WO2013070240A1 - Tige de piston double pour transport contrôlé dans un système de moulage par injection - Google Patents

Tige de piston double pour transport contrôlé dans un système de moulage par injection Download PDF

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Publication number
WO2013070240A1
WO2013070240A1 PCT/US2011/060382 US2011060382W WO2013070240A1 WO 2013070240 A1 WO2013070240 A1 WO 2013070240A1 US 2011060382 W US2011060382 W US 2011060382W WO 2013070240 A1 WO2013070240 A1 WO 2013070240A1
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WIPO (PCT)
Prior art keywords
plunger rod
mold
molten material
melt zone
move
Prior art date
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PCT/US2011/060382
Other languages
English (en)
Inventor
Christopher D. Prest
Joseph C. POOLE
Quoc Tran Pham
Sean O'KEEFFE
Joseph W. STEVICK
Theodore A. WANIUK
Original Assignee
Crucible Intellectual Property, Llc
Apple Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by Crucible Intellectual Property, Llc, Apple Inc. filed Critical Crucible Intellectual Property, Llc
Priority to CN201180076222.6A priority Critical patent/CN104039480B/zh
Priority to PCT/US2011/060382 priority patent/WO2013070240A1/fr
Priority to JP2014541023A priority patent/JP5723078B2/ja
Priority to US13/630,900 priority patent/US8813818B2/en
Publication of WO2013070240A1 publication Critical patent/WO2013070240A1/fr
Priority to US14/467,478 priority patent/US9302320B2/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2053—Means for forcing the molten metal into the die using two or more cooperating injection pistons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
    • B22D17/04—Plunger machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/14—Machines with evacuated die cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/203—Injection pistons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2038—Heating, cooling or lubricating the injection unit
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2069—Exerting after-pressure on the moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/2236—Equipment for loosening or ejecting castings from dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/28—Melting pots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/32—Controlling equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/06—Special casting characterised by the nature of the product by its physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum

Definitions

  • the molten material has to be retained in the melt zone so that it does not mix too much or cool too quickly.
  • One aspect of this disclosure provides an injection molding system having a melt zone configured to melt meltable material received therein and a dual plunger rod assembly.
  • the dual plunger rod assembly includes a first plunger rod and a second plunger rod, at least the first plunger rod being configured to move molten material from the melt zone and into a mold.
  • the dual plunger rod assembly and the melt zone are provided in-line.
  • the first and second plunger rods are configured to move along a longitudinal axis, such that
  • Yet another aspect provides a method of molding an object from meltable material using an injection molding system.
  • the system includes a melt zone configured to melt the meltable material received therein and a plunger rod assembly having a first plunger rod and a second plunger rod, the assembly configured to move molten material from the melt zone and into a mold.
  • the method includes: melting a meltable material in the melt zone, and moving the molten material from the melt zone and into the mold, and the first plunger rod and the second plunger rod are configured to contain the molten material therebetween during movement of the molten material towards the mold.
  • a polymer resin means one polymer resin or more than one polymer resin. Any ranges cited herein are inclusive.
  • the terms “substantially” and “about” used throughout this Specification are used to describe and account for smal l fluctuations. For example, they can refer to less than or equal to ⁇ 5%, such as less than or equal to ⁇ 2%, such as less than or equal to ⁇ 1 %, such as less than or equal to ⁇ 0.5%, such as less than or equal to ⁇ 0.2%, such as less than or equal to ⁇ 0. 1 %, such as less than or equal to ⁇ 0.05%.
  • BMG bulk metal lic glasses
  • Amorphous alloys have many superior properties than their crystalline counterparts. However, if the cooling rate is not sufficiently high, crystals may form inside the alloy during cool ing, so that the benefits of the amorphous state can be lost. For example, one challenge with the fabrication of bulk amorphous alloy parts is partial crystallization of the parts due to either slow cooling or impurities in the raw alloy material.
  • Figure 1 shows a viscosity- temperature graph of an exemplary bulk solidifying amorphous alloy, from the VlT-001 series of Zr-Ti-Ni-Cu-Be family manufactured by Liquidmeial Technology. It should be noted that there is no clear l iquid/solid transformation for a bulk sol idifying amorphous metal during the formation of an amorphous solid.
  • the molten alloy becomes more and more viscous with increasing undercooling until it approaches sol id form around the glass transition temperature. Accordingly, the temperature of solidification front for bulk solidifying amorphous alloys can be around glass transition temperature, where the al loy wil l practically act as a solid for the purposes of pulling out the quenched amorphous sheet product.
  • a "melting temperature" Tm may be defined as the
  • Tnose is the critical crystallization temperature Tx where crystallization is most rapid and occurs in the shortest time scale.
  • 00020 The supercooled liquid region, the temperature region between Tg and Tx is a manifestation of the extraordinary stability against crystallization of bulk solidification alloys. In this temperature region the bulk solidi fying alloy can exist as a high viscous liquid. The viscosity of the bulk solidifying alloy in the supercooled liquid region can vary between l O 12 Pa s at the glass transition temperature down to 10 5 Pa s at the crystallization temperature, the high temperature limit of the supercooled liquid region. Liquids with such viscosities can undergo substantial plastic strain under an applied pressure. The embodiments herein make use of the large plastic formabil ity in the supercooled liquid region as a forming and separating method.
  • Tx is shown as a dashed line as Tx can vary from close to Tm to close to Tg.
  • the SPF process does not require fast cooling to avoid crystal lization during cooling. Also, as shown by example trajectories (2), (3) and (4), the SPF can be carried out with the highest temperature during SPF being above Tnose or below Tnose, up to about Tm. If one heats up a piece of amorphous alloy but manages to avoid hitting the TTT curve, you have heated "between Tg and Tm", but one would have not reached Tx.
  • a phase can refer to a solid solution, which can be a binary, tertiary, quaternary, or more, solution, or a compound, such as an intermetallic compound.
  • amorphous phase is distinct from a crystalline phase.
  • any suitable nonmetal elements can be used.
  • the alloy (or "alloy composition") can comprise multiple nonmetal elements, such as at least two, at least three, at least four, or more, nonmetal elements.
  • a nonmetal element can be any element that is found in Groups 1 3- 1 7 in the Periodic Table.
  • a nonmetal element can be any one of F, CI, Br, I, At, O, S, Se, Te, Po, N, P, As, Sb, Bi, C, Si, Ge, Sn, Pb, and B.
  • the al loy can comprise a boride, a carbide, or both .
  • a transition metal element can be any of 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, dubnium, seaborgium, bohrium, hassium, meitnerium, ununnilium, unununium, and ununbium.
  • a BMG containing a transition metal element can have at least one of Sc , Y, La, Ac , Ti , Zr, H f, V, Nb, Ta, Cr, Mo, W, Mn, Tc , Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, Zn, Cd, and Hg.
  • the alloy composition can comprise multiple transitional metal elements, such as at least nvo, at least three, at least four, or more, transitional metal elements.
  • solution refers to a solid form of a solution.
  • solution refers to a mixture of two or more substances, which may be solids, liquids, gases, or a combination of these. The mixture can be homogeneous or heterogeneous.
  • mixture is a composition of two or more substances that are combined with each other and are generally capable of being separated. Generally, the two or more substances are not chemically combined wi th each other.
  • the alloy composition described herein can be fully alloyed.
  • an "alloy" refers to a homogeneous mixture or solid solution of two or more metals, the atoms of one replacing or occupying interstitial positions between the atoms of the other; for example, brass is an alloy of zinc and copper.
  • An alloy in contrast to a composite, can refer to a partial or complete solid solution of one or more elements in a metal matrix, such as one or more compounds in a metallic matrix .
  • the term alloy herein can refer to both a complete solid solution alloy that can give single sol id phase
  • An alloy composition described herein can refer to one comprising an alloy or one comprising an alloy-containing composite.
  • an "amorphous” or “non-crystalline solid” is a solid that lacks lattice periodicity, which is characteristic of a crystal.
  • an “amorphous solid” includes "glass” which is an amorphous solid that softens and transforms into a liquid-like state upon heating through the glass transition.
  • amorphous materials lack the long-range order characteristic of a crystal, though they can possess some short-range order at the atomic length scale due to the nature of chemica l bonding.
  • the distinction between amorphous solids and crystall ine solids can be made based on lattice periodicity as determined by structural characterization techniques such as x-ray diffraction and transmission electron microscopy.
  • order designate the presence or absence of some symmetry or correlation in a many-particle system.
  • long-range order and “short- range order” distinguish order in materials based on length scales.
  • lattice periodicity a certain pattern (the arrangement of atoms in a unit cell) is repeated again and again to form a translationally invariant ti ling of space . This is the defining property of a crystal . Possible symmetries have been classified in 14 Bravais lattices and 230 space groups.
  • Lattice periodicity implies long-range order. If only one unit cell is known, then by virtue of the translational symmetry it is possible to accurately predict all atomic positions at arbitrary distances. The converse is generally true, except, for example, in quasi-crystals that have perfectly deterministic ti lings but do not possess lattice periodicity. 100037) Long-range order characterizes physical systems in which remote portions of the same sample exhibit correlated behavior. This can be expressed as a correlation function, namely the spin-spin correlation function: 1 ) — ⁇ s(x , s(x )) .
  • a system can be said to present quenched disorder when some parameters defining its behavior are random variables that do not evolve with time (i.e., they are quenched or frozen) - e.g. , spin glasses. It is opposite to annealed disorder, where the random variables are allowed to evolve themselves.
  • Embodiments herein include systems comprising quenched disorder.
  • the alloy described herein can be crystalli ne, partially crystalline, amorphous, or substantially amorphous.
  • the al loy sample/specimen can include at least some crystallinity, with grains/crystals having sizes in the nanometer and/or micrometer ranges.
  • the alloy can be substantially amorphous, such as fully amorphous.
  • the alloy composition is at least substantially not amorphous, such as being substantially crystalline, such as being entirely crystalline.
  • the presence of a crystal or a plurality of crystals in an otherwise amorphous alloy can be construed as a "crystall ine phase" therein.
  • the degree of crystal l inity (or "crystall inity" for short in some embodiments) of an alloy can refer to the amount of the crystalline phase present in the alloy.
  • the degree can refer to, for example, a fraction of crystals present in the alloy.
  • the fraction can refer to volume fraction or weight fraction, depending on the context.
  • amorphous alloy is an alloy having an amorphous content of more than 50% by volume, preferably more than 90% by volume of amorphous content, more preferably more than 95% by volume of amorphous content, and most preferably more than 99% to almost 100% by volume of amorphous content. Note that, as described above, an alloy high in amorphicity is equivalently low in degree of crystal linity.
  • An “amorphous metal” is an amorphous metal material with a disordered atomic-scale structure. In contrast to most metals, which are crystalline and therefore have a highly ordered arrangement of atoms, amorphous alloys are non-crystalline.
  • amorphous metals are commonly referred to as “metall ic glasses” or “glassy metals.”
  • a bulk metallic glass can refer to an alloy, of which the microstructure is at least partially amorphous.
  • Amorphous alloys can be a single class of materials, regardless of how they are prepared.
  • Amorphous metals can be produced through a variety of quick-cooling methods. For instance, amorphous metals can be produced by sputtering molten metal onto a spinning metal disk. The rapid cool ing, on the order of millions of degrees a second, can be too fast for crystals to form, and the material is thus "locked in" a glassy state. Also, amorphous metals/alloys can be produced with critical cool ing rates low enough to allow formation of amorphous structures in thick layers - e.g., bulk metallic glasses.
  • BMG bulk metallic glass
  • BAA bulk amorphous alloy
  • BAA bulk amorphous alloy
  • BMA bulk amorphous alloy
  • bulk solidifying amorphous alloy refers to amorphous alloys having the smal lest dimension at least in the mill imeter range.
  • the dimension can be at least about 0.5 mm, such as at least about 1 mm, such as at least about 2 mm, such as at least about 4 mm, such as at least about 5 mm, such as at least about 6 mm, such as at least about 8 mm, such as at least about 10 mm, such as at least about 12 mm.
  • a BMG can 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. In some embodiments, a BMG can have at least one dimension at least in the meter range.
  • a BMG can take any of the shapes or forms described above, as related to a metallic glass. Accordingly, a BMG described herein in some embodiments can be different from a thin film made by a conventional deposition technique in one important aspect - the former can be of a much larger dimension than the latter.
  • Amorphous metals can be an alloy rather than a pure metal .
  • the alloys may contain atoms of signi ficantly different sizes, leading to low free volume (and therefore having viscosity up to orders of magnitude higher than other metals and alloys) in a molten state.
  • the viscosity prevents the atoms from moving enough to form an ordered lattice.
  • the material structure may result in low shrinkage during cooling and resistance to plastic deformation.
  • the absence of grain boundaries, the weak spots of crystalline materials in some cases, may, for example, lead to better resistance to wear and corrosion.
  • amorphous metals while technically glasses, may also be much tougher and less brittle than oxide glasses and ceramics.
  • Thermal conductivity of amorphous materials may be lower than that of their crystalline counterparts.
  • the alloy may be made of three or more components, leading to complex crystal units with higher potential energy and lower probability of formation.
  • the formation of amorphous alloy can depend on several factors: the composition of the components of the alloy; the atomic radius of the components (preferably with a signi ficant difference of over 12% to achieve high packing density and low free volume); and the negative heat of mixing the combination of components, inhibiting crystal nucleation and prolonging the time the molten metal stays in a supercooled state.
  • Amorphous alloys for example, of boron, silicon, phosphorus, and other glass formers with magnetic metals (iron, cobalt, nickel) may be magnetic, with low coercivity and high electrical resistance.
  • the high resistance leads to low losses by eddy currents when subjected to alternating magnetic fields, a property useful, for example, as transformer magnetic cores.
  • Amorphous alloys may have a variety of potentially useful properties. In particular, they tend to be stronger than crystalline alloys of similar chemical composition, and they can sustain larger reversible ("elastic") deformations than crystalline alloys.
  • Amorphous metals derive their strength directly from their non-crystalline structure, which can have none of the defects (such as dislocations) that l imit the strength of crystalline alloys.
  • VitreloyTM amorphous metal
  • VitreloyTM has a tensile strength that is almost twice that of high-grade titanium.
  • metallic glasses at room temperature are not ductile and tend to fail suddenly when loaded in tension, which l imits the material applicability in rel iability-critical applications, as the impending failure is not evident. Therefore, to overcome this challenge, metal matrix composite materials having a metallic glass matrix containing dendritic particles or fibers of a ductile crystal line metal can be used.
  • a BMG low in element(s) that tend to cause embitterment e.g. , Ni
  • a Ni-free BMG can be used to improve the ductility of the BMG.
  • a material can have an amorphous phase, a crystalline phase, or both.
  • the amorphous and crystalline phases can have the same chemical composition and differ only in the microstructure - i.e. , one amorphous and the other crystal line.
  • Microstructure in one embodiment refers to the structure of a material as revealed by a microscope at 25X magni fication or higher.
  • the two phases can have di fferent chemical compositions and microstructures.
  • a composition can be partially amorphous, substantially amorphous, or completely amorphous.
  • the degree of amorphicity can be measured by fraction of crystals present in the alloy.
  • the degree can refer to volume fraction of weight fraction of the crystalline phase present in the alloy.
  • a partially amorphous composition can refer to a composition of at least about 5 vol% of which is of an amorphous phase, such as at least about 10 vol%, such as at least about 20 vol%, such as at least about 40 vol%, such as at least about 60 vol%, such as at least about 80 vol%, such as at least about 90 vol%.
  • the terms "substantially” and “about” have been defined elsewhere in this application.
  • a composition that is at least substantially amorphous can refer to one of which at least about 90 vol% is amorphous, 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 99.8 vol%, such as at least about 99.9 vol%.
  • a substantially amorphous composition can have some incidental, insigni ficant amount of crystalline phase present therein.
  • an amorphous alloy composition can be homogeneous with respect to the amorphous phase.
  • a substance that is uni form in composition is homogeneous. This is in contrast to a substance that is heterogeneous.
  • composition refers to the chemical composition and/or microstructure in the substance.
  • a substance is homogeneous when a volume of the substance is divided in half and both halves have substantially the same composition.
  • a particulate suspension is homogeneous when a volume of the particulate suspension is divided in half and both halves have substantially the same volume of particles.
  • Another example of a homogeneous substance is air where different ingredients therein are equally suspended, though the partic les, gases and l iquids in air can be analyzed separately or separated from air.
  • a composition that is homogeneous with respect to an amorphous alloy can refer to one having an amorphous phase substantially uniformly distributed throughout its microstructure.
  • the composition macroscopically comprises a substantially uniformly distributed amorphous alloy throughout the composition.
  • the composition can be of a composite, having an amorphous phase having therein a non-amorphous phase.
  • the non-amorphous phase can be a crystal or a plurality of crystals.
  • the crystals can be in the form of particulates of any shape, such as spherical, ellipsoid, wire-like, rod-l ike, sheet-like, flake-like, or an irregular shape. In one embodiment, it can have a dendritic form.
  • an at least partially amorphous composite composition can have a crystalline phase in the shape of dendrites dispersed in an amorphous phase matrix; the dispersion can be uniform or non-uni form, and the amorphous phase and the crystal line phase can have the same or a different chemical composition. In one embodiment, they have substantially the same chemical composition. In another embodiment, the crystalline phase can be more ductile than the BMG phase.
  • the methods described herein can be applicable to any type of amorphous alloy.
  • the amorphous alloy described herein as a constituent of a composition or article can be of any type.
  • the amorphous al loy can comprise the element Zr, H f, Ti, Cu, Ni , Pt, Pd, Fe, Mg, Au, La, Ag, Al, Mo, Nb, Be, or combinations thereof.
  • the alloy can include any combination of these elements in its chemical formula or chemical composition.
  • the elements can be present at di fferent weight or volume percentages.
  • the alloy can also be free of any of the aforementioned elements to suit a particular purpose.
  • the alloy, or the composition including the alloy can be substantially free of nickel, aluminum, titanium, beryllium, or combinations thereof.
  • the alloy or the composite is completely free of nickel, aluminum, titanium, beryllium, or combinations thereof.
  • a is in the range of from 40 to 75, b is in the range of from 5 to 50, and c is in the range of from 5 to 50 in atomic percentages.
  • the alloy can also have the formula (Zr, Ti) a (Ni, Cu) b (Be) c , wherein a, b, and c each represents a weight or atomic percentage.
  • a is in the range of from 45 to 65, b is in the range of from 7.5 to 35, and c is in the range of from 10 to 37.5 in atomic percentages.
  • the alloy can have the formula (Zr) a (Nb, Ti)b(Ni, Cu) c (A l )a, wherein a, b, c, and d each represents a weight or atomic percentage.
  • a is in the range of from 45 to 65
  • b is in the range of from 0 to 10
  • c is in the range of from 20 to 40
  • d is in the range of from 7.5 to 1 5 in atomic percentages.
  • One exemplary embodiment of the aforedescribed alloy system is a Zr-Ti-Ni-Cu-Be based amorphous alloy under the trade name VitreloyTM, such as Vitreloy- 1 and Vitreloy- 101 , as fabricated by Liquidmetal Technologies, CA, USA.
  • VitreloyTM such as Vitreloy- 1 and Vitreloy- 101 , as fabricated by Liquidmetal Technologies, CA, USA.
  • the amorphous alloys can also be ferrous alloys, such as (Fe, Ni , Co) based alloys.
  • ferrous alloys such as (Fe, Ni , Co) based alloys.
  • Examples of such compositions are disclosed in U.S. Patent Nos. 6,325,868; 5,288,344; 5,368,659; 5,61 8,359; and 5,735 ,975, Inoue et a!. , Appl. Phys. Lett., Volume 7 1 , p 464 ( 1997), Shen el al. , Mater. Trans. , JI M, Volume 42, p 2 1 36 (2001 ), and Japanese Patent Application No. 2001 26277 (Pub. No. 2001 3032 1 8 A).
  • One exemplary composition is is.
  • Another iron-based alloy system that can be used in the coating herein is disclosed in U.S. Patent Application
  • the amorphous metal contains, for example, manganese ( 1 to 3 atomic %), yttrium (0. 1 to 10 atomic %), and silicon (0.3 to 3. 1 atomic %) in the range of composition given in parentheses; and that contains the fol lowing elements in the specified range of composition given in parentheses: chromium ( 1 5 to 20 atomic %), molybdenum (2 to 1 5 atomic %), tungsten ( I to 3 atomic %), boron (5 to 1 6 atomic %), carbon (3 to 16 atomic %), and the balance iron.
  • the aforedescribed amorphous al loy systems can further include additional elements, such as additional transition metal elements, including Nb, Cr, V, and Co.
  • the additional elements can be present at less than or equal to about 30 wt%, such as less than or equal to about 20 wt%, such as less than or equal to about 10 wt%, such as less than or equal to about 5 wt%.
  • the additional, optional element is at least one of cobalt, manganese, zirconium, tantalum, niobium, tungsten, yttrium, titanium, vanadium and hafnium to form carbides and further improve wear and corrosion resistance.
  • Further optional elements may include phosphorous, germanium and arsenic, totaling up to about 2%, and preferably less than 1 %, to reduce melting point. Otherwise incidental impurities should be less than about 2% and preferably 0.5%.
  • a composition having an amorphous alloy can inc lude a small amount of impurities.
  • the impurity elements can be intentionally added to modify the properties of the composition, such as improving the mechanical properties (e.g., hardness, strength, fracture mechanism, etc.) and/or improving the corrosion resistance.
  • the impurities can be present as inevitable, incidental impurities, such as those obtained as a byproduct of processing and manufacturing.
  • the impurities can be less than or equal to about 10 wt%, such as about 5 wt%, such as about 2 wt%, such as about I wt%, such as about 0.5 wt%, such as about 0. 1 wt%. In some embodiments, these percentages can be volume percentages instead of weight percentages.
  • sample/composition consists essentially of the amorphous alloy (with only a small incidental amount of impurities).
  • the composition includes the amorphous alloy (with no observable trace of impurities).
  • the final parts exceeded the critical casting thickness of the bulk solidi fying amorphous alloys.
  • An electronic device herein can refer to any electronic device known in the art.
  • it can be a telephone, such as a cell phone, and a land-line phone, or any communication device, such as a smart phone, including, for example an iPhoneTM, and an electronic email sending/receiving device.
  • It can be a part of a display, such as a digital display, a TV monitor, an electronic-book reader, a portable web-browser (e.g. , iPadTM), and a computer monitor.
  • FIG. 3 il lustrates a schematic diagram of such an exemplary system.
  • the system illustrated in the Figures is a system al igned along a horizontal ax is, it should be understood and within the scope of this disclosure that similar features may be provided on a vertically positioned injection molding system (e.g. , wherein there is vertical movement of material into a mold), and that herein disclosed features can be applied to a vertical system.
  • the material e.g., ingot
  • the material may be inserted in a horizontal direction into vessel 20 by plunger 14, or may be inserted in a horizontal direction from the mold side of the injection system 10 by plunger 22 (e.g. , through mold 16 and/or through an optional transfer sleeve 30 and into vessel 20).
  • the meltable material can be provided into melt zone 12 in other manners and/or using other devices (e.g., through an opposite end of the injection system).
  • Melt zone 12 inc ludes a melting mechanism configured to receive meltable material and to hold the material as it is heated to a molten state.
  • injection system 10 includes a heat source that is used to heat and melt the meltable material. At least a melting portion of the vessel , if not substantially the entire body itself, is configured to be heated such that the material received therein is melted. Heating is accomplished using, for example, an induction source 26 positioned within melt zone 12 that is configured to melt the meltable material.
  • induction source 26 is positioned adjacent vessel 20.
  • induction source 26 may be in the form of a coil positioned in a helical pattern substantial ly around a length of the vessel body. Accordingly, vessel 20 is configured to inductively melt a meltable material (e.g.
  • Induction coil 26 is configured to heat up and melt any material that is contained by vessel 20 without melting and wetting vessel 20.
  • Induction coil 26 emits radiofrequency (RF) waves towards vessel 20.
  • RF radiofrequency
  • coi l 26 surrounding vessel 20 may be configured to be positioned in a horizontal direction along a horizontal axis (e.g. , X axis).
  • the ejection mechanism may be associated with or connected to an actuation mechanism (not shown) that is configured to be actuated in order to eject the molded material or part (e.g., after first and second parts 32 and 34 are moved horizontally and relatively away from each other, after vacuum pressure between the plates 32 and 34 is released).
  • the ejector pins may be configured to push molded material away from cavity 44, for example.
  • second plunger rod 22 of dual plunger assembly is configured to eject a molded object from mold 16. Second plunger rod 22 may be provided to eject a molded object in addition to or in place of an ejection mechanism.
  • first and second plunger rods 14 and 22 of the dual plunger assembly as described above are configured to at least move molten material from melt zone 12 and into mold 16 while retaining or containing the molten material therebetween and during movement of the molten material in the horizontal direction.
  • the second plunger rod 22 is configured to move in a horizontal direction (e.g. , from left to right, as indicated by arrow H) to eject a molded object 100 from second mold plate 34. At least its tip 36 is used to apply pressure to the molded object 100 so that it is removed from within the mold 16.
  • the second plunger rod 22 (or first plunger rod 14) can be used in addition to an ejection mechanism or as an alternative option to an ejection mechanism.
  • the first plunger rod 14 may be provided in a stationary position relative to the mold 16.
  • the heating using induction coil 26 can be stopped and the machine will then begin the injection of the molten material from vessel 20, through transfer sleeve 30, and into vacuum mold 16 by moving in a horizontal direction (from right to left) along the horizontal axis.
  • the movement of the molten material is controlled using both plungers 14 and 22 (e.g. , which can be activated using a servo-driven drive or a hydraulic drive).
  • the mold 16 is configured to receive molten material through an inlet and configured to mold the molten material under vacuum. That is, the molten material is injected into a cavity between the at least first and second plates to mold the part in the mold 16.
  • the herein disc losed embodiments i llustrate an exemplary injection system that has its melting system in-line with a dual plunger rod assembly configured for movement along a horizontal axis during the melting and molding process.
  • the system and/or i ts parts do not need to be limited to being positioned for movement of material in a horizontal direction, however.
  • the dual plunger rod assembly can be configured to move along any longitudinal axis in a longitudinal direction.
  • the dual plunger rod assembly and melt zone can be provided along a vertical axis (e.g. , Y-axis, not shown), so that plunger rods 14 and 22 and material are moved from melt zone 1 2 and into mold 16 in a vertical direction.
  • the molten material wil l arrive at the mold at a higher temperature, and that during molding the material is less subject to defects based on the quenching rate of the mold.
  • maintaining a higher temperature and reducing the rate at which such molten material cools as it travels towards the mold improves its glass formability (before quenching quickly in the mold).
  • the surface area can be can kept relatively the same, as well as the temperature.
  • the dimensions and materials used for the plunger rods 14 and 22 should not be limited. Any number of materials can be used to form the rods and/or the tips 24 and 36 thereof. Different materials may be used to form different parts.
  • the tips 24 and 36 may be formed of one or more materials. In an embodiment, at least the tips of both plunger rods 14 and 22 have a similar diameter. In another embodiment, plunger rod 14 and plunger rod 22 have different diameters. In another embodiment, one or more of the rods 14 and/or 22 may include a telescopic body. In yet another embodiment, one plunger may contain another plunger therein.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un système de moulage par injection qui comprend une première tige de piston et une seconde tige de piston conçues pour déplacer ou transporter de la matière fondue d'une zone de fonte vers un moule. Les première et seconde tiges de piston sont conçues pour réguler et contenir entre elles la matière fondue tout en la déplaçant. La seconde tige de piston peut également être positionnée par rapport au moule pour appliquer une pression sur un côté du moule lorsque la première tige de piston pousse de la matière fondue dans le moule sur un côté opposé pour forcer la matière à entrer dans la cavité du moule. La seconde tige de piston peut en outre être utilisée pour éjecter un objet moulé (amorphe en masse) du moule. Les tiges peuvent se déplacer dans une direction longitudinale (par exemple horizontalement) entre la zone de fonte et le moule le long d'un axe longitudinal.
PCT/US2011/060382 2011-11-11 2011-11-11 Tige de piston double pour transport contrôlé dans un système de moulage par injection WO2013070240A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
CN201180076222.6A CN104039480B (zh) 2011-11-11 2011-11-11 用于注塑系统中受控输送的双柱塞杆
PCT/US2011/060382 WO2013070240A1 (fr) 2011-11-11 2011-11-11 Tige de piston double pour transport contrôlé dans un système de moulage par injection
JP2014541023A JP5723078B2 (ja) 2011-11-11 2011-11-11 射出成形システムにおける制御された移送のためのデュアルプランジャロッド
US13/630,900 US8813818B2 (en) 2011-11-11 2012-09-28 Melt-containment plunger tip for horizontal metal die casting
US14/467,478 US9302320B2 (en) 2011-11-11 2014-08-25 Melt-containment plunger tip for horizontal metal die casting

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2011/060382 WO2013070240A1 (fr) 2011-11-11 2011-11-11 Tige de piston double pour transport contrôlé dans un système de moulage par injection

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WO2013070240A1 true WO2013070240A1 (fr) 2013-05-16

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US20150202684A1 (en) * 2012-02-29 2015-07-23 Heishin Techno Werke Ltd. Method for molding amorphous alloy, and molded object prouduced by said molding method
EP3075465A4 (fr) * 2013-11-30 2016-11-30 Inst Metal Res Chinese Acad Sc Dispositif et procédé de formage par coulée de composant d'alliage amorphe

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US9628202B2 (en) 2015-02-27 2017-04-18 Rohde & Schwarz Gmbh & Co. Kg Testing front end modules, testing methods and modular testing systems for testing electronic equipment
US10102092B2 (en) * 2015-03-02 2018-10-16 Rohde & Schwarz Gmbh & Co. Kg Testing front end module, testing methods and modular testing systems for testing electronic equipment
JP6187511B2 (ja) * 2015-03-12 2017-08-30 トヨタ自動車株式会社 ダイカスト鋳造用射出装置
CN111112572B (zh) * 2018-10-31 2022-06-14 惠州比亚迪实业有限公司 非晶合金压铸成型的模具、装置、方法和非晶合金压铸件
EP3827913A1 (fr) * 2019-11-29 2021-06-02 Heraeus Deutschland GmbH & Co KG Système de moulage par injection pour moulage par injection de métaux amorphes
CN110918925B (zh) * 2019-12-02 2021-11-30 无锡广硕精密机械有限公司 一种铝合金铸造设备及其铸造工艺
CN111069566B (zh) * 2020-01-03 2021-12-17 上海交通大学 一种铝/镁合金半固态浆料原位制备与成型方法及装置
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EP3075465A4 (fr) * 2013-11-30 2016-11-30 Inst Metal Res Chinese Acad Sc Dispositif et procédé de formage par coulée de composant d'alliage amorphe

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US20140090799A1 (en) 2014-04-03
US8813818B2 (en) 2014-08-26
CN104039480A (zh) 2014-09-10
CN104039480B (zh) 2016-04-06
JP2014533204A (ja) 2014-12-11

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