Patent Grant
7306643
This invention relates generally to a method for introducing additives into flowing or fluidized media with specific application for metallurgical, metal/ceramic powder technology processes.
U.S. Pat. No. 4,474,717 describes an injection of a small portion of plastics without introducing inert gas (preloading) followed by sectional introduction of inert gas using frequencies from 4 to 100 cycle per second having a pressure of 300-1500 psi (2 to 10 MPa) into the continuous passing plastic material. The result is a multi-layered internal foamed structure. The present invention expands this method by applying injection technology used in the combustion engine technology and reaching a more intensive penetration by higher pressure (40 to 200 MPa), higher frequency (100 to 1000 hz) and more exact dosing by controlled width of the pulses, frequency of the pulses and regulation of pressure using this technology.
The pulsing adding of liquid and gas is state of the art in burner systems, airless jet systems and spraying systems (atomizers). The present invention is distinguished from these applications by higher pressure of the liquid than 40 MPa and high energy atomizing. This pressure is not possible with the nozzles used at this time. Only by electrical activated hydraulic servo valves in common rail technology can these pulsations be realized.
The basic concept of the method for introducing additives consists of obtaining intensive atomizing, mixing and deep penetrating of additives into the medium stream by using high kinetic energy of the additives and exact timed pulsing and exact pulse width using appropriate injectors.
The exact dosing of the additives is obtained by regulation of the operation parameters of introduction for instance pressure, frequency, pulsing width, etc.
The state of the art of combustion engines using the “common rail” injection technology is utilized. The flexibility of this system by modifying the operating parameters is the highlight of this technology in comparison to the present mechanically operated injection methods. The common rail is loaded with fuel being pressurized up to 200 MPa and supplies the injector with this constant pressure. Electronic controller activating solenoid and piezo-operated, electro-hydraulic servo-valves move the nozzle needle by push rods with high precision. According to this technology exact dosing and homogenous distribution will be obtained.
The application and further development of this injection technology is subject to utilizing this improved technology for further applications as mentioned before. Furthermore, detailed design and configuring of nozzles, nozzle-needles, the arrangement of orifices in position and shape as well as arrangement of injectors are aspects of this invention.
The spatially predetermined position of the additives in the flowing material, also called fluid bed, is obtained by controlling the pulsating injection. The introduction and exact dosing of additives, that is hardeners, dyes, gas producers and softener for instance, into a liquid metal melt, metal/ceramic powder technology stream or metal stream for instance or the fluid bed of bulk material, such as powder, granules and pellets, is carried out by means of an injector.
The invention is used in melting units, in hot channel systems, in tools, components of tools and extruders, metal, metal/ceramic powder technology injection moulding, pelletizing, arrangements.
The nozzle needle of at least one nozzle is variable and highly precisely moved for the introduction by means of a device and in such a way that an additive is dosed exactly in relation to the volume flow of the medium and that a pulsating stream is injected into the medium flowing past the pulsating stream by means of at least one well-aimed nozzle opening. The additives are dosed by means of a pressure that can be variably adjusted such as by pulse width and pulse frequency. The desired homogenous distribution is obtained by the penetrating injection jet during compounding for instance.
The invention is particularly directed to the following applications:
i) Introduction into the metal, metal/ceramic powder technology melt stream. The introduction happens after the extruder unit. This is for many processes listed below having advantages noted. Producing material of different properties out of one plasticizing unit is possible.
ii) For metal, metal/ceramic powder technology Injection moulding systems, predetermined properties like porosity, coloring are possible by one process step through variable introduction. Only multi-component metal, metal/ceramic powder technology injection moulding machines can accomplish this today.
iii) For extruder systems, profiles can be extruded with different components at predetermined sections which can be foamed by diverting the metal, metal/ceramic powder technology melt stream and introducing gas creators in one side stream by an injector so that this melt stream will expand and joined together with the material of the main stream.
iv) Metal, metal/ceramic powder technology for sheet and tube extruders can be introduced with dyes, gas processors and softeners after the extruder. Therefore, a fast change of the material properties is possible that leads to economical flexibility in the production process.
The following application, processes and devices can be economically realized with the invention:
Exact dosing and homogenous distribution is utilized. The present invention relates to introducing additives for instance gas processors into the melt stream of low melting metals.
The advantage of this process is the application of light weight structures at locations of a part where it is demanded. The gas processing substance for expanding the matrix material is introduced in spatially predetermined positions. Various operation modes and combination of these can be obtained firstly by pressure differences between melt and gas processing substances and secondly by the frequency of pulsation and thirdly by the shape of the nozzle reaching into the melt channel.
i) Creation of Foam:
Creation of foam is possible using high frequency pulsation and therefore atomizing at high pressure differences and the advantages of counterflow and the subsequent high acceleration of the melt past variable sections of the melt channel. The difference in the speed of melt and additive is selected to be of a high value.
ii) Macro-hollow Cavities:
The introduction happens by drop shaped dosing of the melt flow at low frequency of the pulsation and only small pressure difference in flow direction and essentially laminar streaming conditions of gas processors and melt.
iii) Continuous Introduction:
Continuous introduction of a string of gas processors at nearly adequate flow speed of the passing medium. Small pressure difference is an advantage.
An apparatus for injection molding of compound parts with charger, which are connected to a pump which is compressing a chemical blowing agent has been published in DE1948454 to achieve a spatially predetermined foaming. Because of the insufficient mixing and dosing, the proposed foam quality cannot be reached. The present invention is distinguishes from this apparatus by using injectors (combination of valve and nozzle) and pulsing injection and optionally using a continuously pressurized pipeline “common rail” and hydro-electrical activated valves. Because of the shaping of nozzles and channels according to hydrodynamic principles as well as regulated pressure, the apparatus is different. The solenoid is activated by electrical supply and optionally controlled to generate selected wave forms from an arbitrary wave generator. This leads to operation mode like atomizing, dosage and continuous string. The selection of pressure difference and frequency of pulsation leads to a predetermined introduction of gas processors into the melt. The exact dosing and pressure regulation leads to a targeted dosage of drops into the melt resulting in a subsequent macro hollow cavity expansion.
The apparatus for introduction of gas creating substances into the highly pressurized melt consists of a nozzle in immediate connection with a servo-valve, or consists of a pump-nozzle system with a non-return-valve combination.
The injection technology of combustion engineering has reached a high state of art concerning the exact repeatability due to the demands of strict exhaust specifications and is especially applicable to the invention. The state of the art is shown by “fuel-injection valves for internal combustion engines” disclosed in DE2028442. The hydraulic activation of the valve push rod is regulated by a three way valve. An “injection device” with hydroelectric activation is described in FR2145081. The valve is pushed by a continuous hydraulic pressure and released by a controlled pressure loss on the backside of the push rod. In U.S. Pat. No. 3,990,422, the control of the hydro-electric activation has been improved by using a two circuit hydraulic system.
The present injectors show features which are necessary to comply with the demands of the inventive application and specification thereof. These are pressure regulation, electro-hydraulic activation by a push rod valve and pressure controlled by a sphere valve at the high pressure circuit, which is necessary to reach the high frequency pulsation and have the high pressure available at the nozzle needle immediately at the valve seat by a common rail system. This makes the accuracy independent of pressure and velocity differences between the gas creating substances and the melt.
The present invention relates to this high pressure technology which is to be adapted for the special condition of the introduction into the melt. The high pressure for injectors in melt introduction processes is needed to overcome the high melt pressure of about 100 to 140 MPa. Pressure of about 200 MPa can be reached by the available injectors with common rail. The continuous supply and the activation of the valves are solved with high reliability today.
An essential presupposition for running the injectors is the lubrication by the fuel because gas creating substances (water, alcohol, liquid gas) do not have substantial lubrication effect. The basic idea of the present invention is the use of two circuits applied to the standard injectors available in the market for making additional measures.
The JP 8170569 describes a version of injectors for diesel engines using a high pressurized circuit for injection and a low pressurized circuit for the servo hydraulic system. The inventive injector operates by separation of the hydro-electrical activation of the push rod of the valve which uses standard hydraulic oil and the introduction of gas creating substances that occurs at a slightly lower pressure (different from JP 8170569) because of a non return lock pressure that prevents penetration of the melt into the injector. Only the needle and seat of the valve are in touch with the non-lubrication medium. These parts can be made of sintered highly wear resistant material and are easily changeable. The electro-hydraulic servo circuit is not effected because of the separate circuit.
Further alternative solutions for the injector are:
1) Pump nozzle system with a combination of high pressure piston and spherical valves.
2) An electric activated swing system attached to a pump piston.
3) Limits for the stroke and positioning of the inlet valve as known for airless spraying systems can be used as well. In some applications, it is an advantage to have a small pressure difference between the introduced material and the melt. For this, the above solution can be used.
The regulation and control of the introduction process has the following features. Optionally, the hydraulic circuit can be separated from the gas creating substances to be introduced. The pressure p1 of the medium to be introduced and the pressure p2 of the hydraulic system are regulated by a pressure limit valve. The controller regulating the pressure depends on the melt p3, for the hydraulic system circuit as well as the injection pressure of the introduced medium. The injector is activated by a solenoid or piezo actuator. The regulation is controlled by an “Arbitrary Wave Form Generator”, known to those skilled in the art. Furthermore, the specification of hydraulic, nozzles, injectors and melt channel are described below.
The hydraulics for continuous production for instance extrusion, continuous casting and for part production by injection moulding and die casting are prescribed. The system for continuous production is used for extruders. Continuous charging and multiple injector assembly is preferred. The system for part production is used in injection moulding and die casting systems. Because of the interruption after the injection, a simple solution using a pressure multiplier double cylinder is offered for injection moulding systems. The hydraulic system of existing machines have usually a pressure of 26 MPa that can be used to produce high pressure by a pressure multiplying system. While plastification metal melting, metal/ceramic powder technology takes place, the pressure multiplier for the hydraulic system as well as for the introducing system is loaded with hydraulic oil and gas creating substance respectively. For the dosage of the melt with concrete size and spatially predetermined position it is necessary to achieve a constant pressure difference while injection takes place. A high pressure difference leads to the destroying of the melt. The ramping of the pressure is shown in
The regulation of the solenoid takes place by controlling with “Arbitrary Wave Form Generator”, opening and locking can be optimized by this system. Furthermore the shape of nozzle and melt channel is described.
Examples of Introducing Additives.
The present process relates to the modification of the properties (compounding) of an original extruded material by diversion of the main stream into a side stream and introducing additives into this side stream by dosing, mixing and distribution of the original material. The kind of additives determine the properties of the metallic, metal/ceramic powder technology material of the melt. These additives are for instance additional components such as hardeners, dyes, gas processors, softeners, fillers and reinforcements.
This process can be applied to inside melt channels of mould for extrusion as well as for injection moulding systems, by means of using at least two diverted streams of melt to reach different properties of the plastic material. Profiles produced by this process have different properties of the material at spatially predetermined positions. This method saves an additional extruder to produce the additional material component. The essential advantage is, that based on the same origin material the waste disposal is not necessary, because based on the same material the recycling results in a unique material. The additives are introduced by nozzle, injector, charging tube, mixing head, porous sinter metal, sliding pump, charger and spraying system. The following concrete application for production of profiles are subsequently shown for instance:
i) Aluminum, Metal/ceramic Powder Technology Window Profiles.
Sections of the profile close to the outside or inside can be insulated with the present process by using foam filling at the concerned chambers. The calipers as used for the known multiple chamber systems will be adapted with inside channels and with the present described devices. From the main melt stream, diverted material comes to the channel duct within the caliber in which by means of a metering regulation (as there are valve, throttle) the melt is fed to the device for introduction of the additives. Subsequently devices for mixing and homogenizing are placed in the channel to complete the compounding process. Using aluminum, metal/ceramic powder technology for the window profile the additive will be physical gas creators like water, carbon dioxide, alcohol, glycerin, etc. The pressure ramping in the melt duct is decreasing because the additives provide additional gas volume. For expansion of the material, a conical zone is configured according to the volume increase or the velocity increase and the additional volume comes to an expansion zone (conical increasing outlet) so that the compounded material is fed to the outside as solid aluminum, metal/ceramic powder technology profile shells and can be homogenous and adhesively bound together. The advantage of the profiles with multi components comes by the cost effective production and the better properties of the material for heat and sound insulation (low pressure within the foam cells and therefore lower heat transfer rates) and less cost for recycling of the waste material. As a variation, the additives can be introduced by singular dosage leading to a profile with honeycomb shaped cellular structures of high strength. These structures replace the necessary stiffener profiles.
ii) Window Profiles Out of Low Melting Metals, Metal/Ceramic Powder Technology.
This is as described above but using aluminum, metal/ceramic powder technology
iii) Claddings or Panel Shaped Coverings for Outside or Inside Walls.
This is simpler than described above. The total extruded profile with foam core and large cell structure can be obtained by one diverted material stream from the main stream to be compounded within the center of the profile. The subsequent process of calibrating and cooling remains the same as before. The so obtained profiles can be used for inside cladding, mobile walls etc. having high stiffness by using large cell striker.
iv) Tubes from Low Melting Metals, Powder/ceramic Technology
Because of suitable introduction of gas creating and/or fillers, or reinforcement to the melt stream into spatially predetermined locations (as there are intermediate layer, outside layers, etc.), a multi component tube can be produced with simple measures. The device for compounding is attached in between the flanges of extruder and mould and is supplied by the channels of the mould to modify the properties of the material. Another production process with excellent mixing of the melt consists of introducing the additives before the cellular pump. Another improvement can be installed by attaching a mixer or dynamic mixing head for homogenous compounding.
v) Coloring of the Outside Layers of the Profiles.
The introduction of dyes into the diverted melt channel makes it possible to produce a fast changeable coloring process. The process is most economical, because the expensive dyes are only applied on the outside and no loss of material happens by changing of color because the extruder does not have to be emptied completely. The change of the color comes into force immediately. Further possibilities for cost reduction can be achieved by bringing the coloring to the outside layers only.
vi) Production of Sheets, Insulation Sheet Material and Compound Sheets.
For systems having a large working width, the additives can be introduced into the center layer of the extruded sheet, or diverted to a melt channel similar to that described before for the device as implemented into the calipers having the total width of the sheet.
vii) Apparatus for Adding Up a Extrusion System for Multi Component Process.
The apparatus will be attached in between the flanges of the extruder and the mould. Following elements are included:
viii) Apparatus for Dosage and Mixing of Additives into Liquid Medium by Using Valve Cone Orifice or Pocket Hole Orifice
The invention relates to a multifunctional mixing and dosing head, consisting of a nozzle cone and a nozzle needle, in which the volume flow is metered or blocking the outside flowing medium by the position of the outside nozzle needle and consisting of a nozzle cone and a nozzle needle, in which the volume flow is metered or blocking the inside flowing medium by the position of the inside nozzle needle.
This combination of valve, nozzle and injector leads to an economical mixing and dosing directly on the needle top of the concentric double cone. The invention also relates to a hot runner valve, having an injector, for introducing the additives into the outer flowing medium, instead of the valve needle. Several combinations of mixing and dosing heads are mentioned, especially the attachment to plasticizing unit, extruders, melt channel and the subsequent attachment of static mixer systems.
The economical benefit consists of the spatially predetermined location of the dosage and the excellent mixing and the exact dosing according to the mixing ratio. Applications for this hot runner valve with integrated mixing head includes introducing additives like dyes, hardener, softener, gas processors, etc. directly into the metallic melt and immediately before the gate of the mould. Besides the several known two component hot runner valves, the present suggested solution has the following features:
The application of the concentric positioned nozzle needles within the nozzle needle of this invention can be compared to EP 0310 914, 1987, where a concentric positioned nozzle needle is shown in FIGS. 6.1 to 6.5. The present apparatus is distinguished from the above by using a spatially predetermined dosing of the melt while in EP 0310914 only each of the two media is switched to the mould. The present apparatus can achieve any mixing ratio in between by using the introduction of the additives by pulsation.
In U.S. Pat. No. 4,657,496, a hot runner valve for two components is presented with concentric positioned charging tube. By the cavities (9) and (6) within the nozzle needle, depending on the position either the one or the other component is blocked or opened respectively. The concentric shaping of the inside located nozzle makes it possible to regulate the dosing by moving the outside nozzle needle which is controlled by the inner or outer nozzle. A mixing or a fast pulsing introduction as shown by the present apparatus is not a subject of U.S. Pat. No. 4,657,496.
The target of the present invention is not only to introduce at least two media in a concentric manner, but also to achieve a mixing, i.e., to dosage the outer medium with the inner medium.
In U.S. Pat. No. 5,286,184, a variation of the concentric nozzle is described, which differs from U.S. Pat. No. 4,657,496, in that it discloses the activation of the hollow shaped nozzle needle. Also in this case, there is a concentric introduction, but no mixing or dosage is the target.
The nozzle needle is activated by a push rod within the boring of the nozzle needle and is regulated by a servo-mechanic. To reach a spatially predetermined position by the dosage and/or dosing and excellent mixing the usage of a valve cone orifice VCO and a CDI injectors, as it is used in combustion engines, is an advantage. The activation of the injector is known by a hydraulic piston but also can use for the servo-mechanics for instance, solenoid, piezo actuator, hydraulic servo, etc.
The invention may take form in certain parts and arrangement of parts, preferred embodiments of which will be described in detail and illustrated in the accompanying drawings which form a part hereof and wherein:
a is a schematic representation of a mold for an extruder;
b is an orthogonal representation of the mold depicted in
a and 17b are views similar to
a and 36b cross-sectioned views of the outlet and inlet, respectively, of the arrangement shown in
a and 37b are schematic view of the outlet and inlet, respectively, of the nozzle disclosed in
a, 40b, 40c and 40d illustrate various aerosol profile shapes capable of being produced by the subject invention;
a, 45b and 45c schematically depict, respectively, progressively closing positions of the needle valve used in the subject invention;
a, 46b and 46c represent enlarged views of the orifice/needle shown in
Referring now to the drawings wherein the showings are for the purpose of illustrating preferred embodiments of the invention and not for the purpose of limiting the same, there is shown in
In
In
In
In
In
For accurate dosing with less mixing, the arrangement of
In
The nozzle arrangement is shown in
In
In
In
The arbitrary wave form generator 120 creates the opening current for the electro mechanism 112. The introduction of the gas processors 117 into the melt stream 114 happens in the interface 116 part after the extruder tip 160 by a nozzle 113 extending into the channel. For heating, a heater band 159 is located around the nozzle 113.
The push spring 131 increases the force resulting from the difference of force on the nozzle needle 112 and the hydraulic pressing (bias) 110. The opening is activated by the solenoid 109 which releases the sphere of the valve 108 and hydraulic oil of the servo is streaming out of the high pressure chamber 110.
FIGS. 30,31 and 32 show a nozzle with various orifices.
The introduction of additives to the medium may be in the flow direction 55b or in the counterflow direction 55a. The advantage of the counterflow is the introduction of individually closed dosages. The introduction may optionally be caused by pulsation. Also, use may be made of chicanes (i.e. obstacles) in the flow of the medium so that the change of velocity leads to shear forces and to additional mixing respectively in the expansion zone 60.
In
a and 37b show the version of the invention as it is in
a shows a rectangular profile.
In
In
In
In
The supply of the substance happens through the fitting 91. The melt is supplied by the channel 89.
Indexing of Reference Numbers:
| Number | Date | Country | Kind |
|---|---|---|---|
| 19/2000 | Jan 2000 | AT | national |
| 995/2000 | Jun 2000 | AT | national |
| 1475/2000 | Aug 2000 | AT | national |
| PCT/AT01/00003 | Apr 2001 | AT | national |
This application is a Division of Ser. No. 10/958,855, filed Oct. 5, 2004 which is a Division of Ser. No. 09/936,039, filed Sep. 8, 2001, now U.S. Pat. No. 6,866,171.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4474717 | Hendry | Oct 1984 | A |
| 5129629 | Christensen | Jul 1992 | A |
| 6866171 | Ickinger | Mar 2005 | B2 |
| 20050077642 | Ickinger | Apr 2005 | A1 |
| 20060272702 | Ickinger | Dec 2006 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20060254389 A1 | Nov 2006 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10958855 | Oct 2004 | US |
| Child | 11491443 | US | |
| Parent | 09936039 | Sep 2001 | US |
| Child | 10958855 | US |
