Low pressure injection molding of flat tableware from metal feedstocks
AssigneeRutgers, The State University of New Jersey
InventorsJames Schoonover, Steve Sesny, Michael Sean Zedalis
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Abstract
A process for molding flat tableware from powders and molding compositions therefor are disclosed. Parts produced by this process are formed near net shape without the need for machining or other finishing operations. The process comprises forming a mixture containing a metal powder, a gel-forming material and an aqueous gel-forming material solvent, and molding the mixture in an injection molding machine under conditions of temperature and pressure to produce a self-supporting flat tableware article.
Claims26
A process for forming a long, thin cross section article having a complex shape comprising the steps of:
- a) forming a mixture comprising,
- 1) powder containing at least one member selected from the group consisting of pure stainless steel alloys, stainless steel alloying elements, intermetallic compounds, components of metal matrix composites and mixtures thereof;
- 2) a gel-forming material;
- 3) an aqueous gel-forming material solvent;
- and
- 4) a gel strength enhancing agent selected from the group consisting of calcium borate, magnesium borate, zinc borate and ammonium borate;
- and
- b) molding the mixture in a mold containing a cavity for shaping the article under conditions of temperature and pressure sufficient to produce a self-supporting article.
An injection molding process for forming a flat tableware article having a complex shape comprising the steps of:
- a) forming a mixture comprising,
- 1) a metal powder
- 2) a gel-forming material selected from the group of polysaccharides consisting of agaroids;
- 3) an aqueous gel-forming material solvent;
- and
- 4) a gel strength enhancing agent selected from the group consisting of calcium borate, magnesium borate, zinc borate and ammonium borate;
- b) supplying the mixture to an injection molding machine having a mold containing a cavity for shaping the article, the mixture being maintained during the supply step at a first temperature above the gel point of the gel-forming material;
- and
- c) cooling the mixture in the mold to a second temperature below the gel point of the gel-forming material to form the article.
Dependencies are inferred from the claim text.