Method and means for producing moulded foam bodies

Abstract

Present invention relates to a method and means for producing moulded bodies of a metal foam ( 9 ), in particular an aluminium foam. The Method involves the use of mould ( 1 ) having a cavity ( 8 ) and at least one entrance opening ( 3 ). The mould id filled with a metal foam in a manner where the entrance opening of the mould is submerged into a metal melt ( 4 ) and the melt is caused to foam inside the mould ( 81 ) and fill its cavity ( 8 ).

1 . An apparatus for producing a moulded body of a metal foam, said apparatus comprising: 
 a container for containing a molten metal;    a gas inlet for injecting gas into said container; and,    a mould having a generally closed cavity and having at least one entrance opening for providing fluid communication into said cavity; said cavity having the general shape of the body being formed;    wherein the mould is positioned above said container with the at least one entrance opening being maintained submerged in said molten metal.    
   
   
       2 . The apparatus of  claim 1  wherein said at least one entrance opening is positioned above said gas inlet to receive and direct the foam into said cavity.  
   
   
       3 . The apparatus of  claim 1  further including a positioning means for raising and lowering said mould in the molten metal.  
   
   
       4 . The apparatus of  claim 1  wherein said mould is formed of two or more parts.  
   
   
       5 . The apparatus of  claim 1  wherein said mould is provided with a vent for venting any gas contained therein while being filled with the molten metal or the foam.  
   
   
       6 . The apparatus of  claim 1  wherein said mould includes a heating means.  
   
   
       7 . The apparatus of  claim 1  wherein said mould includes a cooling means.  
   
   
       8 . The apparatus of  claim 1  wherein said gas inlet is chosen from the group consisting of: a rotating impeller; a porous plug; and a porous plate.  
   
   
       9 . The apparatus of  claim 8  wherein said gas inlet comprises a rotating impeller with one or more gas discharge ports.  
   
   
       10 . The apparatus of  claim 1  wherein a plurality of gas inlets are provided in said bath.  
   
   
       11 . The apparatus of  claim 8  wherein a plurality of gas inlets are provided in said bath.  
   
   
       12 . The apparatus of  claim 1  wherein said mould comprises a hollow metal article to be filled with said foam.  
   
   
       13 . The apparatus of  claim 1  wherein said at least one entrance opening includes an outwardly flared end portion for directing entrance of said molten metal or said foam into said cavity.