Polymeric Feedstock Barrel for Rapid Capacitor Discharge Forming

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Solution Overview

Problem

The high cost and complexity of using ceramic materials for feedstock barrels in rapid capacitor discharge forming (RCDF) of metallic glasses, due to their expensive processing and machining requirements, make them prohibitively expensive for many applications.

Innovation Solution

The use of cellulosic materials or synthetic polymeric materials, or their composites, as feedstock barrels in RCDF processes, which provide electrical insulation, mechanical confinement, and thermal stability, allowing for efficient and cost-effective processing of metallic glasses without catastrophic failure or ignition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ceramic materials are used for feedstock barrels in RCDF processes, then electrical insulation and thermal stability are achieved, but manufacturing cost and processing complexity increase significantly

Engineering Contradiction:

Improveelectrical insulation stabilityVSAvoidbarrel manufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameters from ceramic to polymeric materials, specifically selecting polymers with appropriate glass transition temperatures and electrical resistivity. This parameter change maintains the essential functions of electrical insulation and thermal stability while dramatically reducing manufacturing cost and processing complexity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite polymeric materials that combine multiple properties: electrical insulation, thermal stability up to RCDF processing temperatures, and mechanical strength. These composite materials achieve the performance previously requiring ceramic materials but with easier manufacturing processes.

Inventive Principle:

Principle #40Composite materials

2Temperature

If ceramic materials are used for feedstock barrels, then high temperature stability is achieved, but machining difficulty and time increase

Engineering Contradiction:

Improvethermal stability at high temperatureVSAvoidmachining ease

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent selects polymeric materials with glass transition temperatures above the RCDF processing temperature range, ensuring thermal stability without requiring ceramic-level heat resistance. This parameter selection eliminates the need for complex ceramic machining while maintaining functional performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent adopts disposable polymeric barrels that are inexpensive enough to be replaced rather than reused. This eliminates the need for durable, hard-to-machine ceramic barrels and complex machining operations, as each barrel is discarded after a single use.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If ceramic materials are used for feedstock barrels, then chemical stability is achieved, but overall processing cost increases

Engineering Contradiction:

Improvechemical stabilityVSAvoidoverall processing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent selects polymeric materials with chemical inertness comparable to ceramics, ensuring no adverse reactions with the metallic glass feedstock. The chemical stability parameter is maintained while the cost parameter is dramatically improved through the use of conventional polymer materials.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

These materials enable the RCDF of metallic glasses with uniform heating and shaping, maintaining mechanical integrity and preventing electrical current flow, thus reducing costs and simplifying the machining process, making the process more viable for various applications.

Implementation Method 1

the barrel includes a cellulosic material, or synthetic polymeric material, or composite thereof... provide electrical insulation

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

mechanically confine the heated feedstock

Methodology Applied

Scientific EffectMechanical confinement: Physical Containment

Implementation Method 3

rapidly heating and shaping a metallic glass using a rapid discharge of electrical current... to rapidly heat the sample to a processing temperature

Methodology Applied

Scientific EffectRapid heating: Joule Heating

Implementation Method 4

applying a deformational force to shape the heated sample into an article

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 5

cooling said sample to form a metallic glass article... configured to cool the article at a rate sufficient to avoid crystallization

Methodology Applied

Scientific EffectRapid cooling: Adiabatic Cooling

Data Source

PatentUS10273568B2Cellulosic and synthetic polymeric feedstock barrel for use in rapid discharge forming of metallic glasses

Publication Date: 2019.04.30 APPLE INC

AI summary

The present disclosure is directed to the use of cellulosic materials, such as wood, paper, etc., or synthetic polymeric materials, such as a thermoplastic, rubber, etc., or a composite containing one or more of these materials as feedstock barrels for the process of injection molding of metallic glasses by rapid capacitor discharge forming (RCDF) techniques.