CN101835552A - Metal Molded Ducting Assemblies for Metal Molding Systems - Google Patents

Abstract

The present invention relates to a metal molded duct assembly resistant to temperatures from about 680 to 690 degrees Celsius for processing molten metal alloys with light metal alloys, said duct assembly having a body comprising Inconel-720 alloy.

Description

Metal Molded Ducting Assemblies for Metal Molding Systems

technical field

The present invention relates generally to, but not limited to, molding systems, and more particularly, the present invention relates to, but not limited to, metal molding systems or metal molded duct assemblies for metal injection molding systems.

Background technique

Examples of known molding systems are (among others): (i) HyPET ^™ molding system, (ii) Quadloc ^™ molding system, (iii) Hylectric ^™ molding system, and (iv) HyMet ^™ Molding systems, all manufactured by Husky Injection Molding Systems (Location: Canada; Website: www.husky.ca).

U.S. Patent No. 5,040,589 (Inventor: BRADLEY et al; issued August 20, 1991) discloses the following (column 6, lines 4 through 24): "The barrel preferably is bimetallic with an outer shell of alloy I-718, which is a high nickel alloy and provides strength and fatigue resistance at operating temperatures in excess of 600°C. Due to the presence of magnesium in the presence of magnesium, alloy I-718 will corrode rapidly under the circumstances and at the temperatures under consideration, therefore, a liner of high cobalt material (e.g., Stellite 12 (Stoody-Doloro-Stellite Company)) is shrink fitted to the inner surface of the barrel. Any suitable bimetallic barrel that is chemical and heat resistant, has sufficient strength to withstand injection pressure and is resistant to wear.A typical magnesium alloy that can be used in practice is AZ91B, which contains 90% Mg, 9% Al and 1 % Zn. This alloy has a solidus temperature of 465°C, a liquidus temperature of 596°C, and a desired slurry form temperature of approximately 580°C-590°C (preferably 585°C). Therefore, the device of the concept in question must Operates at temperatures much higher than those encountered in thermoplastic injection molding." It appears that 5,040,589 discloses a barrel that uses a combination of Inconel ^™ 718 in the outer casing of the pipe and Stellite ^™ 12 in the inner casing of the pipe (which is an instance of a pipeline).

U.S. Patent No. 5,983,975 (Inventor: NILSSON; issued November 16, 1999) discloses the following (from column 3, line 59 to column 4, line 12): "Due to the The nickel content is easily corroded by molten magnesium (currently the most commonly used thixotropic material), so the barrel is lined with a sleeve or liner of a magnesium-resistant material to stop the magnesium from attacking alloy 718. Several such materials are Stellite 12 (rated at 30Cr, 8.3W, and 1.4C; Stoody-Doloro-Stellite), PM 0.80 alloy (nominally 0.8C, 27.81Cr, 4.11W and bal.Co. also has 0.66N) and Nb-based alloy (for example, Nb-30Ti-20W). Obviously, the expansion coefficients of the barrel and the liner must be compatible with each other to achieve good operation of the machine. Because of the significant thermal gradient cycling in the barrel, the barrel experiences thermal fatigue and Impact. This was found to cause cracks in the barrel and barrel liner. Once cracked in the barrel liner, the magnesium could penetrate the liner and erode the barrel. It was found that both the crack in the barrel and the attack of the magnesium on the barrel caused the above Mentioned premature fatigue of the barrel." It appears that 5,983,975 discloses a barrel (example of tubing) using a combination of Inconel 718 (in the outer shell) and Stellite 12 (in the inner shell).

US Patent No. 6,520,762 (Inventor: KESTLE et al; issued February 18, 2003) discloses the following (from column 11, line 66 to column 12, line 5): " In machine applications where the melt of material is a metal in a thixotropic state (e.g. magnesium), the nozzle can be made from DIN 2888 or DIN 2999. The hopper, first barrel coupling (including axial force isolation device) and the second part may all be made of INCONEL 718 (nickel alloy) with a STELLITE 12 (abrasion resistant cast non-ferrous alloy) liner. In machine applications where the melt of the material is plastic, the nozzle may be made of a H13 tip SAE 4140 steel. The accumulator and first barrel coupling (including the axial force isolator) can be made of 4140 with a cast liner. The second part can be made of 4140 with a cast liner.” It seems that 6,520,762 discloses a A barrel (example of tubing) using a combination of Inconel 718 (in the outer shell) and Stellite 12 (in the inner shell).

Stellite 12 is manufactured by Deloro Stellite (Tel: 1-800-267-2886; Web: www.http://www.stellitesolutions.com). Inconel 718 is manufactured by High Temperature Metals, Inc. (Tel: 1-800-500-2141; Web site: www.http://www.hightempmetals.eom).

Contents of the invention

The inventors believe that those skilled in the art do not understand the problem associated with barrels or pipes used in metal molding systems. According to the current state of the art, molten magnesium alloys are generally not processed by metal molding systems or metal injection molding systems above 650 degrees Celsius because known barrel assemblies contain outer layers with Inconel-718 alloy. Specifically, heating molten magnesium alloys above about 650 degrees Celsius is not possible due to the chemistry associated with Inconel-718 alloys. Problems arise when attempting to make thin-walled metal articles (e.g., mobile phone casings and/or computer portable cases) because molten magnesium heated to less than about 650 degrees Celsius tends to have relatively large spherical particles (i.e., Compared with the size of thin-walled products made). Large spherical particles tend to stick in mold cavities configured to mold extremely thin walled articles and thus disadvantageously prevent or impede the flow of molten magnesium towards the edges of the mold cavity. The use of molten magnesium heated to below 650 degrees Celsius results in molded articles with unacceptable thin wall properties and/or quality. Making thin-walled articles as thin as possible leaves a potential for weight reduction and also demonstrates the possibility of making smaller articles (compared to the size currently possible with the current state of the art in molded thin-walled metal articles) is extremely beneficial.

According to a first aspect of the invention there is provided a metal molded duct assembly (100) comprising a body (105) configured to withstand temperatures from about 30 to about 40 degrees Celsius above about 650 degrees Celsius Higher temperatures are used to process molding materials comprising molten metal alloys with light metal alloys.

According to a second aspect of the invention there is provided a metal molded duct assembly (100) having a body (105) configured to withstand temperatures of from about 30 to about 40 degrees Celsius above about 650 degrees Celsius higher temperature for processing molding material comprising a molten metal alloy having a light metal alloy, said body (105) having: (i) an outer shell (102) comprising an Inconel-720 alloy; and (ii) an inner housing (104) that fits within the outer housing (102), the inner housing (104) comprising a corrosion resistant alloy.

Among other technical effects, one technical effect of the various aspects of the present invention is that the Inconel-720 alloy withstands higher temperatures from about 30 to about 40 degrees Celsius above about 650 degrees Celsius for processing molten molding materials that melt The molding material comprises molten metal alloys with light metal alloys, such as magnesium alloys. For the manufacture of metal thin-walled articles (e.g., mobile phone casings or portable cases, etc.), processing molten magnesium above 650 degrees Celsius improves the ability to make thin-walled metal articles (i.e., the ability to mold even thinner articles), and These thinner articles cannot be manufactured using molding processes that use tubes and/or barrels that operate at temperatures less than about 650 degrees Celsius.

Description of drawings

A better understanding of non-limiting embodiments of the invention, including alternatives and/or variations thereof, can be obtained by reference to the detailed description of non-limiting embodiments of the invention and the following drawings, in which:

1A and 1B depict cross-sectional views taken along the longitudinal axis of a metal-molded duct assembly 100 (hereinafter "assembly 100") according to a first non-limiting embodiment; and

2 is an assembly 100 according to a second non-limiting embodiment, a metal molding system 200 (hereinafter referred to as "system 200") according to a third non-limiting embodiment, and a metal molding system 200 according to a fourth non-limiting embodiment. A schematic representation of a metal injection molding system 202 (hereinafter "system 202").

The drawings are not necessarily to scale and are sometimes illustrated with phantom lines, diagrams and fragment views. In some instances, details that are not necessary for an understanding of the embodiments or that render other details difficult to understand may have been omitted.

Detailed ways

Figure 1A depicts a cross-sectional view taken along the longitudinal axis 101 of an assembly 100 according to a first non-limiting variant of the first non-limiting embodiment. System 200 may be incorporated into assembly 100 . System 202 may be incorporated into assembly 100 . Assembly 100 may be sold with or separately from system 200 or system 202 . Molded article 204 (depicted in FIG. 2 ) may be manufactured or fabricated by system 200 or system 202 incorporating assembly 100 . A longitudinal axis 101 extends from the input of the assembly 100 to its output. The assembly 100 has an outer housing 102 having an Inconel-720 alloy. Inconel-720 alloy withstands higher temperatures from about 30 to about 40 degrees Celsius above about 650 degrees Celsius for processing molding material 103 . The molding material 103 comprises a molten metal alloy with a light metal alloy. Light metal alloys include magnesium alloys, for example. Other alloys such as zinc, aluminum may also be used.

According to a non-limiting variant, the assembly 100 includes a body 105 configured to withstand higher temperatures from about 30 to about 40 degrees Celsius above about 650 degrees Celsius for processing a molding material comprising Molten metal alloys with light metal alloys.

FIG. 1B depicts a cross-sectional view of an assembly 100 according to a second non-limiting variation of the first non-limiting embodiment, wherein the assembly 100 includes: (i) an outer housing 102 , and (ii) an inner housing 104 . The inner housing 104 is assembled in the outer housing 102 . The inner housing 104 comprises a corrosion resistant alloy which is (preferably) wear resistant. For example, the corrosion resistant alloy may include Stellite-12 alloy.

According to a non-limiting variant, the assembly 100 has a body 105 configured to withstand higher temperatures from about 30 to about 40 degrees Celsius above about 650 degrees Celsius for processing molding materials comprising light metal Alloys of molten metal alloys. The body 105 has: (i) an outer shell 102 comprising Inconel-720 alloy, and (ii) an inner shell 104 fitted within the outer shell 102 . The inner housing 104 comprises a corrosion resistant alloy.

FIG. 2 is a schematic representation of assembly 100 , system 200 and system 202 . System 200 or system 202 may include components known to those skilled in the art, and these known components will not be described here; these known components are described at least in part in the following books, for example: (i ) " Injection Molding Handbook (Injection Molding Handbook) " edited by Osswald/Turng/Gramann (ISBN: 3-446-21669-2; Publisher: Hansel ( Hanser)), (ii) " Injection Molding Handbook (Injection Molding Handbook) " edited by Rosetta and Rosetta (Rosato and Rosato) (ISBN: 0-412-99381-3; Publisher: Chapman and Hill (Chapman & Hill), and/or (iii) " Injection Molding Systems " by Johannaber, ed., Third Revision (ISBN3-446-17733-7).

System 200 (or system 202 ) includes, for example: (i) hopper 210 , (ii) feed inlet 212 , (iii) extruder 108 , and (iv) clamping assembly 217 . The charging hopper 210 is connected with the feed port 212 . The feed port 212 is connected to the barrel assembly 106 of the extruder 108 . Extruder 108 can be: (i) a reciprocating screw (RS) extruder, or (ii) a two-stage extruder with a shot pot configuration. Molding material (for example, in the form of solidified magnesium pellets) is received in hopper 210 and then conveyed via feed port 212 to the interior of barrel assembly 106 of extruder 108 . A screw 107 is received in the interior of the barrel assembly 106 . The screw 107 is used to move or convey the molding material. A screw actuator 109 is attached to one end of the screw 107 . A screw actuator 109 is used to actuate the movement of the screw 107 . A controller 111 is operatively coupled with the screw actuator 109 . The controller 111 is used to control the screw actuator 109 . The screw actuator 109 is used to rotate the screw 107 so that a small piece of molding material received in the barrel assembly 106 can be conveyed along the barrel assembly 106 from the feed inlet 212 towards the outlet of the barrel assembly 106 . Heater 117 is coupled to the outer surface of barrel assembly 106 . Heaters 117 are used to melt the chips into a semi-solid or liquid state (as desired) as the chips are transported along the barrel assembly 106 . A check valve (not depicted, but known) is mounted with the tip of the screw 107 and is used to collect the shot of molten molding material in the accumulation zone of the barrel assembly 106 . The accumulation zone is located at the outlet of the barrel assembly 106 . Once the controller 111 issues an injection command to the screw actuator 109 , the screw actuator 109 linearly translates the screw 107 to push molten molding material out of the accumulation zone of the barrel assembly 106 .

According to a non-limiting arrangement (which is depicted in FIG. 2 ), a mold 114 is used to mold an article, and the mold 114 includes or defines a plurality of mold cavities. For this case, hot runner 216 is used, and nozzle assembly 110 is connected to (i) the outlet of barrel assembly 106 , and (ii) hot gate 112 . The hot gate 112 is held or supported in a fixed or stationary position by the stationary platen 152 . The mold 114 is attached with a hot runner 216 . Hot runner 216 is attached together with hot sprue 112 so that molten molding material can be transported from barrel assembly 106 to nozzle assembly 110 , hot sprue 112 , hot runner 216 and then to the mold of mold 114 cavity.

According to another non-limiting arrangement, which is not depicted, the mold 114 contains or delimits a single mold cavity. For this case, the hot runner 216 is not used, and the nozzle assembly 110 is connected to (i) the outlet of the barrel assembly 106 , and (ii) the hot gate 112 . The mold 114 and thermal gate 112 are attached together.

Clamping assembly 217 includes: (i) movable platen 150 , (ii) stationary platen 152 , (iii) clamping unit 154 , (iv) connecting rod 156 , and (v) nut 158 . The movable platen 150 is movable relative to the stationary platen 152 so that the mold 114 can be closed. The clamping units 154 are fixedly mounted on corresponding corners of the static pressing table 152 . The clamping unit 154 is used to apply clamping force to the mold 114 . Nuts 158 are mounted on corresponding corners of the movable platen 150 . The link 156 is coupled with the corresponding clamping unit 154 . Links 156 extend from respective clamping units 154 to respective nuts 158 . The nut 158 is used to lock the link 156 relative to the movable platen 150 so that the clamping force can be transmitted from the clamping unit 154 to the movable platen 150 . Likewise, a nut 158 is used to unlock the link 156 relative to the movable platen 150 so that the movable platen 150 can move relative to the stationary platen 152 .

The mold 114 includes: (i) a movable mold section 140 (hereinafter "section 140"), and (ii) a stationary mold section 142 (hereinafter "section 142"). The section 140 is mounted to the movable platen 150 such that the section 140 faces the stationary platen 152 . Section 142 is mounted to hot runner 216 , and hot runner 216 is mounted to stationary platen 152 such that section 142 faces section 140 .

According to an alternative arrangement (not depicted), hot runner 216 is not used and section 140 is mounted to movable platen 150 and section 142 is mounted to stationary platen 152 such that section 142 faces section 140 .

In operation, the movable platen 150 is moved toward the stationary platen 152 (by a die stroke actuator, which is not depicted) so that the portion 140 can be closed against the portion 142 . A nut 158 locks the platens 150 , 152 together so that the clamping unit 154 can be actuated to transmit a clamping force to the mold 114 . The clamping force serves to prevent the mold 114 from inadvertently releasing (also referred to as bleeding) molding material from the mold 114 when the mold 114 is filled (by pressure) with molten molding material prepared and injected by the extruder 108 . Once the shot amount of molding material has collected in the accumulation zone of the barrel assembly 106, the screw actuator 109 is actuated to linearly translate the screw 107 forward (this causes the check valve to close to prevent melt molding The material flows back toward the feed port 212), and in this way, the injection amount of molten molding material can then be injected from the barrel assembly 106 through the nozzle assembly 110 and (i) directly injected (by means of pressure) (as shown in 2) to the hot gate 112 and then to the hot runner 216 and then to the mold cavity of the mold 114, or (ii) directly (not depicted) to the hot gate 112 and then to the mold cavity of the mold 114 Defined mold cavity.

Once the molded article 204 is formed and solidified in the mold cavity of the mold 114, the clamping unit 154 ceases to apply the clamping force, and the nut 158 is unlocked so that the mold 114 can then be split apart (by applying mold splitting force to the mold 114). force); and then the movable platen 150 can be moved away from the stationary platen 152 so that the molded article 204 can be removed from the mold 114 (manually or by means of an automated device).

According to non-limiting variations, the outer housing 102 is contained in any of the following: (i) barrel assembly 106, (ii) nozzle assembly 110, (iii) thermal sprue 112, (iv) mold 114 , (v) components of the hot runner 216, (vi) the screw 107, and/or any combination and arrangement thereof.

According to another non-limiting variation, both the outer housing 102 and the inner housing 104 are contained in any of the following: (i) barrel assembly 106, (ii) nozzle assembly 110, (iii) thermal Gate 112, (iv) mold 114, (v) assembly of hot runner 216, (vi) screw 107, and/or any combination and arrangement thereof.

The description of non-limiting embodiments provides non-limiting examples of the invention; these non-limiting examples do not limit the scope of the claims of the invention. The non-limiting examples described are within the scope of the claims of the invention. The non-limiting embodiments described above can be: (i) as expected by those skilled in the art, changes, modifications and/or modifications can be made for specific conditions and/or functions without departing from the scope of the claims herein. or enhancement, and/or (ii) further extension to various other applications without departing from the scope of the claims herein. It should be understood that the non-limiting examples illustrate various aspects of the invention. Reference herein to details and description of non-limiting examples is not intended to limit the scope of the invention claimed. Other non-limiting embodiments that may not be described above may be within the scope of the above claims. It is to be understood that (i) the scope of the invention is defined by the claims, (ii) the claims themselves recite those features considered essential to the invention, and (iii) preferred embodiments of the invention are the subject matter of the appended claims . Accordingly, what is protected by patent patent is limited only by the scope of the following claims.

Claims (25)

CLAIMS 1. A metal molded duct assembly (100) comprising: A body (105) configured to withstand higher temperatures from about 30 to about 40 degrees Celsius above about 650 degrees Celsius for processing a molding material comprising a molten metal alloy having a light metal alloy. 2. The metal-molding duct assembly (100) of claim 1, wherein: The ontology (105) contains: Inconel-720 alloy. 3. The metal-molding duct assembly (100) of claim 1, wherein: The light metal alloys include magnesium alloys. 4. The metal-molding duct assembly (100) of claim 1, wherein: The ontology (105) contains: An outer housing (102) comprising: Inconel-720 alloy. 5. The metal-molding duct assembly (100) of claim 1, wherein: The ontology (105) contains: an inner housing (104), which fits within the outer housing (102), the inner housing (104) comprising: Corrosion Resistant Alloy. 6. The metal-molding duct assembly (100) of claim 1, wherein: The ontology (105) contains: an inner housing (104), which fits within the outer housing (102), the inner housing (104) comprising: Corrosion-resistant alloys, the corrosion-resistant alloys comprising: Stellite-12 alloy. 7. The metal-molding duct assembly (100) of claim 1, wherein: The body (105) is contained in a barrel assembly (106) of an extruder (108). 8. The metal-molding duct assembly (100) of claim 1, wherein: The body (105) is contained in a nozzle assembly (110). 9. The metal-molding duct assembly (100) of claim 1, wherein: The body (105) is contained in a thermal gate (112). 10. The metal-molding duct assembly (100) of claim 1, wherein: Said body (105) is contained in a screw (107). 11. The metal-molding duct assembly (100) of claim 1, wherein: The body (105) is contained in a mold (114). 12. The metal-molding duct assembly (100) of claim 1, wherein: The body (105) is contained in a hot runner (216). 13. A metal injection molding system (202) incorporating the metal molded duct assembly (100) of claim 1. 14. A metal molded duct assembly (100) comprising: a body (105) configured to withstand higher temperatures from about 30 to about 40 degrees Celsius above about 650 degrees Celsius for processing a molding material comprising a molten metal alloy having a light metal alloy, The ontology (105) contains: An outer housing (102) comprising: Inconel-720 alloy; and an inner casing (104), which is assembled in the outer casing (102), and the inner casing (104) includes: Corrosion Resistant Alloy. 15. The metal-molding duct assembly (100) of claim 14, wherein: The light metal alloy comprises: magnesium alloy. 16. The metal-molding duct assembly (100) of claim 14, wherein: The corrosion resistant alloy comprises Stellite-12 alloy. 17. The metal-molding duct assembly (100) of claim 14, wherein: The outer housing (102) is contained within a barrel assembly (106) of an extruder (108). 18. The metal-molding duct assembly (100) of claim 14, wherein: The outer housing (102) is contained in a nozzle assembly (110). 19. The metal-molding duct assembly (100) of claim 14, wherein: The outer shell (102) is contained within a thermal gate (112). 20. The metal-molding duct assembly (100) of claim 14, wherein: Said outer housing (102) is contained in a screw (107). 21. The metal-molding duct assembly (100) of claim 14, wherein: The outer shell (102) is contained in a mold (114). 22. The metal-molding duct assembly (100) of claim 14, wherein: The outer housing (102) is contained within a hot runner (216). 23. A metal molding system (200) incorporating the metal molding duct assembly (100) of claim 14. 24. A metal injection molding system (202) incorporating the metal molded duct assembly (100) of claim 14. 25. A metal molded duct assembly (100) comprising: a body (105) configured to withstand higher temperatures from about 30 to about 40 degrees Celsius above about 650 degrees Celsius for processing a molding material comprising a molten metal alloy having a light metal alloy, The light metal alloy comprises: magnesium alloy, The ontology (105) contains: an outer shell (102) comprising Inconel-720 alloy; and an inner housing (104) that fits within the outer housing (102), the inner housing (104) comprising a corrosion resistant alloy comprising a Stellite-12 alloy, Wherein the outer casing (102) and the inner casing (104) are included in any one of the following components: the barrel assembly (106) of the extruder (108), nozzle assembly (110), hot gate (112), screw (107), mold (114), and Hot runner (216).

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