also not include any of the above-described elements to suit a particular purpose. For example, in some embodiments, the alloy, or a composition comprising the alloy, can be substantially free of nickel, aluminum, titanium, beryllium, or combinations thereof. In one embodiment, the alloy or composite material does not include any nickel, aluminum, titanium, beryllium, or combinations thereof.

For example, the amorphous alloy may have the formula (Zr, Ti) _a (Ni, Cu, Fe) _b (Be, A1, Si, B) _c , where a, b, and c are Each represents a weight percentage or an atomic percentage. In one embodiment, in atomic percent, a is in the range of 30-75, b is in the range of 5-60, and c is in the range of 0-50. Alternatively, the amorphous alloy can have the formula (Zr, Ti) _a (Ni, Cu) _b (Be) _c , where a, b, and c are weight percentages or atomic percentages, respectively. Represent. In one embodiment, in atomic percent, a is in the range of 40-75, b is in the range of 5-50, and c is in the range of 5-50. The alloy may also have the formula (Zr, Ti) _a (Ni, Cu) _b (Be) _c , where a, b, and c represent weight percentage or atomic percentage, respectively. In one embodiment, in atomic percent, a is in the range of 45-65, b is in the range of 7.5-35, and c is in the range of 10-37.5. Alternatively, the alloy can also have the formula (Zr) _a (Nb, Ti) _b (Ni, Cu) _c (A1) _d , where a, b, c, and d are each weight Represents a percentage or atomic percentage. In one embodiment, in atomic percent, a is in the range of 45-65, b is in the range of 0-10, c is in the range of 20-40, and d is in the range of 7.5-15. . One exemplary embodiment of the above alloy system is Zr-Ti-Ni- of the trade name Vitreloy (TM), such as Vitreloy-1 and Vitreloy-101, as manufactured by Liquidmetal Technologies (CA, USA). It is a Cu-Be based amorphous alloy. Some examples of various systems of amorphous alloys are listed in Table 1.

These amorphous alloys can also be iron alloys, such as (Fe, Ni, Co) based alloys. Examples of such compositions are US Pat. Nos. 6,325,868, 5,288,344, 5,368,659, 5,618,359, and 735, 975, Inoue et al., Appl. Phys. Lett. , Volume 71, p 464 (1997), Shen et al., Mater. Trans. , JIM, Volume 42, p 2136 (2001), and Japanese Patent Application No. 200126277 (publication number 2001303218A). One exemplary composition is Fe ₇₂ Al ₅ Ga ₂ P ₁₁ C ₆ B ₄ . Another example is Fe ₇₂ Al ₇ Zr ₁₀ Mo ₅ W ₂ B ₁₅ . Another iron-based alloy system that can be used for coating herein is disclosed in U.S. Patent Application Publication No. 2010/0084052, the amorphous metal having a composition described in parentheses, for example. Of manganese (1 to 3 atomic%), yttrium (0.1 to 10 atomic%), and silicon (0.3 to 3.1 atomic%), and the composition described in parentheses The following elements in the specified range: Chromium (15-20 atom%), Molybdenum (2-15 atom%) Tungsten (1-3 atom%), Boron (5-16 atom%), Carbon (3-16 atom%) And the balance iron.

The amorphous alloy system described above may further include additional elements, such as additional transition metal elements including Nb, Cr, V, and Co. These additive elements may be present at about 30 wt% or less, such as about 20 wt% or less, such as about 10 wt% or less, such as about 5 wt%. In one embodiment, the optional additive element is at least one of cobalt, manganese, zirconium, tantalum, niobium, tungsten, yttrium, titanium, vanadium, and hafnium, forming carbides and wear resistant. Further improve the properties and corrosion resistance. Further optional elements may include up to about 2% total, preferably less than 1% phosphorus, germanium, and arsenic to reduce the melting point. Other minor impurities should be less than about 2%, preferably less than 0.5%.

  In some embodiments, a composition having an amorphous alloy can include a small amount of impurities. By intentionally adding impurity elements, the properties of the composition, such as improved mechanical properties (eg, hardness, strength, fracture mechanism, etc.) and / or improved corrosion resistance can be modified. Alternatively, the impurities may be present as inevitable incidental impurities, such as those obtained as processing and manufacturing by-products. These impurities can be up to about 10 wt%, such as about 5 wt%, such as about 2 wt%, such as about 1 wt%, such as about 0.5 wt%, such as about 0.1 wt%. . In some embodiments, these percentages can be volume percentages instead of weight percentages. In one embodiment, the alloy sample / composition consists essentially of an amorphous alloy (with only a small amount of incidental impurities). In another embodiment, the composition comprises an amorphous alloy (having no observable trace impurities).

  In one embodiment, the final part exceeded the critical cast thickness of the bulk solidified amorphous alloy.

  In embodiments herein, superplastic forming is possible due to the presence of a supercooled liquid region in which the bulk solidified amorphous alloy can exist as a high viscosity liquid. Large plastic deformation can be obtained. The ability to plastically deform significantly in the supercooled liquid region is used for the molding and / or cutting process. In contrast to solids, this liquid bulk solidified alloy deforms locally, which greatly reduces the energy required for cutting and forming. The ease of cutting and forming varies with the temperature of the alloy, mold and cutting tool. As the temperature increases, the viscosity decreases, resulting in easier cutting and molding.

  Embodiments herein can utilize a thermoplastic molding process using amorphous alloys, for example, performed at Tg-Tx. As used herein, Tx and Tg are determined from standard DSC measurements at typical heating rates (eg, 20 ° C./min) as the temperature of onset of crystallization and the temperature of onset of glass transition. .

The amorphous alloy component can have a critical casting thickness, and the final part can have a thickness greater than its critical casting thickness. Furthermore, the time and temperature of the heating and shaping operations are selected such that the elastic strain limit of the amorphous alloy can be substantially maintained at 1.0% or higher, preferably 1.5% or higher. In the context of embodiments herein, the temperature near the glass transition means that the molding temperature can be less than the glass transition, near the glass transition temperature or glass transition temperature, and above the glass transition temperature, it is preferably a temperature lower than the crystallization temperature T _x. The cooling step is performed at a rate similar to the heating rate in the heating step, preferably at a rate exceeding the heating rate in the heating step. The cooling step is also preferably accomplished while the forming and forming loads are still maintained.
Electronic devices

  Embodiments herein may be useful in the fabrication of electronic devices that use BMG. As used herein, an electronic device can refer to any electronic device known in the art. For example, the electronic device may be any communication device such as a phone such as a mobile phone and a landline phone, or a smartphone including, for example, iPhone ™, and an e-mail sending / receiving device. The electronic device can be part of a display such as a digital display, TV monitor, electronic book reader, portable web browser (eg, iPad ™), and computer monitor. The electronic device can also be an entertainment device, including music players such as portable DVD players, conventional DVD players, Blu-ray disc players, video game consoles, portable music players (eg, iPod ™), and the like. . The electronic device can also be part of a device that provides control (eg, Apple TV ™), such as controlling image, video, audio streaming, or remote control for an electronic device It can be a device. The electronic device may be part of a computer or computer accessory such as a hard drive tower enclosure or casing, laptop enclosure, laptop keyboard, laptop trackpad, desktop keyboard, mouse, and speakers. . This article can also be applied to devices such as watches or watches.

  The methods, techniques, and apparatus described herein are not intended to limit the described embodiments.

  As disclosed herein, a system (or apparatus or machine) is configured to perform injection molding of a material (eg, an amorphous alloy). The system is configured to process such a material or alloy by melting at a high melting temperature and then pouring the molten material into a mold for molding. As will be described in detail below, the components of the system are placed in line with each other. According to some embodiments, the components of the system (or access to the system) are along a horizontal axis.

  FIG. 3 shows a schematic diagram of such an exemplary system. The system shown in the figure is a system that is aligned along the horizontal axis, but with an injection molding system in which similar features are arranged vertically (eg, where the material moves vertically into the mold) ) As well as the features disclosed herein are applicable to vertical systems and are considered within the scope of this disclosure.

  As shown, the horizontal injection molding system 10 includes a melting zone 12 configured to melt the meltable material received therein, and to transfer the molten material from the melting zone 12 into the mold 16. A dual plunger rod assembly configured. The dual plunger rod assembly includes a first plunger rod 14 and a second plunger rod 22. At least the first plunger rod 14 is configured to move, transport, transfer, and / or remove molten material from the melting zone 12 into the mold 16. In one embodiment, the first plunger rod 14 and the second plunger rod 22 are configured to transfer molten material from the melting zone 12 into the mold 16. The first plunger rod 14 and the second plunger rod 22 are configured to move along the same axis. In particular, the first and second plunger rods are configured to hold the molten material (eg, molten in the melting zone 12) between the rods while moving the molten material into the mold 16. Is done. The first plunger rod 14 and the second plunger rod 22 have movable rods with plunger tips 24 and 36, respectively, which are configured to contact the material and transport the material. Further details regarding the features of the dual plunger rod assembly are described below with reference to FIGS. In one embodiment, the dual plunger rod assembly and melting zone 12 are provided on a line and on a horizontal axis (eg, the X axis) so that the plunger rods 14 and 22 move in a horizontal direction (eg, along the X axis). .

  The meltable material can be received in the melting zone in any number of forms. For example, the meltable material may be fed into the melting zone 12 in the form of an ingot (solid state), semi-solid state, preheated slurry, powder, pellets, and the like. In some embodiments, a charging port (eg, the illustrated example of the ingot charging port 18) may be provided as part of the injection molding system 10. The input port 18 may be a separate opening or region provided in the device at any number of locations. In one embodiment, the input port 18 may be a path through one or more parts of the device. For example, a material (eg, an ingot) can be inserted horizontally into the container 20 by the plunger 14 or can be inserted horizontally from the mold side of the injection system 10 by the plunger 22 (eg, a mold). Through the mold 16 and / or through the optional transfer sleeve 30 into the container 20). In other embodiments, the meltable material can be fed into the melting zone 12 using other methods and / or other devices (eg, through the opposite side of the injection system).

  Melting zone 12 has a melting mechanism configured to receive a meltable material and hold it as it is heated to a molten state. The melting mechanism may be in the form of a container 20, which has, for example, a body configured to receive a meltable material and to melt the material therein. Containers used throughout this disclosure are containers made of materials that have been employed to heat substances to high temperatures. For example, in one embodiment, the container may be a crucible, such as a boat crucible or a skull crucible. In one embodiment, the vessel 20 is a cryogenic hearth melting device configured to be available for meltable material under vacuum (eg, applied by a vacuum device 38 or a pump). In one embodiment, the container is a temperature controlled container.

  The container 20 may also have an inlet for placing material (eg, raw material) within the receiving or melting portion of the body. The container 20 can include any number of shapes or configurations. The container 20 can receive material (eg, in the form of an ingot) within the molten portion using one or more devices of an injection system (eg, a loading port and / or plunger) for delivery. The body of the container may have a length and extend in the longitudinal and horizontal directions, whereby the molten material is removed horizontally therefrom using the plunger 14 and / or the plunger 22. The body can be formed from any number of materials (eg, copper, silver), including one or more coatings, and / or configurations or designs. The body of the container 20 can be configured to receive at least the plunger rod 14 horizontally through the interior. In one embodiment, both the first plunger rod 14 and the second plunger rod 22 and / or at least both the respective tips 24 and 36 are placed in the body of the container (e.g., when melting material) or in the container. It is configured to be disposed adjacent to the main body. That is, in one embodiment, the melting mechanism is on the same axis as the plunger rods 14 and 22 and the body can be configured and / or dimensioned to receive at least a portion of the plunger rods 14 and 22. Thus, at least the plunger rod 14 can be configured to move the molten material (after heating / melting) from the container, substantially through the container 20 and into the mold 16 (eg, FIG. 5). -6 and as described with reference to these).

  In order to heat the meltable zone 12 to melt the meltable material received in the container 20, the injection system 10 includes a heat source that is used to heat and melt the meltable material. At least a molten portion of the container, if not substantially the entire body itself, is configured to be heated to melt the material received therein. Heating is accomplished, for example, using an induction source 26 disposed in the melting zone 12 that is configured to melt the meltable material. In one embodiment, the induction source 26 is disposed adjacent to the container 20. For example, the induction source 26 may be substantially in the form of a coil disposed in a spiral around its length over the length of the container body. Thus, the container 20 uses a power supply or power supply 28 to power the induction source / coil 26 so as to melt the meltable material (eg, the inserted ingot) in its melted portion by electromagnetic induction. Configured. Induction coil 26 is configured to heat and melt any material contained in container 20 without melting and wetting container 20. The induction coil 26 radiates radio frequency (RF) waves to the container 20. As shown, the coil 26 surrounding the container 20 can be configured to be disposed horizontally along a horizontal axis (eg, the X axis).

  In one embodiment, the container 20 is a temperature controlled container. Such containers may include one or more temperature control tubes, which are liquids (eg, water or other liquids) to adjust the temperature of the material received in the container (eg, to force the container to cool). ) To flow inside. Such a forced-cooled crucible can also be provided on the same axis as the plunger rod. The cooling tube serves to prevent the body of the container 20 itself from being overheated and melted. In one embodiment, either or both of the first plunger rod 14 and the second plunger rod 22 may include a temperature control tube. For example, a line can be provided (not shown) to the interior of each rod and to the tips 24 and 36 of the plunger rods 14 and 22. The addition of such coolant helps to keep the plunger tips 24 and 36 cool during material transfer, for example, preventing tip overheating and / or melting. In one embodiment, both plunger rods are water cooled (or forced cooled) and act as a quench mechanism. In one embodiment, both plungers can be provided at a similar temperature or cooled to a similar temperature. In another embodiment, one plunger (and / or tip) may have a higher temperature than the other plunger (and / or tip). In another embodiment, one plunger (and / or tip) can be at a temperature above the Tg of the material / alloy. In yet another embodiment, one plunger may be at a temperature within the supercooled region of the cast alloy.

  Any of the cooling tubes herein can be connected to a cooling system (not shown) that is configured to direct the flow of liquid in the container. The cooling tube may include one or more inlets and outlets for liquid or fluid to flow therethrough. The inlet and outlet of the cooling tube can be configured in any number of ways and is not intended to be limiting. The number, arrangement and / or orientation of the cooling tubes should not be limited. The cooling liquid or cooling fluid is applied to the cooling pipe during melting of the meltable material in the melting zone 12 when the induction source 26 is energized and / or while the molten material is being transferred from the melting zone 12. Can be configured to flow through.

  As mentioned above, systems such as the injection molding system 10 used to mold materials such as metals or alloys can utilize a vacuum when extruding molten material into a mold or die cavity. . The injection molding system 10 may further include at least one vacuum source 38 or pump configured to apply vacuum pressure to at least the melt zone 12 and the mold 16. This vacuum pressure can be applied to at least a portion of the injection molding system 10 used to melt, move or transfer, and mold the material therein. For example, the container 20, the transfer sleeve 30 (described below), and the dual plunger rod assembly may be entirely under vacuum pressure and / or enclosed in a vacuum chamber during the melting and injection process.

  In one embodiment, the mold 16 is a vacuum mold that is an encapsulated structure configured to adjust the internal vacuum pressure when molding the material. For example, as shown in FIGS. 6-8, in one embodiment, the vacuum molds 16 are arranged in a first mold plate 32 (“A” mold or “ A "plate), a second mold plate 34 (also referred to as a" B "mold or" B "plate), and a vacuum ejector box 36. The first plate 32 and the second plate 34 each have associated mold cavities 42 and 44 for molding the molten material therebetween. As shown in the exemplary cross-sectional view of FIG. 7, mold cavities 42 and 44 are configured to mold molten material received therebetween via transfer sleeve 30. Mold cavities 42 and 44 may include part mold cavities for forming and casting parts therein.

  In general, the first plate 32 can be connected to the transfer sleeve 30. A transfer sleeve 30 (sometimes referred to in the art as a cold sleeve or an injection sleeve) is provided between the melting zone 12 and the mold 16. The transfer sleeve 30 has an opening that is configured to receive molten material therethrough and transfer (using the plunger 14) into the mold 16. This opening may be provided in a horizontal direction along a horizontal axis (eg, the X axis). The transfer sleeve need not be a cold chamber. In one embodiment, the plunger rods 14 and 22, the container 20 (e.g., the receiving or melting portion thereof), and the opening of the transfer sleeve 30 are provided on a line and on a horizontal axis, whereby the plunger rod 14 and / or The plunger rod 22 can be moved horizontally through the container 20 to move the molten material into the opening of the transfer sleeve 30 (and then pass through).

The first plate 32 may include an inlet for the mold 16 so that molten material can be inserted therein. The molten material is pushed horizontally through the transfer sleeve 30 and enters the mold cavity via an inlet between the first plate 32 and the second plate 34. During molding of the material, at least the first plate 32 and the second plate 34 are configured to substantially eliminate exposure of the material therebetween (eg, an amorphous alloy) to at least oxygen and nitrogen. Specifically, a vacuum is applied so that atmospheric air is substantially excluded from within plates 32 and 34 and mold cavities 42 and 44. The vacuum pressure is applied inside the vacuum mold 16 using at least one vacuum source 38 connected to a vacuum line. For example, the vacuum pressure or level of the system can be maintained at 13.3 to 0.013 Pa (1 × 10 ⁻¹ to 1 × 10 ⁻⁴ Torr) during melting and subsequent molding cycles. In another embodiment, the vacuum level is maintained between about 1.33 and 0.013 Pa (1 × 10 ⁻² to about 1 × 10 ⁻⁴ Torr) during the melting and molding process. Of course, other pressure levels or ranges, for example, 1.3310 ^-7 to about 0.13Pa (1 × 10 ^-9 Torr~ about 1 × 10 ^-3 Torr), and / or 0.13Pa~ about 13.3 Pa ( 1 × 10 ⁻³ Torr to about 0.1 Torr) can be used.

  Although not shown, a removal mechanism may optionally be provided to remove the molded (amorphous alloy) material (eg, article) from at least the mold cavity between the first and second plates 32 and 34. . The removal mechanism can be vacuum sealed to the mold and can include an ejector plate with one or more ejector pins (not shown) extending in a linear direction. As is well known in the art, movement of the ejector plate causes the ejector pins to move relative to each other to remove the molded material from the mold cavity of the mold 16. This removal mechanism may be associated with or connected to an actuating mechanism (not shown) configured to actuate to remove molded material or parts (eg, vacuum pressure between plates 32 and 34). After the first part 32 and the second part 34 have moved horizontally away from each other). The ejector pin can be configured, for example, to extrude the molded material from the cavity 44. In one embodiment, as described in detail below with reference to FIG. 8, the second plunger rod 22 of the dual plunger rod assembly is configured to remove the molded article from the mold 16. A second plunger rod 22 may be provided for removing the molded article in addition to or instead of the removal mechanism.

  The mold 16 is an example of a mold 16 that can be used with the injection molding system 10. It will be appreciated that other types of molds may be employed. For example, any number of additional plates can be provided between and / or adjacent to the first plate and the second plate to form the mold. For example, molds known as “A” series, “B” series, and / or “X” series molds may be attached to the injection molding system 10. Further, in one embodiment, an article can be molded using a single plate type mold.

  Referring to FIG. 3, the first plunger rod 14 and the second plunger rod 22 of the dual plunger rod assembly are configured to move horizontally along a horizontal axis. For example, as indicated by arrow A, the first plunger rod 14 is configured to move toward (and past) the melting zone 12 and return in the opposite direction. As indicated by arrow B, the second plunger rod 22 is configured to move toward (and at least adjacent to or into) the melting zone 12 and return in the opposite direction. Again, the first plunger rod 24 and the second plunger rod 22 may have movable rods (eg, bases) with respective plunger tips 24 and 36 at their respective ends. In one embodiment, the tips 24 and / or 36 of the rods 14 and 22 are configured to transport material. At least the first plunger rod 14 is configured to move the molten material toward the mold 16. As described above, in one embodiment, the first plunger rod 14 and the second plunger rod 22 may be configured to move relative to each other to move the molten material from the melting zone 12 into the mold 16. it can. Each rod can be controlled and moved independently and / or together using a controller and / or actuation system (eg, servo or hydraulic drive, not shown). Also, the speed, pressure, and other measurements applied to the material during this process should be limited. For example, in one embodiment, the first plunger rod 14 and the second plunger rod 22 are configured to apply a pressure of about 100 MPa (1000 bar) to about 140 MPa (1400 bar) to the molten material during the molding process. Is done. In another embodiment, the pressure applied (on one or both sides of the material) is about 120 MPa (1200 bar).

  To do this, as shown in FIG. 4, the first plunger rod 14 moves on a horizontal axis towards the container 20 in the melting zone 12, as indicated by arrow C. Similarly, the second plunger rod 22 moves in a horizontal axis toward the container 20 in the melting zone 12 as indicated by arrow D. In one embodiment, at least a portion (eg, a tip) of each of the plunger rods 14 and 22 may be provided adjacent to or within the container 20, thereby containing the material being melted in a molten form. For example, an ingot can be placed in the body of the container so that the first and second plunger rods are placed at a distance from each other during the melting process. This distance can be predetermined. The tip 24 of the first plunger rod 14 and the tip 36 of the second plunger rod 22 can be spaced or in contact with the meltable material (ingot) just before the melting process begins. . When the induction coil 26 is energized to melt the material ingot, the first plunger rod 14 is typically held in that position. In one embodiment, the second plunger rod 22 is located at a distance from the first plunger rod 14 in the melting zone 12, so that the second plunger rod 22 is therefore held or received at least during the melting process. Work as a gate.

  After the material has melted in the material container 20, the second plunger rod 22 is configured to move in concert with the first plunger rod 14, thereby causing a horizontal laminar flow of molten material toward the mold 16. Promote. The mold can be placed adjacent to the melting zone. By containing the molten material between the plunger rods 14 and 22 during the movement of the molten material, the rotation of the molten material is reduced (which reduces the mixing of the internal skull material). Can) to help maintain the molten material at a high melting temperature. FIG. 5 shows the movement of the molten material to the mold 16 by the first plunger rod 14 and the second plunger rod 22 and is represented by arrows F and E, respectively. For example, the first plunger rod 14 and the second plunger rod 22 can move horizontally from right to left to move the molten material from the container 20 in the melting zone 12 to the mold 16 and push it out. The molten material is maintained in the distance between the tips 24 and 36 (eg, controlling the transport of the molten material while at the same time preventing additional air or material from entering the space) 12 / Moved from container 20 through transfer sleeve 30 as desired. Thus, the second plunger rod 22 acts as a gate that holds the molten material during part or all of the injection molding process.

  In the mold 16, the first plunger rod 14 can be used to push molten material into the mold 16 for molding into an article, part, or component piece. In the case where the meltable material is an alloy (eg, an amorphous alloy), the mold 16 is configured to form a shaped bulk amorphous alloy object, part or component. Mold 16 has an inlet for receiving molten material therethrough. The outlet of the container 20 and the inlet of the mold 16 can be provided on a line and on a horizontal axis so that the plunger rods 14 and 22 move horizontally from the container 20 and allow the molten material to flow through the mold 16. Inject into the mold through the inlet.

  The dual plunger rod assembly is a molten material that facilitates filling the mold cavity (eg, high aspect part) of the mold without the large or extra force applied by the plunger rods 14 and / or 22. Can be used to increase the pressure that pushes the mold into the mold. In one embodiment, the first plunger rod 14 is configured to move in one direction along a certain axis toward the mold, and the second plunger rod 22 is arranged in a second opposite direction (first One plunger rod). For example, as shown in FIG. 6, the second plunger rod 22 is positioned and configured relative to the mold to stop the melted material and / or apply pressure on one side 34 of the mold 16. At the same time, the first plunger rod 14 moves in the horizontal direction (see arrow F) to push the molten material against the cavity (or bonded cavities 42 and 44) of the mold 16 on the opposite side 32. Or it is configured to inject and thereby continue and / or continue (without pause or complete stop) as the material is pushed in. More specifically, in one embodiment, the second plunger rod 22 stops at a position, thereby positioning at least its tip 36 relative to the mold cavity. The second plunger rod 22 can be configured to be held in a stop position so that when the molten material is injected into the mold 16, at least the first plunger rod 14 is pressured against it. Apply. In another embodiment, the second plunger rod 22 is configured to move in a reverse or opposite direction (eg, from left to right), whereby both plungers 14 and 22 move relative to each other or toward each other, Apply pressure to the material. In yet another embodiment, the pressure can be selectively applied by the second plunger rod 22 in the opposite or opposite horizontal direction as needed. Thus, the second plunger rod 22 can be used to add pressure to the mold cavity fill from either or both sides. This additional pressure can, for example, apply a greater pressure to the molten material, thereby making the part thinner than what is normally moldable.

  Thus, as described above, the first plunger rod 14 and the second plunger rod 22 of the dual plunger rod assembly retain at least the molten material therebetween while the molten material is moving in the horizontal direction at least, The molten material is configured to move from the melting zone 12 into the mold 16.

  Note, however, that the dual plunger assembly can be configured for operation in different ways. FIG. 7 shows another embodiment that is practical for the described injection system 10, wherein at least one first plunger rod 14 moves molten material from a container 20 into a mold 16 (horizontally, eg, (See arrow G). Although the second plunger rod 22 can be used to transfer molten material from the melting zone 12, in another embodiment, the second plunger rod 22 is moved adjacent to or in the mold 16 and positioned. Then, the molten material can be injected into the inside by the first plunger rod 14. Accordingly, the second plunger rod 22 is provided adjacent to the mold cavity (s) in the mold 16 to increase the squeezing pressure without applying extra force and to increase the high aspect ratio cavity (eg, The second plunger rod 22 is not necessarily continuous, as the molten material from the melting zone 12 toward the mold 16 is used (as detailed above with reference to FIG. 6). It is not necessary to be used for transporting to, and is not limited to this.

  In addition to transferring the melted material, in one embodiment, one of the first plunger rod 14 and the second plunger rod 22 of the dual plunger rod assembly is used as a removal mechanism to complete the molding process. Sometimes it can be used to remove a molded article or part from the mold 16. For example, as indicated by arrows M1 and M2 in FIG. 7, the first mold plate 32 and the second mold plate 34 can move relative to each other, that is, toward and away from each other. During molding, for example, plates 32 and 34 are adjacent to each other and under vacuum pressure. When molding is complete, the vacuum pressure is released and the molded article can be removed or removed from the mold. Typically, for example, a takeout mechanism (eg, a takeout plate and / or a takeout pin) can be used to remove a molded part, for example, from the second side 34 of the mold. According to one embodiment shown in FIG. 8, the second plunger rod 22 moves in a horizontal direction (eg, from left to right, as indicated by the arrow H) to move the molded article 100 to the second mold plate. 34 is configured to be taken out. At least its tip 36 is used to apply pressure to the molded article 100 and is thereby removed from within the mold 16. The second plunger rod 22 (or first plunger rod 14) can be used as an addition to the removal mechanism or as another option for the removal mechanism. The first plunger rod 14 can also be provided in a stationary position relative to the mold 16.

  Alternatively, in another embodiment, when the molded article is held in the first mold plate 32 when the plates are separated, or only a single mold is employed as the mold 16 First, the first plunger rod 14 is configured to move in the horizontal direction (for example, from right to left) and take out the molded article from the first mold plate 32. In some embodiments, the first plunger rod 14 can be used in addition to or as an alternative to the removal mechanism.

  In general, the injection molding system 10 can be operated as follows: a meltable material (eg, an amorphous alloy or BMG) is charged into a supply mechanism (eg, the charging port 18) It is inserted into the melting zone 12 (which is surrounded by an induction coil 26) and received. Using the “nozzle” stroke or plunger 14 of the injection molding apparatus, this material is moved into the molten portion of the container 20 as needed. The system can be placed under vacuum using a vacuum source 38. The first plunger rod 14 and the second plunger rod 26 move into the melting zone 12 relative to each other and toward the material to be melted and are positioned at a suitable distance to accommodate the material. The material is then heated in an induction process by heating the induction coil 26. Once the temperature for melting the meltable material has been reached and maintained, heating using the induction coil 26 can be stopped and the apparatus can then transfer the molten material from the container 20 through the transfer sleeve 30 to a vacuum mold. Infusion is started by moving horizontally in 16 along the horizontal axis (from right to left). The movement of the molten material is controlled using both plungers 14 and 22 (which can be actuated using a servo drive or a hydraulic drive). The mold 16 is configured to receive the molten material through the inlet and is configured to mold the molten material under vacuum. That is, the melted material is injected into at least the cavity between the first plate and the second plate, and the part is molded by the mold 16. The second plunger rod 22 can be placed on the second side 34 of the mold so that the pressure in the mold is maintained while the first plunger rod 14 continues to move or push the molten material into the cavity. Hold. Once the cavity begins to fill, hold the vacuum pressure (via the vacuum line and vacuum source 38) at a predetermined pressure to “fill” the molten material into the remaining cavity area within the cavity and mold the material Can do. After the molding process (eg after about 10-15 seconds), the vacuum pressure applied to the mold 16 is released. The mold 16 is then opened to release the pressure and expose the parts to the atmosphere. The second plunger rod 22 (and / or the take-out mechanism) is actuated in the horizontal and linear directions (for example, toward the right) to solidify and shape the article into at least the first plate and the second plate of the mold 16. Can be taken out from between. After this, the process can be started again. The mold 16 is closed by moving at least the first and second plates closer together, thereby allowing the first and second plates to be adjacent to each other. When the plungers 14 and 22 are returned to the loading position (possibly the melting position), the melting zone 12 and the mold 16 are evacuated by a vacuum source, thereby further melting the received meltable material and transferring the next part. Can be molded.

  Accordingly, embodiments disclosed herein include an exemplary injection system having a dual plunger rod assembly configured to move along a horizontal axis during a melting and molding process and a melting system in line. Indicates. However, the system and / or portion need not be limited to being arranged for horizontal material movement. The dual plunger rod assembly can be configured to move along any longitudinal axis in the longitudinal direction. For example, in another embodiment, a dual plunger rod assembly and melting zone can be provided along a vertical axis (eg, Y axis, not shown) so that the plunger rods 14 and 22 and the material are in a vertical direction. And move from the melting zone 12 into the mold 16.

  Accordingly, the dual plunger rod assembly described herein provides a number of employable features for the injection molding system 10 described herein. For example, two plungers are used to hold material between them and control its transfer. Also, for a system that is provided in line with at least a melting zone and a mold on the horizontal axis, the rate at which the molten material is injected into the mold 16 is particularly prone to rapidly pour the material into the mold. Compared to certain pouring systems and conventional die casting systems, it can be controlled by movement of the plungers 14 and 22. With the disclosed dual plunger system, the parts can be cooled more uniformly, allowing for faster speeds than a single plunger system.

  In addition, the second plunger rod 22 acts as a holding or confinement gate (e.g., during molding), so no additional gate is required. This reduces the length and size of the space that may have been required in prior or known systems. In addition, this can also reduce the length of the transfer sleeve 30 (if provided). Thus, the ability to shorten the dual plunger adjacent sleeve, such as the transfer sleeve 30, and / or other parts of the device reduces the distance required to travel from the melting zone to the mold inlet, resulting in a molten material. Can be pushed more quickly into the mold. This also means that the molten material arrives at the mold at a higher temperature and that during molding the material is less prone to defects due to the rapid cooling rate of the mold. In particular, when using materials that become amorphous, maintaining a higher temperature and reducing the rate at which such molten material cools as it moves toward the mold (rapidly at the mold) Improve glass formability (before cooling). By storing the molten material in a space or distance between the two plunger rods 14 and 22 that move in concert towards the mold, its surface area and temperature can be kept relatively constant. .

  In addition, the use of a dual plunger rod assembly can help to reduce surface defects in the molded article by further enhancing the laminar flow of material. Typically, when the molten material is rotatable, at least a portion of the skull material (eg, from the bottom) can become entrained in the molten material. Thus, some of the undesired crystallized material can be molded and remain in the final part. However, if the molten material moves relatively linearly as provided by the plungers 14 and 22, the entrapment of the skull material in the melt can be reduced and / or avoided. The dual plunger rod assembly disclosed herein is further maintained by constantly maintaining pressure on the melt, by filling smaller shapes in the mold, and (by being controlled by both plungers). It is possible to reduce defects by filling larger parts because the flow rate can be increased. This also traps and / or prevents air or bubbles that occur within the distance or space between the two plungers.

  In addition to the features described herein, it will be understood that the dimensions and materials used for the plunger rods 14 and 22 should not be limited. Any number of materials can be used to form the rod and / or its tips 24 and 36. Different parts can be formed using different materials. The tips 24 and 36 can be formed of one or more materials. In one embodiment, at least the tips of both plunger rods 14 and 22 have a similar diameter. In another embodiment, plunger rod 14 and plunger rod 22 have different diameters. In another embodiment, one or more of the rods 14 and / or 22 may include a telescoping body. In yet another embodiment, one plunger may house the other plunger inside.

  Although not described in detail, the injection system of the present disclosure includes one or more sensors, flow meters, etc. (eg, for monitoring temperature, coolant flow, etc.) and / or one or more controllers. Additional parts that are not limited to may be included. In addition, any number of parts or adjacent to assist in melting and forming part of the molten material by substantially limiting or eliminating significant air exposure or leakage when under vacuum pressure. And a sealing part may be provided. For example, the seal can be in the form of an O-ring. A seal can be made of any material and is defined as a device that stops a substance (eg, air) from moving between the parts to be sealed. The injection system may perform an automated or semi-automated process for inserting meltable material therein, applying a vacuum, heating, pouring, shaping the material to form a part.

  The material formed (and / or melted) using any embodiment of the injection system disclosed herein can include any number of materials and should not be limited. In one embodiment, the material to be molded is an amorphous alloy, as detailed above.

  Although the principles of the present disclosure are clarified in the exemplary embodiments described above, various modifications may be made to the structures, arrangements, proportions, elements, materials, and components used in the practice of the present disclosure. This will be apparent to those skilled in the art.

  It will be appreciated that many of the above and other features and functions, or alternatives thereof, may be suitably combined with many other different systems / devices or applications. Various alternatives, modifications, variations, or improvements in these that are not currently anticipated or anticipated may subsequently be made by those skilled in the art and are intended to be included within the scope of the following claims. The

Claims (20)

A melting zone configured to melt the meltable material received therein;
A dual plunger rod assembly comprising a first plunger rod and a second plunger rod, wherein at least the first plunger rod moves molten material from the melting zone into the mold. Wherein the dual plunger rod assembly and the melting zone are provided in line, and the first and second plunger rods are configured to move along a longitudinal and horizontal axis, respectively, thereby at least the A first plunger rod moves the molten material longitudinally from the melting zone to move the molten material horizontally into the mold, and the injection molding system includes a bulk solidified amorphous alloy. A system configured to mold an article.   The melting zone includes a container having a body for receiving the meltable material, the body receiving at least the first plunger rod through the interior thereof in a longitudinal direction, and the molten material in the mold. The system of claim 1, wherein the system is configured to be moved.   The first plunger rod and the second plunger rod are provided adjacent to the meltable material in the melting zone, and the first and second plunger rods direct the molten material toward the mold. The system of claim 2, wherein the system is configured to receive the molten material therebetween during longitudinal movement.   The second plunger rod is configured to be disposed relative to the mold and is configured to apply pressure to the molten material on one side of the mold, the first plunger rod being The molten material is configured to move in the longitudinal direction and be pushed into the mold on the opposite side of the mold, whereby the molten material is pushed into the cavity of the mold. The system described in.   The system of claim 1, wherein the second plunger rod is configured to remove a molded article from the mold.   The apparatus of claim 1, further comprising at least one controller, wherein movement of each of the first plunger rod and the second plunger rod along the longitudinal axis is independently controlled via the at least one controller. The system described.   The system of claim 1, further comprising an induction source disposed in the melting zone configured to melt the meltable material.   The system of claim 1, further comprising a transfer sleeve configured to receive the molten material through an interior between the melting zone and the mold.   The system of claim 1, further comprising at least one vacuum source configured to apply a vacuum pressure to at least the melting zone and the mold. A melting zone configured to melt the meltable material received therein;
A mold configured to receive the material melted therein for molding;
An injection molding system comprising a first plunger rod and a second plunger rod configured to move relative to each other along a horizontal axis, wherein the first plunger rod and the second plunger rod are the melt The system is configured to move the material from the melting zone horizontally into the mold and the injection molding system is configured to mold an article comprising a bulk solidified amorphous alloy.   The first plunger rod and the second plunger rod are configured to be provided adjacent to the meltable material in the melting zone during melting and move the molten material toward the mold. The system of claim 10, wherein the system is configured to contain the molten material therebetween.   12. The first plunger rod and the second plunger rod are arranged at a distance from each other during melting of the meltable material, and the distance is maintained during movement of the molten material. The system described in.   The first plunger rod is configured to move in one direction along the horizontal axis toward the mold, and the second plunger rod moves in a second opposite direction along the horizontal axis. The system of claim 10, wherein the system is configured.   The second plunger rod is configured to be disposed relative to the mold and is configured to apply pressure to the molten material on one side of the mold, the first plunger rod being 11. The system of claim 10, wherein the system is configured to move molten material to the mold on the opposite side of the mold, thereby pushing the molten material into the mold cavity.   The system of claim 10, wherein the second plunger rod is configured to remove a molded article from the mold.   The system of claim 10, further comprising at least one controller, wherein movement of each of the first plunger rod and the second plunger rod is independently controlled via the at least one controller.   The system of claim 10, further comprising at least one vacuum source configured to apply a vacuum pressure to at least the melting zone and the mold. A method of forming an article comprising a bulk solidified amorphous alloy from a meltable material using an injection molding system, the system configured to melt the meltable material received therein, and a horizontal zone A plunger rod assembly including a first plunger rod and a second plunger rod movable along an axis, wherein the assembly is configured to move molten material from the melting zone horizontally into the mold. And the method comprises
Melting the meltable material in the melting zone;
Moving the molten material from the melting zone into the mold in a horizontal direction;
And wherein the first plunger rod and the second plunger rod receive the molten material therebetween while moving the molten material horizontally along the horizontal axis toward the mold. A method wherein the injection molding system is configured to mold an article comprising a bulk solidified amorphous alloy. 19. The first plunger rod and the second plunger rod move along a longitudinal axis, and movement of the molten material from the melting zone into the mold is longitudinal. Method. The method of claim 18, further comprising molding the molten material and removing the article from the mold using the second plunger rod after molding.

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