JP6101743B2 - Confinement gate for in-line temperature controlled melting - Google Patents

Description

  The present disclosure relates generally to gates and containers for melting material and holding the molten material therein during melting.

  Some injection molding devices use an induction coil to melt the material and then inject the material into a mold. However, the magnetic flux emanating from the induction coil can cause unpredictable movement in the molten material, which can make it difficult to control the uniformity and temperature of the molten material. In addition, the molten material needs to be held in the melting zone so that it does not mix too much or cool too quickly.

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

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 gate according to one embodiment of the present disclosure.

FIG. 3 is a detailed cross-sectional view of a gate associated with a container in an injection molding system, in a first position and a second position, according to one embodiment. FIG. 3 is a detailed cross-sectional view of a gate associated with a container in an injection molding system, in a first position and a second position, according to one embodiment.

FIG. 6 is a detailed perspective view of a gate associated with a container in an injection molding system, respectively, in a first position and a second position according to another embodiment. FIG. 6 is a detailed perspective view of a gate associated with a container in an injection molding system, respectively, in a first position and a second position according to another embodiment.

FIG. 2 is a detailed cross-sectional view of a rotatable gate associated with a container in an injection molding system, respectively, in a first position and a second position according to one embodiment. FIG. 2 is a detailed cross-sectional view of a rotatable gate associated with a container in an injection molding system, respectively, in a first position and a second position according to one embodiment.

FIG. 6 is a detailed cross-sectional view of another gate associated with a container in an injection molding system, respectively, in a first position and a second position according to another embodiment. FIG. 6 is a detailed cross-sectional view of another gate associated with a container in an injection molding system, respectively, in a first position and a second position according to another embodiment.

FIG. 4 is a detailed cross-sectional view of a hinged gate associated with a container in an injection molding system, respectively, in a first position and a second position according to one embodiment. FIG. 4 is a detailed cross-sectional view of a hinged gate associated with a container in an injection molding system, respectively, in a first position and a second position according to one embodiment.

FIG. 13 is an overhead perspective view of the hinged gate of FIG. 12 in the first position.

2 are detailed cross-sectional views of a dual gate system associated with a container in an injection molding system, respectively, in a first position and a second position according to one embodiment. 2 are detailed cross-sectional views of a dual gate system associated with a container in an injection molding system, respectively, in a first position and a second position according to one embodiment.

Is a method for melting materials and forming parts according to one embodiment of the present disclosure.

  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. As used throughout this specification, the terms “substantially” and “about” 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, vitreous) 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, and so the benefits of the amorphous state may be lost. 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 a method for molding BMG parts with a controlled amount of amorphization needs to be developed. There is sex.

  FIG. 1 (obtained from US Pat. No. 7,575,040) is an exemplary bulk solidification from the VIT-001 series of the Zr--Ti--Ni--Cu--Be family manufactured by Liquidmetal Technology. The viscosity-temperature graph of an 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 for the purpose of drawing 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 experience liquid / solid crystallization transformations upon cooling. Instead, the more fluid, amorphous form of metal observed at high temperatures (near the “melting temperature” Tm) becomes more viscous as the temperature is reduced (to near the glass transition temperature Tg). Eventually, 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 is most rapid and occurs on the shortest time scale.

  The supercooled liquid region, Tg-Tx temperature region, 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 the supercooled liquid region varies from 1012 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 do. 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-cast processing method with a time-temperature trajectory (shown as (1) as an exemplary trajectory as (1)) that does not hit the TTT curve and is between Tm and less than Tg. . During die casting, this forming is performed at the same time as substantially 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 is much larger than die casting, which can result 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 distinct, 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. A phase may refer to a compound such as a solid solution, which may be a solution of two components, three components, four components or more, or an intermetallic compound. As another example, the amorphous phase is completely different 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, the non-metallic element may refer to a specific metalloid 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, an electronics enclosure / casing, or even a portion of a structural component having dimensions in the millimeter, centimeter, or meter range.

Solid solution The term “solid solution” refers to a solid form of a 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.

Alloys 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, which 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 exact form of order in a solid is lattice periodicity. A specific pattern (the arrangement of atoms in the unit cell) is repeated many times to form a translationally invariant, space filling. 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 of the 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 of more than 50% by volume, preferably more than 90% by volume, more preferably more than 95% by volume, most preferably 99% by volume. An alloy having an amorphous content of from super to almost 100% by volume. 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 that 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 exhibit any of the shapes or forms described above with respect to 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 depends on several factors: the composition of the alloy components and the atomic radii of the components (preferably greater than 12% in order to achieve high packing density and low free volume). And the negative heat of mixing 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 properties that are potentially useful. 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, metal matrix composites with a metallic glass matrix containing ductile crystalline metal dendritic particles or fibers can be used. Alternatively, BMG with fewer 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 can be intrinsic glasses, in other words, bulk amorphous alloys can soften and flow when heated. This allows easy processing, such as by injection molding, in much the same way as a 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 25X or higher. 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 can have any attendant minor crystalline phase present therein.

  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 substance is homogeneous when the volume of the substance 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 suspended, but 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 non-negligible weight percentage of iron present therein, the weight percentage being at least about 40% by weight, for example, at least about 40% by weight. It may be at least about 20%, such as 50%, such as at least about 60%, such as at least about 80%. 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 can 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 No. 2001303218 A). One exemplary composition is Fe72A15Ga2PllC6B4. Another example is Fe72A17Zr10Mo5W2B15. 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 phosphorus, germanium, and arsenic, up to a total of about 2%, preferably less than 1%, to lower 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. This impurity is about 10% or less, such as about 5% or less, such as about 2% or less, such as about 1% or less, such as about 0.5% or less, such as about 0.1% or less. can do. 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 (having 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 so that the elastic strain limit of the amorphous alloy can be substantially maintained above 1.0%, preferably above 1.5%. In the context of embodiments herein, the temperature near the glass transition means that the molding temperature can be below the glass transition temperature, near the glass transition temperature or glass transition temperature, and above the glass transition temperature. The temperature is preferably lower than the crystallization temperature Tx. 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 shaping loads are still maintained.

Electronic Device The embodiments described herein can be valuable in the production of electronic devices using BMG. As used herein, an electronic device can refer to any electronic device known in the art. For example, the electronic device can 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. This electronic device can be part of a computer or a 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, an apparatus or system (or apparatus or machine) may be configured to melt and injection mold a material (eg, an amorphous alloy). The apparatus is configured to process such materials or alloys by melting at a high melting temperature and then injecting the molten material into a mold for molding. As will be described in detail below, the components of this device are placed in line with each other. According to some embodiments, the parts of the device (or access to the device) are along a horizontal axis.

  The following embodiments are for illustrative purposes only and are not intended to be limiting.

  FIG. 3 shows a schematic diagram of such an exemplary system. More specifically, FIG. 3 shows an injection molding apparatus or system 10. In accordance with one embodiment, the injection molding system 10 is configured to inject a melt zone 12 configured to melt the meltable material received therein and the molten material from the melt zone 12 to the mold 16. And at least one plunger rod 14 configured. In one embodiment, at least the plunger rod 14 and the melting zone 12 are provided in-line and on a horizontal axis (e.g., the X axis) so that the plunger rod 14 is substantially horizontally (e.g., X through the melting zone 12). Along the axis) to move the molten material into the mold 16. The mold can be placed adjacent to the melting zone.

  The meltable material can be received in the melting zone in any number of forms. For example, the meltable material may be supplied to 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 charging 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, the material (eg, 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 (eg, the mold 16 Through and / or through the 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, as described in detail below, 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 24 of the body. In the illustrated embodiment, the body of the container 20 includes a substantially U-shaped structure. However, this illustrated shape is not meant to be limiting. The container 20 can include any number of shapes or configurations. The body of the container may have a length, extend longitudinally and horizontally, whereby molten material is transferred from here horizontally using the plunger 14. For example, the body can include a bottom with sidewalls extending vertically therefrom. The material for heating or melting can be received in the molten portion 24 of the container. The molten portion 24 is configured to receive a meltable material that is melted therein. For example, the molten portion 24 has a surface for receiving material. The container 20 can receive material (eg, in the form of an ingot) within the melted portion 24 using one or more devices (eg, a loading port and a plunger) of the injection system for delivery.

  In one embodiment, the body and / or its melted portion 24 may include a substantially rounded and / or smooth surface. For example, the surface of the melted portion 24 can be formed in an arc shape. However, the shape and / or surface of the body is not intended to be limiting. The body may be a unitary structure or may be formed from separate parts that are joined or machined together. The body of the container 20 may be formed from any number of materials (eg, copper, silver), including one or more coatings and / or configurations or designs. For example, one or more surfaces can have a recess or groove therein.

  The body of the container 20 can be configured to receive a plunger rod horizontally through the interior for moving the molten material. That is, in one embodiment, the melting mechanism is on the same axis as the plunger rod, and the body can be configured and / or dimensioned to receive at least a portion of the plunger rod. Thus, the plunger rod 14 can be configured to move the melted material (after heating / melting) from the container into the mold 16 by moving substantially through the container 20. Referring to the embodiment of the system 10 illustrated in FIG. 3, for example, the plunger rod 14 moves horizontally from right to left through the container 20 to move the molten material into the mold 16. Push out.

  In order to heat the meltable zone 12 to melt the meltable material received in the container 20, the injection system 10 also includes a heat source that is used to heat and melt the meltable material. At least the molten portion 24 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 in the form of a helically arranged coil that wraps substantially around 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 to melt the meltable material (eg, the inserted ingot) in the melted portion 24 by electromagnetic induction. Can be configured. Thus, the melting zone 12 can include an induction zone. The induction coil 26 is configured to heat and melt any material contained in the container 20 without melting and wetting the container 20. The induction coil 26 radiates radio frequency (RF) waves to the container 20. As illustrated, the main body and the coil 26 surrounding the container 20 may be configured to be arranged in a horizontal direction along a horizontal axis (for example, the X axis).

  In one embodiment, the container 20 is a temperature controlled container. Such a container may include one or more temperature control tubes, which adjust the temperature of the body of the container 20 during melting of the material received in the container (eg, to force the container to cool). In addition, a fluid (for example, water or other fluid) is allowed to flow inside. Such a forced cooled crucible can also be provided on the same axis as the plunger rod. The cooling tube can help prevent the body of the container 20 itself from overheating and melting. The cooling tube can be connected to a cooling system configured to direct the flow of liquid within the container. The cooling tube may include one or more inlets and outlets for liquid or fluid to flow through. The inlet and outlet of the cooling tube can be configured in any number of ways and is not intended to be limiting. For example, the cooling tube may be positioned relative to the melted portion 24 so that the material therein melts and the container temperature is adjusted (ie, heat is absorbed and the container is cooled). The number, arrangement and / or orientation of the cooling tubes should not be limited. The cooling liquid or cooling fluid may be configured to flow through the cooling tube during melting of the meltable material when the induction source 26 is energized.

  After the material is melted in the container 20, the plunger 14 can be used to push the molten material from the container 20 into the mold 16 for molding into an object, part or component. 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 single line and on a horizontal axis so that the plunger rod 14 moves horizontally through the body 22 of the container, allowing the molten material to move into the mold 16. Injection into the mold through the entrance.

  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 mold hole. . 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 parts of the injection molding system 10 used to melt, move or transfer and mold the internal material. For example, the container 20, transfer sleeve 30, and plunger rod 14 may all be under vacuum pressure and / or enclosed within a vacuum chamber.

  In one embodiment, the mold 16 is a vacuum mold that is an encapsulating structure configured to adjust the vacuum pressure therein as the material is molded. For example, in one embodiment, the vacuum mold 16 is a first plate (also referred to as an “A” mold or “A” plate), a second plate (“B”), disposed adjacent to each other (respectively). Also called “die” or “B” plate). Each of the first plate and the second plate generally has a mold cavity associated therewith to mold the molten material therebetween. The mold cavity is configured to mold the molten material received therebetween through the infusion sleeve or transfer sleeve 30. The mold cavity can include a part mold cavity for forming and molding a part therein.

  In general, the first plate can be connected to the transfer sleeve 30. According to one embodiment, the plunger rod 14 is configured to move molten material from the container 20 through the transfer sleeve 30 to the mold 16. A transfer sleeve 30 (sometimes referred to in the art and herein as a shot sleeve, cold sleeve or injection sleeve) may be 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) to the mold 16. The opening may be provided in the horizontal direction along the horizontal axis (for example, the X axis). The transfer sleeve need not be a cold chamber. In one embodiment, at least the plunger rod 14, 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 so that the plunger rod 14 has melted. The material can be moved horizontally through the container 20 to move the material into the opening of the transfer sleeve 30 (and then pass through).

  The molten material is pushed horizontally through the transfer sleeve 30 and enters the mold cavity through the inlet (eg, in the first plate), between the first plate and the second plate. During molding of the material, at least the first plate and the second plate are configured to substantially eliminate exposure of the material in between (eg, an amorphous alloy) to at least oxygen and nitrogen. Specifically, a vacuum is applied so that atmospheric air is substantially excluded from within the plate and mold cavity. A 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 vacuum level of the system can be maintained at 13.3 to 0.013 Pa (1 x 10-1 to 1 x 10-4 Torr) during melting and subsequent molding cycles. In another embodiment, the vacuum level is maintained between 1.3 and 0.013 Pa (1 × 10 −2 to about 1 × 10 −4 Torr) during the melting and molding cycle. Of course, other pressure levels or ranges, for example, 0.013 μPa (1 × 10 −9 Torr) to about 0.13 Pa (1 × 10 −3 Torr), and / or 0.13 Pa (1 × 10 −3 Torr) to about 13 .3 Pa (0.1 Torr) can also be used. The vacuum ejector mechanism (not shown) is configured to remove the molded (amorphous alloy) material (or molded part) from the mold cavity between the first plate and the second plate of the mold 16. Yes. This removal mechanism is associated with or connected to an actuating mechanism (not shown) configured to actuate to remove the molded material or part (eg, at least the vacuum between the plates is released) After, after the first part and the second part have moved horizontally away from each other).

  The apparatus 10 can employ any number or type of molds. For example, an arbitrary number of plates may be provided between and / or next to the first plate and the second plate to form a mold. For example, molds known as “A” series, “B” series, and / or “X” series molds may be provided in the injection molding system / apparatus 10.

  Heating the molten material uniformly and maintaining the temperature of the molten material in such an injection molding apparatus 10 helps to form a uniformly molded part. For illustrative purposes only, throughout the present disclosure, the material to be melted is described and illustrated as being in the form of an ingot 25 that is a solid state raw material. However, the material to be melted may be received in the injection molding system or apparatus 10 in the form of a solid state, semi-solid state, preheated slurry, powder, pellets, etc., and the form of the material is not limited. Please be careful. In accordance with the present disclosure, at least one gate is provided in the apparatus for receiving molten and / or molten material in such a system. The gate is configured to confine the molten material within the melting zone of the device and minimize heat loss. In addition, the molten material needs to be held in the melting zone so that it does not mix too much or cool too quickly.

  In an injection molding apparatus 10 that is arranged inline and horizontally, each material can be accommodated in the melting zone 12 adjacent to the induction coil 26 in order to apply most of the power input to the material for melting. It is effective to provide consistent melting in the cycle (eg, as opposed to directing and / or exiting the molten material stream to and from the removal path of the container 20).

  Accordingly, the present disclosure requires at least one gate in at least the induction / melting zone of the injection molding apparatus / equipment and presents several different concepts to address this. Without a gate containing the melt in the melting zone, the material to be melted (or melted material) tends to stretch and move beyond the range of the melting source (eg induction field), loss of temperature It has been found to cause increased power input requirements and reduced quality of formed or molded parts (for example, to melt the melt or maintain the temperature of the melt). The disclosed and illustrated gate embodiments further maintain the function of the rest of the apparatus during the heating and melting process (eg, the plunger function and the ability to generate sufficient vacuum during the process). And / or ensure that the material to be melted is contained without affecting the reliability of the machine. This embodiment confines the material during the melting process (eg, to apply a radio frequency from the induction source 26) and facilitates a steady state temperature distribution while the material is melted.

  When BMG is used as the material in the injection molding apparatus 10, the use of at least one gate as disclosed herein results in a material with high elastic limit, corrosion resistance, and low density. Also cost effective.

  The gate can be made of any material including, but not limited to, a radio frequency transmissive material (eg, thereby induced current from the heat source / induction source 26 or radio frequency does not heat the gate). This material can be a material whose temperature can be controlled by gas, fluid or other means. For example, such exemplary materials that can be used to form the gate can be metal (eg, copper), glass, ceramic, or any other material. In one embodiment, the gate can be made of a highly conductive metal with a small skin thickness, such as copper or a copper alloy. The gate can also be coated with magnetic material, ceramic, non-magnetic material, insulator or other material.

  Furthermore, it should be noted that the gate body need not be made entirely of the same material. For example, the gate has a tip made from one or more materials configured to be heat resistant and / or configured to accommodate the material without damaging the material during melting. It may be included and the body of the gate may be made of another material.

  In the embodiments disclosed herein, for example, each gate is movable to a first (closed) position and a second (open) position. The gate limited the penetration of the container 20 into the take-out path and melted through the take-out path and the first position for accommodating the meltable form of material in the container 20 during the melting of the material. It is configured to move between a second position that allows movement of the form material. Device 10 is configured to melt the material, and the gate is configured so that device 10 can be maintained under vacuum during material melting and forming / casting.

  Exemplary embodiments of both a single gate (eg, the plunger 14 is in contact with the ingot during the melt stage) (see, eg, FIGS. 4-14) and a dual gate system (see, eg, FIGS. 15-16) are described below. Further explained. In one embodiment employed as a single gate system, for example, the plunger 14 restricts the opposite side of the take-out path in the container 20 and, during the melting of the material, a meltable form of material into the container 20. Can be configured to accommodate. The plunger 14 may also be further configured to move the molten form of material through the removal path of the container 20 and into the mold 16 when the gate is moved to the second position (open position) after melting. Can do. For example, the tip of the plunger 14 can be formed of a material (eg, ceramic) that can withstand high temperatures and allow high temperatures and minimal heat loss from the melt. In one embodiment, the plunger tip can be cooled by liquid / air cooling during melting and / or once in the mold to facilitate solidification. For example, by using a single gate with a plunger, a simple design with few sealing points can be obtained. Alternatively, the gate can be heated during the melting phase by a dual gate system. With such a configuration, the tip of the plunger 14 can be kept cool and can be safely pulled back from the melting zone 12 during the melting phase (heating the material). After the gate is pulled back to the second position, the plunger 14 can be brought into contact with the molten material and the melt can be cooled before being inserted into the mold 16.

  In each of the illustrated embodiments of FIGS. 4-16, the container 20 is positioned along a horizontal axis (X-axis), and movement of the molten form of material through the removal path (eg, the plunger 14). The container 20 is positioned along the horizontal axis so that it is horizontal when guided. At least a portion of the container 20 is surrounded by a coil-shaped induction source 26 that is arranged and configured to heat and melt the material. For illustrative purposes only, the illustrated image of the container 20 is a cross-sectional view along the X-axis of the U-boat / container, and the molten portion 24 for receiving the material to be melted therein (eg, in the form of an ingot). Have For example, the overhead view shown in FIG. 14 shows an example of the U-shaped container shown in the drawing in detail. However, this illustrated shape is not intended to be limiting.

  In addition, each embodiment includes a sleeve 42 that is positioned to surround at least a portion of the container 20. The sleeve 42 extends horizontally with the container 20 (ie, along the X axis). The sleeve 42 can be made of any material, provided in any shape, and is not intended to be limiting. For example, the sleeve 42 can be a formed quartz tube. The sleeve 42 is placed around the outside of the container 20 so that a vacuum can be applied and the melting process can be carried out under vacuum. The sleeve 42 is configured so that the gate 40 can be disposed at the first (closed) position and the second (open) position.

  An actuating mechanism is associated with each gate to selectively move the gate between the first position and the second position. Any type of actuation mechanism can be used and / or controlled (eg, by a controller). Some examples of actuation mechanisms that can be used in the gate embodiments disclosed herein include pneumatic pistons, hydraulic pistons, solenoids, and / or servo motors. The gate can be controlled using a direct shaft, magnet, gravity, or other device. The type of actuation mechanism used to move the gate toward and between the first and second positions is not intended to be limiting.

  Referring now to the drawings, FIGS. 4 and 5 show detailed cross-sectional views of one embodiment of a gate 40 associated with a container 20 in an injection molding system 10 in a first position and a second position, respectively. Show. In this embodiment, the sleeve 42 includes a protrusion 44 extending from itself, within which the gate is configured to move (stretched and pulled back) to a first position and a second position. The protrusion 44 is arranged such that at least a portion of the gate 40 can move into the body of the container 20 and contact the melted portion 24 thereof. The protrusion 44 is disposed on the sleeve 42 so that the gate 40 can enter into the upper portion of the U-shaped container 20. More specifically, the gate 40 is a linear actuating gate attached at an angle to the container 20. The protruding portion 44 of the sleeve 42 is attached obliquely on an axis A-A arranged at an angle α with respect to the axis of the container 20 (on the X axis). Therefore, the gate 40 is configured to move in an oblique direction with respect to the container between the first position and the second position in a straight line along the axis AA. In one embodiment, the protrusion 44 can be provided at an angle α of about 15 to about 90 degrees with respect to the sleeve 42 such that the gate 40 is positioned at a similar angle with respect to the container 20. However, the mounting angle of the gate 40 is not intended to be limited.

  In one embodiment, the angle α at which the protrusion 44 is provided to the container is approximately 90 degrees, ie, the gate is in the container as it moves between the first position and the second position. It is configured to move in the vertical direction. By making the angle about 90 degrees, the length of the container (horizontal / longitudinal) can be shortened, which helps to reduce the undesirable cooling of the molten material, and thereby the casting quality of the material Is improved.

  The gate 40 includes a contact surface (or tip) 46 configured to limit the movement of material that has been melted and / or in a molten state during the melting process. This tip can be provided at an angle to the body. For example, in the first position, the gate tip 46 can be configured to extend perpendicular to the melted portion 24 of the container 20. This contact surface or tip 46 can be formed of a similar material to the body of the gate 40 or a different material. Any number of materials can be used to form the gate 40. As described above, the gate 40 is moved to the first position (FIG. 4) or the second position (FIG. 5) by an operating mechanism or device (not shown). For example, the gate 40 can be placed (or moved as needed) in the first (closed) position of FIG. 4 prior to melting. The gate 40 can be provided in the first position before or after the material to be melted (ingot 25) is inserted into the container 20. The gate 40 remains in place during the melting process to confine the meltable form of material in the container 20 during the melting of the material, and when the desired temperature / stable / molten material is achieved, the gate 40 is activated. Then, as shown in FIG. 5, it is moved to the second (open) position, so that the material in the molten form can be moved into the mold 16 through the take-out path of the container 20. Accordingly, the configuration of the gate 40 is designed to provide uninterrupted movement between and to the first and second positions. The gate 40 can maintain the molten material in the induction coil field / melting zone 12 during the melting process (eg, with the plunger 14 on the opposite side or end of the container).

  According to one embodiment, the gate 40 can be configured to include a body and / or tip 46 that can be temperature controlled or cooled (eg, during the melting process). The gate can be cooled continuously, intermittently by conduction, convection, gas, or fluid. In one embodiment, as shown in FIG. 4, to adjust the temperature of the gate (or its tip) during the melting of the material received in the container (eg, to force the gate and / or its tip to cool). ) One or more temperature control tubes 48 may be provided in the gate and configured to allow liquid (eg, water or other fluid) to flow through it. This tube can help to prevent the gate or gate tip itself from overheating and melting. This tube can be connected to a cooling system configured to direct the flow of liquid in the container. The tube may include one or more inlets and outlets for liquid or fluid to flow through. The inlet and outlet of the tube can be configured in any number of ways and is not intended to be limiting. The number, arrangement and / or orientation of the tubes should not be limited. When the gate is in the first (closed) position and the ingot is accommodated during melting and / or when the induction source 26 is energized, the coolant or fluid is melting the meltable material. It can be configured to flow through the tube.

  6 and 7 each show a detailed perspective cross-sectional view of the gate 50 associated with the container 20 of the injection molding system 10 in a first position and a second position, respectively, according to another embodiment. In this embodiment, penetration and relative movement of the gate 50 is accomplished outside the sleeve 42. More specifically, the gate 50 is configured to enter the container 20 by extending through the transfer sleeve 30 and to enter the removal path of the container 20 so that at least its tip 54 is in the molten material. It is provided so that it may touch and hold this. The transfer sleeve 30 may include a seal, which maintains the melt zone 12 in a vacuum-tight state during use. The gate 50 is configured to move internally (forward and backward) to first and second positions. The gate 50 is a linear actuating gate attached to the container 20 at an angle β. More specifically, the gate 50 is attached obliquely on an axis BB arranged at an angle with respect to the axis of the container 20 (on the X axis). Therefore, the gate 50 is configured to move in an oblique direction with respect to the container between the first position and the second position in a straight line along the axis BB. In one embodiment, the gate 50 may be provided at an angle β of about 30 to about 90 degrees with respect to the sleeve 42 and / or the container 20. In one embodiment, the angle β is about 45 degrees. In one embodiment, the reach within the induction zone or melting zone 12 may vary depending on the installation angle of the gate 50. However, the mounting angle of the gate 50 is not intended to be limited.

  The gate 50 includes a body 52 and a contact surface (or tip) 54 configured to limit the movement of material that is molten and / or in a molten state during the melting process. This tip can be provided at an angle to the body. For example, in the first position, the gate tip 54 can be configured to extend perpendicular to the melted portion 24 of the container 20. 6 and 7, the contact surface or tip 54 is formed of a different material than the body 52 of the gate 54. For example, the body 52 can be made of a copper material and the tip 54 is made of a ceramic material. Any number of materials can be used to form the gate 50. The gate 50 is moved to the first position (FIG. 6) or the second position (FIG. 6) by the actuation mechanism or device 56 as described above. For example, the actuation mechanism 56 may include a pneumatic piston for moving the gate 50 toward or between the first and second positions. Prior to melting, the gate 50 can be placed (or moved as needed) in the first (closed) position of FIG. The gate 50 can be provided in the first position before or after the material to be melted (ingot 25) is inserted into the container 20. The gate 50 remains in place during the melting process to confine the meltable form of material in the container 20 during the melting of the material, and when the desired temperature / stable / molten material is achieved, the gate 50 is activated. Then, as shown in FIG. 7, the material is moved to the second (open) position, whereby the material in the molten form is moved through the take-out path of the container 20 through the transfer sleeve 30 and into the mold 16. It becomes possible. Accordingly, the configuration of the gate 50 is designed to provide uninterrupted movement between and to the first and second positions. The gate 50 can maintain the molten material in the induction coil field / melting zone 12 during the melting process (eg, with the plunger 14 on the opposite side or end of the container). This does not require reconfiguration or modification of the sleeve 42. The gate 50 maintains the simple design of the sleeve 42 (without the need to form a protrusion such as the protrusion 44 shown in FIG. 4) and provides an easily integrated actuation mechanism provided adjacent to the melting zone 12. Bring.

  8 and 9 show detailed cross-sectional views of the rotatable gate 60 associated with the container 20 in the injection molding system 10 in a first position and a second position, respectively, according to one embodiment. In this embodiment, the sleeve 42 includes a protrusion 45 extending from itself, in which at least a portion of the gate is configured to rotate and move to a first position and a second position. The protrusion 45 is disposed on the sleeve 42 so that the gate 60 can enter here through the body in the upper portion of the U-shaped container 20. More specifically, the gate 60 is a gate that operates by rotating. The protruding portion 45 of the sleeve 42 is vertically attached to an axis CC (on the Y axis) arranged perpendicular to the axis (on the X axis) of the container 20 (for example, 90 degrees with respect to the X axis). Angle). Therefore, the gate 60 is arranged to move about an axis (axis CC) perpendicular to the axis (X axis) of the container 20. The gate 60 includes an extension 62 that extends vertically through the protrusion 45 to actuate and move (ie, rotate) the body 64 to the first or second position. The body 64 is formed such that its walls contain molten material in the melting zone of the device, thereby preventing the molten material from moving or flowing out through the extraction path. The main body 64 also includes an opening 66 extending therethrough. For example, in one embodiment, the gate 60 may be in the shape of a ball valve. Opening 66 allows molten material to move from / to the molten portion 24 of the container, through the extraction path, into / into the mold 16. In one embodiment, the gate can be temperature controlled by a fluid.

  The body 64 of the gate 60 is configured to limit the movement of material that is melted and / or in a molten state during the melting process. The body 64 can be formed of the same or different material as the extension 62. Any number of materials can be used to form the gate 60. As described above, the gate 60 is moved to the first position (FIG. 8) or the second position (FIG. 8) by an operating mechanism or device (not shown). The actuating device is configured to move the extension while rotating about the axis CC. For example, before melting, the gate 60 can be placed (or moved as needed) in the first (closed) position of FIG. 8 so that the body 64 prevents movement of material. The gate 60 can be provided in the first position before or after the material to be melted (ingot 25) is inserted into the container 20. The gate 60 remains in place during the melting process, confining the meltable form of material in the container 20 during the melting of the material, and when the desired temperature / stable / molten material is achieved, the gate 60 is activated. Then, as shown in FIG. 9, it is rotated about the axis C-C and moved to the second (open) position, so that the material in the molten form is passed from the opening 66 through the take-out path of the container 20. , It can be moved into the mold 16. The gate 60 is configured to rotate 90 degrees from the first position to the second position. Thus, the configuration of the gate 60 is designed to provide uninterrupted movement between and to the first and second positions. This results in the use of a 90 degree rotational movement between the first position and the second position. Any seal used with this is unlikely to be compromised. The gate 60 can maintain the molten material within the induction coil field / melting zone 12 during the melting process (eg, with the plunger 14 on the opposite side or end of the container). In one embodiment, the tip of the plunger is dimensioned such that it can extend through the opening 66 to move the molten material into the mold 16. In one embodiment, the gate can be temperature controlled by a fluid.

  10 and 11 show detailed perspective views of another alternative gate 70 associated with the container 20 of the injection molding system 10 in a first position and a second position, respectively. In this embodiment, the sleeve 42 includes a protrusion 74 similar to the protrusion 44 shown in FIGS. 4 and 5, which extends from the sleeve and at least a portion of the gate is internally moved to a first position and a second position. It is possible to move while rotating. The protrusion 74 is positioned such that at least a portion of the gate 70 (eg, the tip 76) can move within the body of the container 20 and contact the melted portion 24 thereof. The protrusion 74 is disposed on the sleeve 42 so that the gate 70 can enter here through the body in the upper portion of the U-shaped container 20. More specifically, the gate 70 is a gate that rotates and is attached to the container 20 at an angle. The protrusion 74 of the sleeve 42 is attached obliquely on an axis DD arranged at an angle θ with respect to the axis of the container 20 (on the X axis). The gate 70 is disposed obliquely with respect to the container between the first position and the second position along the axis AA, but with respect to the container 20 between the first position and the second position. It is configured to rotate. In one embodiment, the protrusion 74 can be provided at an angle θ of about 30-90 degrees relative to the sleeve 42, whereby the gate 70 is positioned at a similar angle relative to the container 20. In another embodiment, the protrusion 74 is disposed at an angle θ of about 45 degrees with respect to the axis (X axis) of the container 20. However, the mounting angle of the gate 70 is not intended to be limited. In one embodiment, the gate can be temperature controlled by a fluid.

  The gate 70 includes a contact surface (or tip) 76 that is configured to limit the movement of molten and / or molten material during the melting process. This tip can be provided at an angle to the body. For example, in the first position, the gate tip 76 can be configured to extend perpendicular to the melted portion 24 of the container 20. However, after rotating the gate 70, the tip 76 can be configured to extend horizontally and parallel to the molten portion 24 of the container. This contact surface or tip 76 can be formed of a material similar to or different from the body 72 of the gate 70. Any number of materials can be used to form the gate 70. As described above, the gate 70 is moved to the first position (FIG. 10) or the second position (FIG. 11) by an operating mechanism or device (not shown). For example, the gate 70 can be placed (or moved as needed) in the first (closed) position of FIG. 10 prior to melting. The gate 70 can be provided in the first position before or after the material to be melted (ingot 25) is inserted into the container 20. The gate 70 remains in place during the melting process to confine the meltable form of material in the container 20 during the melting of the material and activate the gate 70 once the desired temperature / stable / molten material has been achieved. 11 and moved to the second (open) position, as shown in FIG. 11, so that the material in molten form can be moved into the mold 16 through the take-out path of the container 20. . The gate 70 is configured to rotate 180 degrees from the first position to the second position. Thus, the configuration of the gate 70 is designed to provide uninterrupted movement between and to the first and second positions. This provides for the use of 180 degrees of rotational motion between the first position and the second position. Any seal used with this is unlikely to be compromised. The gate 70 can maintain the molten material within the induction coil field / melting zone 12 during the melting process (eg, with the plunger 14 on the opposite side or end of the container). In one embodiment, the tip of the plunger is dimensioned so that it can extend under the tip 76 when the gate 70 is in the second position to move the molten material into the mold 16. In one embodiment, the gate can be temperature controlled by a fluid.

  12 and 13 show detailed cross-sectional views of the hinged gate 80 associated with the container 20 in the injection molding system 10 in a first position and a second position, respectively, according to another embodiment. In this embodiment, the sleeve 42 surrounds at least the molten portion 24 of the container 20. The gate 80 has a body 82 and a hinge 84 for rotating between the first and second positions. The gate 80 is configured to rotate with respect to the container 20. More specifically, the gate 80 is configured to be a gravity actuated gate (such as a flapper) that pivots within the induction zone and is held in the first (closed) position by its own weight. The gate 80 is moved or opened to its second position by the force with which the melt is pressed (as it advances through the removal part of the container after the melting process) or for example by the force of a push rod. Can do. Other methods and / or components, such as rods, magnets, and / or actuators, can be used in combination or alternatively to move the gate 80. In one embodiment, the gate can be temperature controlled by a fluid.

  As better shown in the overhead view of FIG. 14, the gate 80 can be attached to a portion 86 surrounding the container 20. Portion 86 can be disposed on a portion of vessel 20 adjacent to the location of induction coil 26, for example, whereby gate 80 is disposed to accommodate material within the induction zone of melting zone 12 during melting. Can do. Portion 86 can be formed or fabricated separately and attached to the container, or can be formed or fabricated as an integral part of the container body. Portion 86 can be configured to be surrounded by sleeve 42.

  Portion 86 includes at least one attachment region 88 for the hinge of gate 80. In the illustrated embodiment, the portion 86 is a circular piece with a mounting region 88 on either side of the U-shaped container that is configured to receive the ends of the hinges 84, respectively. Portion 86 is positioned on container 20 such that gate 80 can enter here through the body in the upper portion of U-shaped container 20. The attachment region 88 of the portion 86 is aligned to place the hinge 84 horizontally on an axis (Z-axis) that is perpendicular to the axis of the container 20 (on the X-axis) (eg, X 90 degrees to the axis and perpendicular to the Y axis). Therefore, the gate 80 is arranged to rotate or hinge about the Z axis with respect to the axis of the container 20 (on the X axis).

  The body 82 of the gate 80 is configured to limit the movement of material that is molten and / or in a molten state during the melting process. Any number of materials can be used to form the gate 80. Again, the gate 80 is a gravity operated gate that is provided in a first (closed) position by its own weight (eg, the weight of the body 82). Thus, the gate 80 is provided (eg, as a default) in a first position (FIG. 12) before melting and / or before the material to be melted (ingot 25) is inserted into the container 20. The gate 80 remains in place during the melting process to confine the meltable form of material in the container 20 during the melting of the material, and when the desired temperature / stable / molten material is achieved, the gate 80 is activated. As shown in FIG. 13, the material is in the molten form by rotating it around the Z axis and moving the material in the molten form from the opening 66 by moving the plunger 14 through the container 20. The container 20 can be moved into the mold 16 through the take-out path of the container 20. The melted material and / or force applied from the tip of the plunger 14 causes the gate 80 to rotate about the hinge 84 and flip upward toward the sleeve 42. The gate 80 is configured to rotate 90 degrees from the first position to the second position. Accordingly, the configuration of the gate 80 is designed to provide uninterrupted movement between and to the first and second positions. This provides for the use of a 90 degree rotational movement between the first position and the second position. This does not require reconfiguration or modification of the sleeve 42. The gate 80 can maintain the molten material within the induction coil field / melting zone 12 during the melting process (eg, with the plunger 14 on the opposite side or end of the container). The gate 80 maintains a simple design of the sleeve 42 (without the need to form a protrusion such as the protrusion 44 shown in FIG. 4) and provides an easy-to-integrate actuation mechanism provided adjacent to the melting zone 12. Bring.

  According to yet another embodiment (instead of having a plunger 14 acting as a single gate on one end side or take-off path of the container 20 and a gate on the other opposite end during the melting process). The dual gate system can be employed in an injection molding system such as device 10. 15 and 16 show an example of a gate mechanism that is both downstream and upstream of the induction coil. Shown are detailed cross-sectional views of a dual gate system associated with a container 20 of an injection molding system 10 in a first position and a second position, respectively, according to one embodiment. FIGS. 15 and 16 are similar to the design shown and described in FIGS. 4 and 5 and are disposed within the protrusion 44 of the sleeve 42 and move between a first position and a second position as described above. Including a gate 40 configured as described above. The description of gate 40 is here incorporated into the present embodiment and is therefore not repeated here for purposes of simplicity only. Further, FIGS. 15 and 16 show an additional gate 90 configured to restrict the opposite side of the container 20. This opposite side is an end side that in some embodiments can be used as an injection side, eg, for injecting material (eg, ingot 25) from charging port 18. The additional gate 90 is configured to contain a meltable form of material in the container during material melting instead of using the plunger 14 (or plunger tip) during the melting process. In this embodiment, the sleeve 42 further includes a second protrusion 92 extending from itself so that the additional gate 90 can move (stretched and pulled back) into the first and second positions. It is configured. The protrusion 92 is positioned such that at least a portion of the additional gate 90 can move into the body of the container 20 and contact its molten portion 24 at the opposite end of the container 20. The protrusion 92 is disposed on the sleeve 42 so that an additional gate 90 can enter the upper portion of the U-shaped container 20. More specifically, the additional gate 90 is a linear actuation gate attached at an angle to the container 20. The protruding portion 92 of the sleeve 42 is attached obliquely on an axis EE disposed at an angle σ with respect to the axis of the container 20 (on the X axis). Thus, the additional gate 90 moves in an oblique direction with respect to the container between the first position and the second position linearly along the axis EE in the same manner as indicated by the gate 40. It is configured as follows. In one embodiment, the protrusion 92 can be provided at an angle σ of about 15 to about 90 degrees with respect to the sleeve 42 such that the additional gate 90 is positioned at a similar angle with respect to the container 20. The However, the mounting angle of the additional gate 90 is not intended to be limited.

  Similar to the gate 40, the additional gate 90 includes a contact surface (or tip) 96 configured to limit the movement of the molten and / or molten material during the melting process. This tip can be provided at an angle to the body. For example, in the first position, the tip 96 of the additional gate 90 can be configured to extend perpendicular to the molten portion 24 of the container 20. The contact surface or tip 96 of this additional gate 90 can be formed of a similar material or a different material to its body. Any number of materials can be used to form the additional gate 90. The additional gate 90 is moved to the first position (FIG. 15) or the second position (FIG. 16) by an actuation mechanism or device (not shown) as described above. The gates 40 and 90 can be configured to move substantially together between their respective first and second positions. For example, an additional gate 40 can be placed (or moved as needed) in the first (closed) position of FIG. 4 prior to melting. The gate 40 can be provided in the first position before or after the material to be melted (ingot 25) is inserted into the container 20. On the other hand, when the ingot 25 is charged into the molten portion 24 of the container 20 using the charging port 18 and / or the plunger 14, the gate 90 is first (closed) after the ingot 25 is inserted as shown in FIG. Can be moved to a position. Alternatively, both gates 40 and 90 can be linearly moved to their respective first (closed) positions after material loading. Both the gate 40 and the additional gate 90 remain in the first position during the melting process to confine the meltable form of material in the container 20 and once the desired temperature / stable / molten material is achieved, the gate 40 and additional gate 90 are actuated to move to their respective second (open) positions as shown in FIG. 16, thereby allowing the material in molten form to pass through the take-out path of container 20 to mold 16 It becomes possible to move in. In another embodiment, the additional gate 90 is first moved to the second position so that the plunger 14 can be moved into the container 20, and once the gate 40 is moved to the second position, the molten material is moved. It can be constituted as follows. Nonetheless, once both gates are in the second position, the plunger 14 is configured to push the molten material through the removal path of the container 20 into the mold. Thus, the configuration of gate 40 and additional gate 90 is designed to provide uninterrupted movement between and to the first and second positions. Both the gate 40 and the additional gate 90 can maintain the molten material in the induction coil field / melting zone 12 during the melting process.

  15 and 16 illustrate the use of two gates similar to the configuration of the gate 40 shown in FIGS. 4 and 5, but any of the embodiments disclosed herein (eg, linear motion). Note that a rotating gate) can be applied and employed as an upstream gate, either alone or in addition to a downstream gate as shown. In addition, combinations of different gate designs can be used together.

  Accordingly, the gates described herein are intended as examples only. The configuration of gate attachment and / or movement is not limited.

  FIG. 17 illustrates a method for material melting and part molding of a part according to one embodiment of the present disclosure using the apparatus 10 shown in FIG. The device is designed to include a gate, a container 20 and a mold 16 as shown at 102. This gate is described herein to allow movement between a first position and a second position, respectively, to stop and flow the material flow in the container 20, as described above. Any configuration, or any other configuration. In general, the injection molding system / device 10 can be operated as follows: a meltable material (eg, an amorphous alloy or BMG in the form of a single ingot 25) is fed into a feed mechanism (eg, an input port 18). ) And is inserted and received in the melting zone 12 (enclosed by the induction coil 26) in the container 20, as shown at 104. At 106, a gate is provided in a first position to limit entry into the container removal path and to accommodate a meltable form of material within the container during material melting. As shown at 108, a vacuum may be applied to the gate and / or device 10 before or after charging the material to be melted. The “nozzle” stroke or plunger 14 of the injection molding device can be used to move this material into the molten portion 24 of the container 20 as needed. At 110, the material is heated by an induction process (ie, by supplying power to induction coil 26 by a power source). The injection molding apparatus controls the temperature via a closed loop or open loop system, thereby stabilizing the material at a specific temperature (eg, using a temperature sensor and controller). During the melting of the material, the gate is further configured to allow liquid (coolant liquid) to flow into the vessel 20 and / or any cooling tube of the gate (or gate tip) during heating / melting that is configured to maintain the device under vacuum. ). Once the desired temperature is reached and the meltable material is maintained in the molten state, heating using the induction coil 26 can be stopped. As shown at 112, the gate is moved from the first position to the second position so that the molten shaped material can be moved through the take-out path and into the mold, and the apparatus is then moved to the horizontal axis ( By moving in the horizontal direction (from right to left) along the X axis, injection of the molten material from the container 20 through the transfer sleeve 30 to the vacuum mold 16 is started. This can be controlled using the plunger 14, which can be actuated using a servo driven drive or a hydraulic drive. As shown at 114, 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, in order to mold a part with the mold 16, a molten material is injected into at least the mold cavity between the first plate and the second plate. As mentioned above, in some embodiments, this material can be an amorphous alloy material used to form bulk amorphous alloy parts. Once the mold cavity begins to fill, the vacuum pressure (via the vacuum line and vacuum source 38) is held at a predetermined pressure to “fill” the molten material into the remaining cavity area within the mold cavity and mold the material. be able to. After the molding process (eg, after about 10-15 seconds), as indicated at 116, the vacuum pressure is released at least in the mold 16 (if not the entire apparatus 10). The mold 16 is then opened to release the pressure and the parts are exposed to the atmosphere. At 118, the ejector mechanism is actuated to remove the solidified molded article from between at least the first plate and the second plate of the mold 16 via the actuating device. After this, the process can be started again. The mold 16 can be closed by moving at least the first and second plates toward each other such that the first and second plates are adjacent to each other. After pulling the plunger 14 back to the loading position, the melting zone 12 and the mold 16 can be evacuated by a vacuum source, allowing further material to be inserted and melted to form another part. After the gate is returned to the first position, the next ingot material can begin to melt.

  Accordingly, the embodiments disclosed herein illustrate the use of at least one gate in an exemplary injection system having an in-line melting system along a horizontal axis. By providing at least one gate on the downstream / unload side of the vessel, the material can be retained during melting, maintained in its molten state, and a steady state melting can be induced during the melting process. By holding the material adjacent to the induction zone formed by the induction coil during melting, a more uniform molded part can be obtained. Any of the gates disclosed herein can be used in combination with different gate designs. Any gate can be temperature controlled using a fluid. In addition, in a design that uses two gates to contain the material to be melted in the induction / melting zone, either or both of the gates can be temperature controlled with a fluid.

  Although not described in detail, the injection system of the present disclosure includes one or more sensors, flow meters, etc. (eg, for monitoring temperature, cooling water flow, etc.) and / or one or more controllers. Additional parts that are not limited to may be included. In addition, when under vacuum, to or adjacent to any number of parts to assist in melting and forming part of the molten material by substantially limiting or eliminating significant air exposure or leakage. 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 molded (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.

  The types and materials used for the gates in any of the embodiments shown herein are not intended to be limiting. Further, although only illustrated in FIG. 4, any of the gate (or tip) embodiments described herein shown in FIGS. 6-16 may be temperature controlled or cooled in some manner. Note that can be configured to:

  According to one embodiment, the gate is a copper temperature controlled gate. In another embodiment, the gate is a copper, temperature controlled gate that is coated with a coating of another material, such as ceramic. In another embodiment, the gate is a temperature controlled gate that is lined with a material such as ceramic.

  In another embodiment, the gate is a ceramic temperature controlled gate. In another embodiment, the gate is a ceramic temperature controlled gate that is coated with a coating of another material. In another embodiment, the gate is a temperature controlled gate lined with any material.

  However, the gate does not necessarily need to be temperature controlled. In yet another embodiment, the gate is a ceramic gate. In another embodiment, the gate is a ceramic gate that is coated with a coating material of another material. In another embodiment, the gate is lined with material.

  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 to implement the present disclosure. It will be apparent to those skilled in the art to obtain.

  It will be appreciated that the above and many other features and functions, or alternatives thereof, may be suitably combined with many other different systems / devices or applications. Various alternatives, changes, 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 .

Claims (20)

A container that includes a melting zone that is within the melting source and is configured to receive the material, and a removal path adjacent to the melting zone;
An apparatus including a gate disposed between the take-out path and the melting zone and configured to maintain a vacuum in the melting zone during melting of the material,
The gate further includes
A first position for confining the material within the melting zone during melting of the material ;
The through extraction path, device configured to move between a second position to allow movement of the horizontal direction of the material in the form melted.   An apparatus further comprising a plunger disposed at a second end of the melting zone opposite the first end;
  The plunger is
    During melting of the material, confine the material in the melting zone; and
    Configured to move the molten form of the material through the removal path; and
  The apparatus of claim 1, wherein the gate is located at the first end of the melting zone.   The apparatus of claim 1, further comprising an actuation mechanism associated with the gate to selectively move the gate between the first position and the second position.   The apparatus of claim 1, further comprising a hinge configured to allow rotation of the gate relative to the container.   Further comprising an additional gate disposed at a second end of the melting zone opposite the first end and configured to confine the material in the melting zone during melting of the material;
  The apparatus of claim 1, wherein the gate is located at the first end of the melting zone.   The apparatus of claim 1, further comprising an induction coil surrounding the melting zone and configured to melt the material.   The apparatus of claim 1, wherein the gate further comprises one or more temperature control tubes configured to flow a liquid therein to adjust the temperature of the gate during melting of the material.   A method of melting a material,
    Placing the material in the melting zone of the container, said melting zone being within the melting source; and
    Placing the gate in the first position;
    Applying a vacuum to at least the melting zone;
    Melting the material;
    Confining the material in the melting zone at the gate during melting of the material;
    Moving the gate from the first position to the second position so as to allow horizontal movement of the material through an extraction path adjacent to the melting zone.   Disposing a plunger at the second end of the melting zone opposite the first end of the melting zone;
  Confining the material in the melting zone with the plunger and the gate during melting of the material;
  The method further comprises moving the material through the removal path by moving the plunger through at least a portion of the melting zone after moving the gate to the second position. 9. The method according to 8.   9. The method of claim 8, further comprising flowing a liquid through one or more temperature control tubes in the gate to adjust the temperature of the gate during the operation of melting the material.   Placing an additional gate at the second end of the melting zone opposite the first end of the melting zone;
  Further comprising confining the material in the melting zone with a first gate and a second gate during melting of the material;
  The method of claim 8, wherein the gate is disposed at the first end of the melting zone.   9. The method of claim 8, wherein the melting source is an induction coil and the operation of melting the material includes energizing the induction coil to melt the material.   The method of claim 8, wherein the material is an amorphous alloy.   Moving the material through the extraction path into a mold;
  Releasing the vacuum;
  Solidifying the material in the mold to form a part;
  9. The method of claim 8, further comprising removing the part from the mold.   9. The method of claim 8, wherein the operation of confining the material in the melting zone comprises contacting the material with the gate after the material is melted.   The induction coil defines an internal volume;
  The method of claim 12, wherein confining the material within the melting zone comprises confining the material within the interior volume.   The apparatus of claim 1, wherein the gate is configured to contact the material after the material is melted.   The apparatus of claim 1, wherein the gate comprises a material insensitive to radio frequency magnetic fields.   The gate is
    A base containing copper;
    2. A device according to claim 1, comprising a ceramic material and a tip configured to contact the material after the material is melted.   The induction source includes an induction coil defining an internal volume; and
  The apparatus of claim 6, wherein the gate is configured to confine the material within the internal volume while the gate is in the first position.

Images