Apparatus for casting solder on a moving strip

Abstract

An apparatus for casting molten metal onto a moving strip of material includes a stationary die having upstream and downstream portions with a casting portion, past which the strip of material is capable of being moved. The casting portion has a casting channel extending from the upstream portion through the downstream portion for facing the moving strip to contain and shape the molten metal into a profile against the moving strip. A heating arrangement heats the upstream portion of the stationary die to prevent the molten metal from solidifying within the casting channel at the upstream portion, thereby allowing the molten metal to fill the casting channel. The casting channel at the downstream portion allows the molten metal to cool while passing therethrough to solidify sufficiently to retain the shape of the casting channel when exiting the stationary die.

What is claimed is:  
     
         1 . An apparatus for casting molten metal onto a moving strip of material comprising a stationary die having upstream and downstream portions with a casting portion, past which the strip of material is capable of being moved, the casting portion having a casting channel for filling with the molten metal extending from the upstream portion through the downstream portion and for facing the moving strip to contain and shape the molten metal into a profile against the moving strip, the casting channel at the downstream portion allowing the molten metal to cool while passing therethrough to solidify sufficiently to retain the shape of the casting channel when exiting the stationary die, the stationary die having only a stationary support for supporting the moving strip against the casting channel.  
     
     
         2 . The apparatus of  claim 1  in which the apparatus is configured for casting molten solder onto a moving metallic strip.  
     
     
         3 . The apparatus of  claim 1  further comprising a cooling system for cooling the downstream portion of the stationary die.  
     
     
         4 . The apparatus of  claim 3  further comprising a heating arrangement for heating the upstream portion of the stationary die to prevent the molten metal from solidifying within the casting channel at said upstream portion.  
     
     
         5 . The apparatus of  claim 1  in which the casting portion of the stationary die is adapted to abut the moving strip and form sealing surfaces such that the casting channel of the stationary die and the moving strip define the profile of the cast metal therebetween.  
     
     
         6 . The apparatus of  claim 5  in which a guide channel is formed in the casting portion of the stationary die for guiding the moving strip therethrough, the moving strip being held against the casting portion by a support portion of the stationary die.  
     
     
         7 . The apparatus of  claim 1  in which a reservoir for containing a supply of molten metal is formed in the stationary die in communication with the casting channel.  
     
     
         8 . The apparatus of  claim 7  in which the reservoir and casting channel are connected by a tapering transition region.  
     
     
         9 . The apparatus of  claim 8  in which the transition region and the casting channel are longitudingly aligned and configured to face the moving strip.  
     
     
         10 . An apparatus for casting and bonding molten solder onto a moving metallic strip comprising a stationary die having upstream and downstream portions with a casting portion, past which the metallic strip is capable of being moved, the casting portion having a casting channel for filling with the molten solder extending from the upstream portion through the downstream portion and for facing the moving metallic strip to contour and shape the molten solder into a profile against the moving metallic strip, the casting channel at the downstream portion allowing the solder to cool while passing therethrough to solidify sufficiently to retain the shape of the casting channel when exiting the stationary die, the stationary die having guide surfaces for guiding the moving metallic strip in relation to the casting channel and also having only a stationary support for supporting the moving strip against the casting channel.  
     
     
         11 . A method of forming an apparatus for casting molten metal onto a moving strip of material comprising: 
 providing a stationary die having upstream and downstream portions with a casting portion, past which the strip of material is capable of being moved, the casting portion having a casting channel for filling with the molten metal extending from the upstream portion through the downstream portion and for facing the moving strip to contain and shape the molten metal into a profile against the moving strip, the casting channel at the downstream portion allowing the molten metal to cool while passing therethrough to solidify sufficiently to retain the shape of the casting channel when exiting the stationary die; and    providing the stationary die with only a stationary support for supporting the moving strip against the casting channel.    
     
     
         12 . The method of  claim 11  in which the moving strip is a metallic strip and the molten metal is molten solder, the method further comprising providing a cooling system for cooling the downstream portion of the stationary die.  
     
     
         13 . The method of  claim 12  further comprising providing a heating arrangement for heating the upstream portion of the stationary die to prevent the molten metal from solidifying within the casting channel at said upstream portion.  
     
     
         14 . The method of  claim 11  further comprising adapting the casting portion of the stationary die to abut the moving strip and form sealing surfaces such that the casting channel of the stationary die and the moving strip define the profile of the cast metal therebetween.  
     
     
         15 . The method of  claim 14  further comprising forming a guide channel in the casting portion of the stationary die for guiding the moving strip therethrough, the moving strip being held against the casting portion by a support portion of the stationary die.  
     
     
         16 . The method of  claim 11  further comprising forming a reservoir for containing a supply of molten metal in the stationary die in communication with the casting channel.  
     
     
         17 . The method of  claim 16  further comprising connecting the reservoir and casting channel with a tapering transition region, the transition region and the casting channel being longitudinally aligned and configured to face the moving strip.  
     
     
         18 . A method of casting molten metal onto a moving strip of material comprising: 
 moving the strip of material past a stationary die having upstream and downstream portions, a casting channel facing the moving strip extending from the upstream portion through the downstream portion;    filling the casting channel with the molten metal;    containing and shaping the molten metal into a profile against the moving strip with the casting channel, the stationary die having only a stationary support for supporting the moving strip against the casting channel; and    allowing the molten metal to cool while passing through the casting channel at the downstream portion to solidify sufficiently to retain the shape of the casting channel when exiting the stationary die.    
     
     
         19 . The method of  claim 18  in which the moving strip is a metallic strip and the molten metal is molten solder, the method further comprising cooling the downstream portion of the stationary die with a cooling system.  
     
     
         20 . The method of  claim 18  further comprising heating the upstream portion of the stationary die with a heating arrangement to prevent the molten metal from solidifying within the casting channel at said upstream portion.  
     
     
         21 . The method of  claim 18  further comprising abutting the casting portion of the stationary die against the moving strip to form sealing surfaces such that the casting channel of the stationary die and the moving strip define the profile of the cast metal therebetween.  
     
     
         22 . The method of  claim 21  further comprising guiding the moving strip through the stationary die with a guide channel formed in the casting portion of the stationary die, the moving strip being held against the casting portion by a support portion of the stationary die.  
     
     
         23 . The method of  claim 18  further comprising containing a supply of molten metal in a reservoir in the stationary die, the reservoir being in communication with the casting channel.  
     
     
         24 . The method of  claim 23  further comprising connecting the reservoir and casting channel with a tapering transition region, the transition region and the casting channel being longitudingly aligned and configured to face the moving strip.  
     
     
         25 . The method of  claim 24  further comprising delivering the molten metal to the reservoir in the stationary die with a delivery conduit.  
     
     
         26 . The method of  claim 25  further comprising storing the molten metal in a heated chamber and supplying the delivery conduit with the molten metal.  
     
     
         27 . The method of  claim 26  further comprising pumping the molten metal through the delivery conduit with a pumping device.  
     
     
         28 . The method of  claim 18  further comprising preheating the moving strip prior to casting the molten metal thereon with a preheating station.