Injection molding of amorphous alloy using an injection molding system

Abstract

Disclosed is an injection molding system including a plunger rod and a melt zone that are provided in-line and on a horizontal axis. The plunger rod is moved in a horizontal direction through the melt zone to move molten material into a mold. The melt zone can have a vessel that is configured to receive the plunger therethrough. A transfer sleeve provided between the vessel and the mold and/or an inlet into a mold can also be horizontally in line with the plunger. The injection molding system can perform the melting and molding processes under a vacuum.

What is claimed is: 
     
         1 . An injection molding system comprising:
 a melt zone configured to melt meltable material received therein, and   a plunger rod configured to eject molten material from the melt zone and into a mold,   wherein the plunger rod and melt zone are provided in-line and on a horizontal axis, such that the plunger rod is moved in a horizontal direction through the melt zone to move the molten material into the mold.   
     
     
         2 . The system according to  claim 1 , wherein the melt zone comprises a vessel having a body for receiving the meltable material, the body configured to receive the plunger rod therethrough in a horizontal direction to move the molten material. 
     
     
         3 . The system according to  claim 2 , wherein the vessel comprises one or more temperature regulating lines configured to flow a liquid therein for regulating a temperature of the vessel. 
     
     
         4 . The system according to  claim 1 , further comprising an induction source positioned within the melt zone that is configured to melt the meltable material. 
     
     
         5 . The system according to  claim 1 , further comprising a transfer sleeve between the melt zone and the mold configured to receive the molten material therethrough. 
     
     
         6 . The system according to  claim 1 , further comprising at least one vacuum source that is configured to apply vacuum pressure to at least the melt zone and mold. 
     
     
         7 . The system according to  claim 1 , wherein the meltable material is an alloy and wherein the mold is configured to form a molded bulk amorphous alloy object. 
     
     
         8 . An injection molding system comprising:
 a vessel comprising a body for receiving meltable material and configured to melt the material therein,   a plunger rod configured to move molten material from the vessel, through a transfer sleeve, and into a mold,   wherein the plunger rod, vessel, and transfer sleeve are provided in-line and on a horizontal axis, such that the plunger rod is moved in a horizontal direction through the vessel to move the molten material into the transfer sleeve.   
     
     
         9 . The system according to  claim 8 , wherein the vessel comprises one or more temperature regulating lines configured to flow a liquid therein for regulating a temperature of the vessel. 
     
     
         10 . The system according to  claim 8 , further comprising an induction source positioned adjacent the vessel that is configured to melt the meltable material. 
     
     
         11 . The system according to  claim 8 , further comprising at least one vacuum source that is configured to apply vacuum pressure to at least the vessel and the mold. 
     
     
         12 . The system according to  claim 8 , wherein the meltable material is an alloy and wherein the mold is configured to form a molded bulk amorphous alloy object. 
     
     
         13 . An injection molding system comprising:
 a temperature regulated vessel comprising a body for receiving amorphous alloy material and configured to melt the amorphous alloy material therein, the vessel comprising one or more temperature regulating lines configured to flow a liquid therein for regulating a temperature of the vessel;   an induction source positioned adjacent the temperature regulated vessel that is configured to melt the amorphous alloy material;   a vacuum mold configured to receive molten amorphous alloy through an inlet and configured to mold the molten amorphous alloy material and under vacuum, and   a plunger rod configured to eject the molten amorphous alloy material from the body of the temperature regulated vessel into the vacuum mold,   wherein the temperature regulated vessel, the inlet of the vacuum mold, and the plunger rod are provided in-line and on a horizontal axis, such that the plunger rod is moved in a horizontal direction through the body of the temperature regulated vessel to eject molten material from the temperature regulated vessel and into the vacuum mold via the inlet.   
     
     
         14 . The system according to  claim 13 , further comprising a transfer sleeve between the temperature regulated vessel and the mold configured to receive the molten material therethrough. 
     
     
         15 . The system according to  claim 13 , further comprising at least one vacuum source that is configured to apply vacuum pressure to at least the temperature regulated vessel and mold. 
     
     
         16 . The system according to  claim 13 , wherein the meltable material is an alloy and wherein the mold is configured to form a molded bulk amorphous alloy object.