Device for casting

Abstract

A casting machine includes a processing cylinder formed in a thermally conductive block. The cylinder has a processing chamber, a first end configured to receive the metal feed stock and a second end. An injector cylinder formed in the thermally conductive block has a shooting pot coupled to the second end of the processing cylinder by a passage configured to permit feed stock to pass from the processing cylinder into the shooting pot. A nozzle is coupled to the injector cylinder and to the mold. A processing drive drives the feed stock from the first end of the processing cylinder through the passage into the shooting pot. A heater is thermally coupled to the processing cylinder to heat the feed stock. An injector plunger coupled to an injector actuator for driving the plunger sufficiently to force the metal from the shooting pot through the nozzle and into the mold.

Therefore, what is claimed is:  
     
         1 . A casting machine for casting parts in a mold out of a metal using a metal feed stock, the machine comprising:
 a a processing cylinder formed in a thermally conductive block, said processing cylinder having a processing chamber and opposite first and second ends, the first end of the processing cylinder being configured to receive the metal feed stock;   b an injector cylinder formed in the thermally conductive block adjacent the processing cylinder, the injector cylinder having a shooting pot coupled to the second end of the processing cylinder by a passage configured to permit feed stock to pass from the processing cylinder into the shooting pot, a nozzle coupled to the injector cylinder configured to couple to the mold;   c a processing drive for driving the feed stock from the first end of the processing cylinder through the passage into the shooting pot, a heater thermally coupled to the processing cylinder, the heater and processing cylinder configured to heat the feed stock such that the feed stock becomes progressively more liquid as it passes from the first to the second end of the processing cylinder, and   d an injector plunger coupled to an injector actuator for driving the plunger sufficiently to force the metal from the shooting pot through the nozzle and into the mold.   
     
     
         2 . The casting machine of  claim 1  wherein the injector cylinder and the processing cylinder are positioned side by side. 
     
     
         3 . The casting machine of  claim 2  comprising a plurality of processing cylinders surrounding the injector cylinder. 
     
     
         4 . A device for casting a part is a mold comprising a plurality of casting machines as defined is  claim 1  coupled to said mold. 
     
     
         5 . The casting machine of  claim 3  wherein the injector cylinder and the processing cylinders are all formed in a single thermally conductive block. 
     
     
         6 . The casting machine of  claim 5  wherein each in the processing cylinders are coupled to the passage. 
     
     
         7 . The casting machine of  claim 6  wherein the passage has a volume greater than the shooting pot. 
     
     
         8 . The casting machine of  claim 1  wherein the processing drive comprises a processing plunger coupled to a processing actuator configured to drive the processing plunger in the processing cylinder between the first and second ends of the processing cylinder. 
     
     
         9 . The casting machine of  claim 3  further composing a distributor for distributing the feed stock from a hopper into each of the processing cylinders. 
     
     
         10 . The casting machine of  claim 7  wherein the processing drive comprises a processing plunger for each processing cylinder coupled to a processing actuator configured to drive the processing plungers in the processing cylinders between the first and second ends of the processing cylinders. 
     
     
         11 . The casting machine of  claim 10  wherein the processing drive further comprises a first member coupled to each of the processing plungers, the first member coupled to the processing actuator. 
     
     
         12 . The casting machine of  claim 9  further comprising a distributor for distributing the feed stock from a hopper into each of the processing cylinders, the distributor comprising an annular member rotatably mounted to the block adjacent the first ends of the processing cylinders, the annular member having at least one finger dimensioned to spread the feed stock among the processing cylinders as the annual member rotates. 
     
     
         13 . The casting machine of  claim 11  further comprising a distributor for distributing the feed stock from a hopper into each of the processing cylinders, the distributor comprising an annular member rotatably mounted to the block adjacent the first ends of the processing cylinders, the annular member having a plurality of fingers dimensioned to spread the feed stock among the processing cylinders, the annular member having a plurality of passages to permit the processing plungers to pass there through, the processing plunger drive being further configured to withdraw the plungers from the processing cylinders and away from the second member to permit the second member to rotate relative to the processing cylinders. 
     
     
         14 . A casting machine for casting parts in a mold out of a metal feed stock, the casting machine comprising:
 a a thermally conductive block,   b a processing cylinder having opposite first and second ends formed in the block, the first end configured to receive the feed stock;   c the block being thermally coupled to a heater, the heater, block and processing cylinder being configured to heat the feed stock such that the feed stock, becomes progressively more liquid as it passes from the first to the second end of the processing cylinder;   d an injector cylinder formed in the block adjacent the processing cylinder, the injector cylinder having a shooting pot and an injector plunger coupled to a nozzle, the shooting pot being coupled to the second end of the feed stock processing cylinder by a passage configured to permit the one way movement of heated feed stock from the processing cylinder into the shooting pot, the injector plunger configured to inject the heated feed stock through the nozzle into the mold.   
     
     
         15 . The casting machine of  claim 14  comprising a plurality of processing cylinders formed in the block and surrounding the injector cylinder, each of the processing cylinders being coupled to the passage. 
     
     
         16 . The casting machine of  claim 15  further comprising a processing drive for urging the feed store through the processing cylinders, the processing drive comprising a processing plunger for each processing cylinder, the processing plungers coupled to a processing actuator for moving the processing plungers between the first and second ends of the processing cylinder. 
     
     
         17 . The casting machine of  claim 16  further comprising a distributor for distributing the feed stock from a hopper into each of the processing cylinders, the distributor comprising at least one finger movably mounted to the block adjacent the first ends of the processing cylinders, and further comprising a finger actuator for moving the finger sufficiently to spread the feed stock among the processing cylinders. 
     
     
         18 . The casting machine of  claim 17  further comprising a cap mounted onto the thermally conductive block adjacent the first ends of the processing cylinders, the cap configured to permit the processing and injection plungers to pass there through, the thermally conductive block having a mounting plate adjacent the mold and further comprising a compression actuator coupled to the cap and mounting plate for keeping the cap, the block and the mounting plate in compression. 
     
     
         19 . A machine for molding a part out of a feed stock, said device comprising:
 a a mold having a plurality of mold portions, each mold portion configured to mold a different portion of the part;   b a plurality of molding units, each molding unit being coupled to one of said portions for molding said portion;   c each molding unit comprising a thermally conductive block with a processing cylinder formed therein, said processing cylinder having opposite first and second ends, the first end configured to receive the feed stock;   d the block being thermally coupled to a heater, the heater, block and processing cylinder being configured to heat the feed stock such that the feed stock becomes progressively more liquid as it passes from the first to the second end of the processing cylinder;   e an injector cylinder formed in the block adjacent the processing cylinder, the injector cylinder having a shooting pot, an injector plunger and a nozzle, the nozzle being coupled to the mold portion, the shooting pot being coupled to the second end of the feed stock processing cylinder by a passage configured to permit the movement of heated feed stock from the processing cylinder into the shooting pot, the injector plunger configured to inject the heated feed stock through the nozzle and into the mold.   
     
     
         20 . The machine of  claim 19  wherein the molding units each comprise a plurality of processing cylinders formed in the block and surrounding the injector cylinder, each of the processing cylinders being coupled to the passage. 
     
     
         21 . The machine of  claim 20  wherein the molding units each further comprise a processing drive for urging the feed stock through the processing cylinders, the processing drive comprising a processing plunger for each processing cylinder, the processing plungers coupled to a processing actuator for moving the processing plungers between the first and second ends of the processing cylinder. 
     
     
         22 . The machine of  claim 21  wherein the molding units each further comprise a distributor for distributing the feed stock from a hopper into each of the processing cylinders, the distributor comprising at least one finger movably mounted to the block adjacent the first ends of the processing cylinders, and further comprising a finger actuator for moving the finger sufficiently to spread the feed stock among the processing cylinders. 
     
     
         23 . The machine of  claim 1  wherein the thermally conductive block is isolated. 
     
     
         24 . The casting machine of  claim 1  further comprising a mold cooler for removing heat from the mold, the mold cooler configured to transfer a portion of the heat removed from the mold to the feed stock before the feed stock enters the processing cylinder.