Application of ultrasonic vibrations to molten liquidmetal during injection molding or die casting operations

Abstract

Described herein is an injection molding or die casting machine having an ultrasonic vibration generator associated therewith that is configured to apply ultrasonic vibrations during melting and/or injection of the molten material (e.g., molten alloy). The ultrasonic vibrations may be applied to molten material via the plunger tip of the plunger in the machine, and/or the mold and/or the vessel, for example. The ultrasonic vibration may be applied during plunger tip movement so that the molten material vibrates ultrasonically during melting and injection. A connector may be connected to the ultrasonic vibration generator and the plunger. Channels may be provided in the plunger tip and/or vessel to accommodate a cooling fluid during melting and injection.

What is claimed is: 
     
         1 . A plunger of an injection molding or die casting machine, comprising:
 a plunger body;   a plunger tip associated with the plunger body, the plunger tip comprising an end surface configured to directly contact a molten material used the injection molding or die casting machine; and   a connector, the connector being connected to an ultrasonic vibration generator that is associated with the injection molding or die casting machine,   wherein at least the end surface of the plunger tip is configured to vibrate at ultrasonic vibrations applied via the ultrasonic vibration generator and through the connector during injection of the molten material.   
     
     
         2 . The plunger of  claim 1 , wherein the ultrasonic vibration generator comprises an ultrasonic transducer. 
     
     
         3 . The plunger of  claim 1 , wherein the connector is an electronic connector, and the ultrasonic vibration generator is configured to create ultrasonic vibrations electronically. 
     
     
         4 . The plunger of  claim 1 , wherein the connector is a mechanical connector, and the ultrasonic vibration generator is configured to create ultrasonic vibrations mechanically. 
     
     
         5 . The plunger of  claim 1 , wherein the plunger tip comprises one or more channels therein configured to accommodate a cooling fluid. 
     
     
         6 . The plunger of  claim 1 , wherein the plunger tip is removeably connected to the plunger body. 
     
     
         7 . An injection molding or die casting machine comprising an ultrasonic vibration generator that is configured to apply ultrasonic vibrations during melting and injection of the molten material. 
     
     
         8 . The machine of  claim 7 , further comprising:
 a plunger comprising a plunger body and a plunger tip comprising an end surface configured to directly contact a molten material;   a vessel configured to receive a meltable material for melting therein;   a heat source configured to melt the meltable material in the vessel; and   a mold for molding the molten material,   wherein the plunger tip of the plunger is configured to move the molten material from the vessel and to inject the molten material into the mold during the application of the ultrasonic vibrations to at least the end surface of the plunger tip by the ultrasonic vibration generator.   
     
     
         9 . The machine of  claim 8 , wherein the plunger tip comprises one or more channels therein configured to accommodate a cooling fluid and wherein the vessel further comprises one or more temperature regulating channels to accommodate the cooling fluid therein. 
     
     
         10 . The machine of  claim 8 , wherein the plunger and vessel are positioned along a horizontal axis, and wherein movement of the molten material from the vessel via the plunger tip is in a horizontal direction towards the mold. 
     
     
         11 . The machine of  claim 8 , wherein the ultrasonic vibration generator is further connected to the mold and is configured to apply ultrasonic vibrations to the molten material during injection into the mold. 
     
     
         12 . The machine of  claim 8 , wherein the ultrasonic vibration generator is further connected to the vessel and is configured to apply ultrasonic vibrations to the meltable material during melting of the meltable material by the heat source. 
     
     
         13 . A method of injection molding a meltable material in an injection molding or die casting machine comprising a plunger, an ultrasonic transducer, a vessel configured to receive the meltable material for melting therein; and a mold for molding the molten material, wherein the plunger comprises a plunger body and a plunger tip configured to directly contact a molten material in the vessel and move the molten material from the vessel and to inject the molten material into the mold, and wherein the ultrasonic transducer is configured to apply ultrasonic vibrations to at least the plunger tip; the method comprising:
 applying ultrasonic vibrations to at least the plunger tip of the plunger via the ultrasonic transducer;   melting the meltable material into a molten state in the vessel; and   forcing the molten material from the vessel and into the mold using the plunger,   wherein at least the plunger tip applies ultrasonic vibrations to the material during both the melting and the forcing of the material.   
     
     
         14 . The method of  claim 13 , further comprising solidifying the molten material in the mold. 
     
     
         15 . The method of  claim 13 , wherein the plunger tip comprises one or more channels therein configured to accommodate a cooling fluid and wherein the vessel further comprises one or more temperature regulating channels to accommodate the cooling fluid therein, and wherein the method further comprises:
 regulating a temperature of the vessel during the melting of the meltable material by flowing the cooling fluid therein, and   regulating a temperature of the plunger by flowing the cooling fluid therein.   
     
     
         16 . The method of  claim 13 , wherein the vessel is positioned along a horizontal axis in the injection molding or die casting machine, and wherein the forcing of the molten material from the vessel using the plunger comprises moving the plunger in a horizontal direction towards the mold. 
     
     
         17 . The method of  claim 13 , wherein the ultrasonic transducer is further connected to the mold, and wherein the method further comprises: applying ultrasonic vibrations to the molten material during the forcing of the molten material into the mold. 
     
     
         18 . The method of  claim 13 , wherein the ultrasonic transducer is further connected to the vessel, and wherein the method further comprises: applying ultrasonic vibrations to the meltable material during the melting into a molten state. 
     
     
         19 . The method of  claim 13 , further comprising: stopping the applying of the ultrasonic vibrations by the ultrasonic transducer; and ejecting molded material from the mold using the plunger. 
     
     
         20 . The method of  claim 13 , wherein the injection molding or die casting machine further comprises a connector that connects the ultrasonic transducer to at least the plunger tip, wherein the connector is an electronic connector or a mechanical connector, and wherein the applying of the ultrasonic vibrations is performed electronically or mechanically.