The present invention is a casting machine for casting parts in a mold out of a metal using a metal feedstock. The machine feeds solid metal feedstock into a processing cylinder formed in a thermally conductive block and a heater elevates the temperature of the feedstock as it passes along the said
The present invention is a casting machine for casting parts in a mold out of a metal using a metal feedstock. The machine feeds solid metal feedstock into a processing cylinder formed in a thermally conductive block and a heater elevates the temperature of the feedstock as it passes along the said processing cylinder first and second ends, the first end of the processing cylinder being configured to receive. The feedstock becomes more liquid and is transferred to an injector cylinder formed in the thermally conductive block adjacent the processing cylinder. The injector cylinder has a shooting pot coupled to the second end of the processing cylinder by a passage configured to permit feedstock to pass from the processing cylinder into the shooting pot from where is it injected into a mold.
대표청구항▼
1. A casting machine for casting parts in a mold out of a metal using a metal feedstock, the machine comprising: a. a thermally conductive block, being a unified cylindrical block having at least one processing cylinder and an injector cylinder;b. each processing cylinder being formed in said therma
1. A casting machine for casting parts in a mold out of a metal using a metal feedstock, the machine comprising: a. a thermally conductive block, being a unified cylindrical block having at least one processing cylinder and an injector cylinder;b. each processing cylinder being formed in said thermally conductive block, said processing cylinder having a processing chamber and opposite first and second ends;c. a particulate feedstock feed housing to hold particulate feedstock, said feed housing having an outlet connected to the first end of the processing cylinder being configured to transfer particulate feedstock from the feed housing to the first end of the processing cylinder;d. said injector cylinder formed in said thermally conductive block adjacent the processing cylinder, so as to have a common wall extending along said cylinders between said processing cylinder and said injector cylinder, from the opposite first to second ends, and thereby be thermally connected thereto;e. a shooting pot formed at one end of said injector cylinder and coupled to the second end of the processing cylinder by a passage within said thermally conductive block configured to permit feedstock to pass from the processing cylinder into the shooting pot;f. a nozzle coupled to the injector cylinder to transfer material from the shooting pot to the mold;g. a processing drive for driving the feedstock from the first end of the processing cylinder through the passage into the shooting pot;h. a coaxially-placed heater thermally coupled to the thermally conductive block to transfer heat to the processing cylinder, and through said common wall, extending from the opposite first to second ends, to said injector cylinder and to the shooting pot, the heater and processing cylinder configured to supply heat to the feed stock such that the feedstock becomes progressively more liquid as it passes from the first to the second end of the processing cylinder; andi. 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 said thermally conductive block includes a plurality of processing cylinders surrounding the injector cylinder, wherein said processing cylinder and said injector cylinder are in thermal communication over the full length of the injector cylinder. 3. The casting machine of claim 2 wherein each of the processing cylinders are coupled to the passage. 4. The casting machine of claim 3 wherein the passage has a volume greater than the shooting pot. 5. The casting machine of claim 4 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. 6. The casting machine of claim 5 wherein the processing drive further comprises a first member operatively coupled to a processing actuator to each of the processing plungers, and a first member of the processing actuator operatively connected to a first member of the processing plungers. 7. The casting machine of claim 6 further comprising a distributor for distributing the feedstock 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 feedstock 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 annular member to permit the annular member to rotate relative to the processing cylinders. 8. The casting machine of claim 2 further comprising a distributor for distributing the feedstock from a hopper into each of the processing cylinders. 9. The casting machine of claim 8 further comprising a distributor for distributing the feedstock 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 annular member rotates. 10. 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. 11. The machine of claim 1 wherein the thermally conductive block is insulated, directing heat radially to said processing cylinder and said injector cylinder. 12. 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 feedstock before the feedstock enters the processing cylinder. 13. A device for casting a part in a mold comprising a plurality of casting machines as defined in claim 1 coupled to said mold, wherein processing cylinders and injector cylinders of the casting machines are operatively connected to the mold, the mold being disposed below the injector cylinders, such that gravity causes a liquid phase of the processing stock to flow into the mold. 14. A casting machine for casting parts in a mold out of a metal feedstock, the casting machine comprising; a. a thermally conductive block, the block being a cylindrical block having a plurality of processing cylinders and an injector cylinder;b. said plurality of processing cylinders each having opposite first and second ends formed in the thermally conductive block, the first end to receive the feedstock;c. the block being thermally coupled to a coaxially placed heater, wherein the heater, block and each processing cylinder are configured to supply heat to feedstock introduced in particulate solid state into said processing cylinder, said heater supplying heat through said block to elevate the temperature of said feedstock, whereby said feedstock becomes progressively more liquid as it passes from the first to the second end of the processing cylinder;d. said injector cylinder formed in the block adjacent said processing cylinders, and having a common wall extending along and between said cylinders from the opposite first to second ends, so as to be thermally connected to said heater, 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 each of the feedstock processing cylinders by a passage including a valve configured to permit the one way movement of heated feedstock from the processing cylinder into the shooting pot, the injector plunger configured to inject the heated feedstock through the nozzle into the mold. 15. The casting machine of claim 14 further comprising a processing drive for urging the feedstock 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. 16. The casting machine of claim 15 further comprising a distributor for distributing the feedstock 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 feedstock among the processing cylinders. 17. The casting machine of claim 16 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 injector 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. 18. A machine for molding a part out of a feedstock, 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 cylindrical block with at least one processing cylinder and an injector cylinder formed therein, said processing cylinder having opposite first and second ends, the first end configured to receive the feedstock;d. the block being thermally coupled to a coaxially-placed heater, wherein the heater, block and processing cylinder are configured to supply heat to the feedstock such that the feedstock becomes progressively more liquid as it passes from the first to the second end of the processing cylinder;e. said injector cylinder formed in the block adjacent the processing cylinder and having a common wall with the processing cylinder extending from the opposite first to second ends, 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 feedstock processing cylinder by a passage configured to permit the movement of heated feedstock from the processing cylinder into the shooting pot, the injector plunger configured to inject the heated feedstock through the nozzle and into the mold. 19. The machine of claim 18 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. 20. The machine of claim 19 wherein the molding units each further comprise a processing drive for urging the feedstock 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. 21. The machine of claim 20 wherein the molding units each further comprise a distributor for distributing the feedstock 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 feedstock among the processing cylinders.
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