METALLIC GLASS
20230070081 · 2023-03-09
Inventors
Cpc classification
C22F1/002
CHEMISTRY; METALLURGY
International classification
C22C45/10
CHEMISTRY; METALLURGY
C22F1/00
CHEMISTRY; METALLURGY
Abstract
A metallic glass having a general formula of Zr.sub.15-65Cu.sub.0-25Ni.sub.0-20Al.sub.0-30Hf.sub.0-30Ti.sub.0-30Co.sub.0-30.
Claims
1. A metallic glass having a general formula of Zr.sub.15-65Cu.sub.0-25Ni.sub.0-20Al.sub.0-30Hf.sub.0-30Ti.sub.0-30Co.sub.0-30.
2. The metallic glass of claim 1, wherein the metallic glass is a bulk metallic glass.
3. The metallic glass of claim 2, wherein the metallic glass is selected from the group consisting of: Zr.sub.59±2Cu.sub.16±2Ni.sub.12±2Al.sub.10±2Hf.sub.2.5±0.5Ti.sub.0.5±0.3, Zr.sub.55±2Cu.sub.20±2Al.sub.15±2Co.sub.10±1, Zr.sub.54±2Ni.sub.16±2Cu.sub.14±2Ti.sub.10±2Al.sub.6±1, Zr.sub.55±2Cu.sub.20±2Co.sub.10±2Ti.sub.8±2Al.sub.7±1, Zr.sub.55±2Cu.sub.20±2Ti.sub.10±1Co.sub.10±1Al.sub.5±1, and Zr.sub.45±2Cu.sub.20±2Ti.sub.10±2Al.sub.10±2Co.sub.10±2Hf.sub.5±1.
4. The metallic glass of claim 3, wherein the metallic glass is selected from the group consisting of: Zr.sub.59.2Cu.sub.16.2Ni.sub.12.6Al.sub.9.6Hf.sub.2.2Ti.sub.0.2, Zr.sub.55Cu.sub.20Al.sub.15Co.sub.10, Zr.sub.54Ni.sub.16Cu.sub.14Ti.sub.10Al.sub.6, Zr.sub.55Cu.sub.20Co.sub.10Ti.sub.8Al.sub.7, Zr.sub.55Cu.sub.20Ti.sub.10Co.sub.10Al.sub.5, and Zr.sub.45Cu.sub.20Ti.sub.10Al.sub.10Co.sub.10Hf.sub.5.
5. The metallic glass of claim 2 in the form of a rod.
6. The metallic glass of claim 5, wherein the metallic glass has an average diameter of about 1 mm to about 5 mm.
7. The metallic glass of claim 1, wherein the metallic glass is a ribbon metallic glass.
8. The metallic glass of claim 7, wherein the metallic glass is selected from the group consisting of: Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67Cu.sub.16.67, Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20Cu.sub.20, Zr.sub.25Hf.sub.25Al.sub.25Co.sub.25, Ti.sub.20Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20, Ti.sub.16.67Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67, and Ti.sub.25Zr.sub.25Hf.sub.25Co.sub.25.
9. The metallic glass of claim 1, wherein the metallic glass has an average thickness of about 10 μm to about 100 μm.
10. The metallic glass of claim 1 having a hardness of about 4 GPa to about 9 GPa.
11. The metallic glass of claim 1, wherein the metallic glass is non-toxic.
12. The metallic glass of claim 1, wherein the metallic glass is metalloid-free.
13. A method of fabricating the metallic glass of claim 1, comprising: melting a mixture essentially consisting of, in atomic percentage, about 15% to about 65% of Zr, 0% to about 25% of Cu, 0% to about 20% of Ni, 0% to about 30% of Al, 0% to about 30% of Hf, 0% to about 30% of Ti, and 0% to about 30% of Co; and quenching the molten mixture in a mold to form a casted metallic glass.
14. The method of claim 13, wherein the melting is performed in an arc-melting furnace with a vacuum level of up to 8×10.sup.−4 Pa.
15. The method of claim 13, wherein the metallic glass is a ribbon metallic glass, and the method further includes: melting the casted metallic glass; and melt spinning the molten mixture.
16. The method of claim 15, wherein the melt spinning is performed in an induction-melting furnace with a vacuum level of up to 8×10.sup.−4 Pa.
17. The method of claim 15, wherein the melt spinning is performed at a rotating speed of about 60 r/s to about 90 r/s.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0015]
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
DETAILED DESCRIPTION
[0038] Unless otherwise specifically provided, all tests herein are conducted at standard conditions which include a room and testing temperature of 25° C., sea level (1 atm.) pressure, pH 7, and all measurements are made in metric units. Furthermore, all percentages, ratios, etc. herein are by weight, unless specifically indicated otherwise. It is understood that unless otherwise specifically noted, the materials, compounds, chemicals, etc. described herein are typically commodity items and/or industry-standard items available from a variety of suppliers worldwide.
[0039] Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Terms of degree, such as “about” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, testing, and use of the described embodiments.
[0040] As used herein, the term “metallic glass” refers to a material containing one or more glass-forming alloys. The glass-forming alloy may have a relatively high glass forming ability (GFA) for producing a bulk metallic glass (BMG) (e.g., having an average diameter or an average thickness of at least 1 mm). Alternatively, a ribbon metallic glass (RMG) (e.g., having an average thickness of about 10 nm to about 100 nm) may be produced from a glass-forming alloy has a relatively low GFA.
[0041] In one embodiment, a machine learning algorithm is used to project different multicomponent MGs. The algorithm comprises calculating factors of different stable compounds. The metallic glass may be a BMG or a RMG depending on the composition of the glass-forming alloys. Metallic glasses obtained by the algorithm has a general formula of Zr.sub.15-65Cu.sub.0-25Ni.sub.0-20Al.sub.0-30Hf.sub.0-30Ti.sub.0-30Co.sub.0-30. In an alternative embodiment, the metallic glass may include additional transition metals, such as Fe and Nb. The metallic glasses may further include unavoidable impurities. These metals are non-toxic and easy to access (containing no rare earth metals or precious metals), thus offering substantial economic values. Due to the absence of any metalloid, toxic or noble element, these MGs may be used in wearables and biomedical applications including manufacturing (e.g., by additive manufacturing or other known techniques) of watch parts, surface coatings, medical equipment, or sports equipment.
[0042] The metallic glass may include, by atomic percentage, about 15% to about 65%, about 15.5% to about 62%, or about 16% to about 60% Zr. In one embodiment, the BMG may include at least 40%, at least 42%, or at least 45% Zr. The RMG may include at least 15%, at least 15.5%, or at least 16% Zr.
[0043] The metallic glass may include, by atomic percentage, 0% to about 25%, about 10% to about 23%, or about 13% to about 20% Cu. In one embodiment, the BMG may include at least 10%, at least 12%, or at least 13% Cu. The RMG may include 0%, at least 10%, or at least 15% Cu.
[0044] The metallic glass may include, by atomic percentage, 0% to about 20%, about 5% to about 18%, or about 10% to about 17% Ni. In one embodiment, the BMG may include 0%, at least 10%, or at least 12% Ni. The RMG may include 0%, at least 13%, or at least 15% Ni.
[0045] The metallic glass may include, by atomic percentage, 0% to about 30%, about 3% to about 28%, or about 5% to about 27% Al. In one embodiment, the BMG may include at least 1%, at least 3%, or at least 5% Al. The RMG may include 0%, at least 15%, or at least 17% Al.
[0046] The metallic glass may include, by atomic percentage, 0% to about 30%, about 1% to about 28%, or about 2% to about 26% HE In one embodiment, the BMG may include 0%, at least 1%, or at least 2% Hf. The RMG may include at least 10%, at least 12%, or at least 16% Hf.
[0047] The metallic glass may include, by atomic percentage, 0% to about 30%, about 0.1% to about 27%, or about 0.2% to about 26% Ti. In one embodiment, the BMG may include 0%, at least 0.1%, or at least 0.2% Ti. The RMG may include 0%, at least 15%, or at least 16% Ti.
[0048] The metallic glass may include, by atomic percentage, 0% to about 30%, about 5% to about 27%, or about 9% to about 25% Co. In one embodiment, the BMG may include 0%, at least 5%, or at least 9% Co. The RMG may include at least 10%, at least 15%, or at least 16% Co.
[0049] In one embodiment where the metallic glass is a BMG, the BMG is selected from the group consisting of: Zr.sub.59±2Cu.sub.16±2Ni.sub.12±2Al.sub.10±2Hf.sub.2.5±0.5Ti.sub.0.5±0.3, Zr.sub.55±2Cu.sub.20±2Al.sub.15±2Co.sub.10±1, Zr.sub.54±2Ni.sub.16±2Cu.sub.14±2Ti.sub.10±2Al.sub.6±1, Zr.sub.55±2Cu.sub.20±2Co.sub.10±2Ti.sub.8±2Al.sub.7±1, Zr.sub.55±2Cu.sub.20±2Ti.sub.10±1Co.sub.10±1Al.sub.5±1, and Zr.sub.45+2Cu.sub.20±2Ti.sub.10±2Al.sub.10±2Co.sub.10±2Hf.sub.5±1. Additionally or alternatively, the BMG or RMG is selected from the group consisting of: Zr.sub.59.2Cu.sub.16.2Ni.sub.12.6Al.sub.9.6Hf.sub.2.2Ti.sub.0.2, Zr.sub.55Cu.sub.20Al.sub.15Co.sub.10, Zr.sub.54Ni.sub.16Cu.sub.14Ti.sub.10Al.sub.6, Zr.sub.55Cu.sub.20Co.sub.10Ti.sub.8Al.sub.7, Zr.sub.55Cu.sub.20Ti.sub.10Co.sub.10Al.sub.5, Zr.sub.45Cu.sub.20Ti.sub.10Al.sub.10Co.sub.10Hf.sub.5, Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67Cu.sub.16.67, Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20Cu.sub.20, Zr.sub.25Hf.sub.25Al.sub.25Co.sub.25, Ti.sub.20Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20, Ti.sub.16.67Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67, and Ti.sub.25Zr.sub.25Hf.sub.25Co.sub.25. Unless otherwise specified, the atomic masses or percentages used herein refer to the particular value ±2%.
[0050] The metallic glass may have a reduced modulus of about 70 GPa to about 140 GPa, about 75 GPa to about 138 GPa, or about 80 GPa to about 135 GPa. In one embodiment, the BMG may have a reduced modulus of at least 90 GPa, at least 92 GPa, or at least 93 GPa. The RMG may have a reduced modulus of at least 70 GPa, at least 75 GPa, or at least 80 GPa. The metallic glass may have a hardness of about 3 GPa to about 10 GPa, about 3.5 GPa to about 9.5 GPa, or about 4 GPa to about 9 GPa. In one embodiment, the BMG may have a hardness of at least 5 GPa, at least 5.5 GPa, or at least 5.8 GPa. Compared with conventional alloys, such as steel, copper alloys, magnesium alloys and aluminium alloys, the BMGs of the present embodiments may have an outperforming hardness value of about 6 GPa to about 9 GPa. The RMG may have a hardness of at least 4 GPa, at least 4.5 GPa, or at least 4.7 GPa.
[0051] The metallic glass may have a glass transition temperature of about 600 K to about 850 K, about 605 K to about 840 K, or about 606 K to about 830 K. In one embodiment, the BMG may have a glass transition temperature of at least 610 K, at least 615 K, or at least 616 K. The RMG may have a glass transition temperature of at least 600 K, at least 605 K, or at least 606 K.
[0052] In one embodiment, the metallic glass (BMG or RMG) may be fabricated by melting a mixture essentially consisting of, in atomic percentage, about 15% to about 65% of Zr, 0% to about 25% of Cu, 0% to about 20% of Ni, 0% to about 30% of Al, 0% to about 30% of Hf, 0% to about 30% of Ti, and 0% to about 30% of Co; and quenching the molten mixture.
[0053] Preferably, the BMG is in the form of a rod having an average diameter or an average thickness of about 2 mm to 5 mm, and the RMG is in the form of a ribbon with an average thickness of about 50 nm. Alternatively, the BMG and RMG may have other shapes and sizes.
[0054] The raw materials used in the mixture may have a purity of higher than 95%, 97%, 99%, and preferably higher than 99.95%. The raw materials may be provided in the form of ingots, wires, powder, etc.
[0055] The melting may be performed in a furnace (e.g., an arc-melting furnace, an induction-melting furnace, a resistance-melting furnace, etc.) which may be pre-pumped and evacuated with vacuum prior to back-filling with inert gas (e.g., argon, nitrogen, helium, or any combination thereof). The vacuum level may be set to about 5×10.sup.−4 Pa, about 7×10.sup.−4 Pa, or about 8×10.sup.−4 Pa to avoid possible oxidation. The melting may be repeated for enhanced homogeneity. For example, the molten mixture may be remelted for at least 3 times or at least 5 times, and preferably 6 times.
[0056] The quenching may be performed with the use of a mold (e.g., a water-cooled mold) to form a casted metallic glass, e.g., a casted BMG. For example, the mold may be a copper mold having a diameter of 2 mm, 3 mm, or 5 mm. To fabricate RMG, the casted metallic glass may further be melted in a furnace and then subjected to melt spinning. Similar to the above, the furnace may be an arc-melting furnace, an induction-melting furnace, a resistance-melting furnace, etc. that is pre-pumped and evacuated with vacuum prior to back-filling with inert gas. The melt spinning may be performed with a copper wheel that is rapidly rotated at a rotating speed of about 60 r/s to about 90 r/s, or about 70 r/s to about 80 r/s, and preferably about 75 r/s.
[0057] Hereinafter, the present invention is described more specifically by way of examples, but the present invention is not limited thereto.
[0058] Unless otherwise specified, each of the raw materials for the MGs in the following examples has a purity level of higher than 99.95%. DSC experiments are performed using both DSC3/700 and TGA DSC3+HT/1600 (METTLER TOLEDO) with a heating rate of 20 K/min and argon flow with a rate of 50 mL/min. For scanning transmission electron microscope (STEM) experiments, STEM samples are prepared by PIPS II MODEL 695 (GANTAN) and the experiments are carried out using a JEM-ARM300F transmission electron microscope equipped with double spherical aberration correctors. For atom probe tomography (APT) experiments, needle-shaped APT specimens are fabricated by lift-outs and annular milled in a FEI Scios focused ion beam/scanning electron microscope (FIB/SEM). The APT characterizations are performed in a local electrode atom probe (CAMEACA LEAP 5000 XR). The specimens are analyzed at 70 K in voltage mode, at a pulse repetition rate of 200 kHz, a pulse fraction of 20%, and an evaporation detection rate of 0.2% atom per pulse. Imago Visualization and Analysis Software (IVAS) version 3.8 is used for creating the 3D reconstructions and data analysis.
[0059] Preparation of BMGs
[0060] Pure metals, including Ti, Zr, Hf, Al, Co, Ni, and Cu are used to prepare six BMGs having a general formula of Zr.sub.59.2Cu.sub.16.2Ni.sub.12.6Al.sub.9.6Hf.sub.2.2Ti.sub.0.2, Zr.sub.55Cu.sub.20Al.sub.15Co.sub.10, Zr.sub.54Ni.sub.16Cu.sub.14Ti.sub.10Al.sub.6, Zr.sub.55Cu.sub.20Co.sub.10Ti.sub.8Al.sub.7, Zr.sub.55Cu.sub.20Ti.sub.10Co.sub.10Al.sub.5, and Zr.sub.45Cu.sub.20Ti.sub.10Al.sub.10Co.sub.10Hf.sub.5. The raw materials (including Ti ingots) are first melted in a lab-scale arc-melting furnace under an argon atmosphere that is pre-pumped to a high vacuum level of 8×10.sup.−4 Pa. After 6 times of remelting, the molten samples are then casted in copper molds. Specifically, Zr.sub.55Cu.sub.20Ti.sub.10Co.sub.10Al.sub.5 and Zr.sub.45Cu.sub.20Ti.sub.10Al.sub.10Co.sub.10Hf.sub.5 are casted in a copper mold with dimensions of Φ2 mm; Zr.sub.55Cu.sub.20Al.sub.15Co.sub.10, Zr.sub.54Ni.sub.16Cu.sub.14Ti.sub.10Al.sub.6, and Zr.sub.55Cu.sub.20Co.sub.10Ti.sub.8Al.sub.7 are casted in a copper mold with dimensions of Φ3 mm; and Zr.sub.59.2Cu.sub.16.2Ni.sub.12.6Al.sub.9.6Hf.sub.2.2Ti.sub.0.2 is casted in a copper mold with dimensions of Φ5 mm to form the rod-shaped BMGs, as shown in
[0061] Preparation of RMGs
[0062] Pure metals, including Ti, Zr, Hf, Al, Co, Ni, and Cu are used to prepare six RMGs having a general formula of Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67Cu.sub.16.67, Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20Cu.sub.20, Zr.sub.25Hf.sub.25Al.sub.25Co.sub.25, Ti.sub.20Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20, Ti.sub.16.67Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67, and Ti.sub.25Zr.sub.25Hf.sub.25Co.sub.25. The raw materials (including Ti ingots) are first melted in a lab-scale arc-melting furnace under an argon atmosphere that is pre-pumped to a high vacuum level of 8×10.sup.−4 Pa. After 6 times of remelting, the molten ingot samples are then casted in copper molds. The casted ingots are then melted in a lab-scale induction-melting furnace under an argon atmosphere that is pre-pumped to a high vacuum level of 8×10.sup.−4 Pa. The molten ingots are then subjected to melt spinning with a single copper roller at a rotating speed of 75 r/s to form the RMGs, as shown in
[0063] Characterization of the BMGs and RMGs
[0064]
[0065]
[0066] The chemical composition of the glass-forming alloys is measured with energy dispersive X-ray spectroscopy (EDX). As shown in Table 1, the results show that the exact composition is consistent with the predicted composition (using the machine learning model) within a relative error of 9%.
TABLE-US-00001 TABLE 1 The EDX results of the twelve MGs. Zr Cu Ni Al Hf Ti Co Composition at % at % at % at % at % at % at % Zr.sub.59.2Cu.sub.16.2Ni.sub.12.6Al.sub.9.6Hf.sub.2.2Ti.sub.0.2 59.2 16.1 12.2 10.1 2.2 0.2 — Zr.sub.55Cu.sub.20Al.sub.15Co.sub.10 55.3 19.2 — 15.7 — — 9.9 Zr.sub.54Ni.sub.16Cu.sub.14Ti.sub.10Al.sub.6 53.9 13.8 15.9 6.1 — 10.3 — Zr.sub.55Cu.sub.20Co.sub.10Ti.sub.8Al.sub.7 56.0 19.0 — 7.2 — 8.1 9.7 Zr.sub.55Cu.sub.20Ti.sub.10Co.sub.10Al.sub.5 55.3 19.2 — 5.1 — 10.3 10.0 Zr.sub.45Cu.sub.20Ti.sub.10Al.sub.10Co.sub.10Hf.sub.5 45.0 19.6 — 10.4 5.4 10.0 9.6 Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67Cu.sub.16.67 17.0 16.2 15.9 18.2 16.6 — 16.0 Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20Cu.sub.20 19.7 19.5 — 21.1 20.4 — 19.4 Zr.sub.25Hf.sub.25Al.sub.25Co.sub.25 24.5 — — 26.9 24.9 — 23.6 Ti.sub.20Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20 19.5 — — 21.0 20.2 20.1 19.3 Ti.sub.16.67Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67 16.2 — 16.2 17.7 17.0 16.8 16.0 Ti.sub.25Zr.sub.25Hf.sub.25Co.sub.25 24.7 — — — 25.3 25.7 24.3
[0067]
[0068] where T.sub.g is the glass transition temperature, M is the molar mass, σ.sub.y is the yielding strength, ρ.sub.0 is the density at the ambient temperature, and T.sub.0 is the ambient temperature (298 K). M and ρ.sub.0 are calculated directly from the composition of the MGs. Reduced modulus and hardness are measured via nanoindentation. Yielding strength σ.sub.y is correlated to the measured hardness by:
σ.sub.y=H/3 (Equation 2)
TABLE-US-00002 TABLE 2 The mechanical and thermal properties of the twelve MGs. Reduced modulus Hardness T.sub.g T.sub.x T.sub.m T.sub.l Compositions (GPa) (GPa) (K) (K) (K) (K) Zr.sub.59.2Cu.sub.16.2Ni.sub.12.6Al.sub.9.6Hf.sub.2.2Ti.sub.0.2 99.28 6.41 657 750 1055 1165 Zr.sub.55Cu.sub.20Al.sub.15Co.sub.10 113.50 7.07 695 769 1163 1225 Zr.sub.54Ni.sub.16Cu.sub.14Ti.sub.10Al.sub.6 93.20 5.89 616 676 1063 1104 Zr.sub.55Cu.sub.20Co.sub.10Ti.sub.8Al.sub.7 95.46 5.94 640 691 1084 1171 Zr.sub.55Cu.sub.20Ti.sub.10Co.sub.10Al.sub.5 96.18 5.89 631 672 1074 1145 Zr.sub.45Cu.sub.20Ti.sub.10Al.sub.10Co.sub.10Hf.sub.5 125.13 8.67 830 870 1109 1224 Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67Cu.sub.16.67 130.27 8.41 764 830 1506 1625 (calculated) Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20Cu.sub.20 134.38 8.80 677 810 1201 1487 Zr.sub.25Hf.sub.25Al.sub.25Co.sub.25 111.16 7.72 808 866 1345 1649 Ti.sub.20Zr.sub.20Hf.sub.20Al.sub.20Co.sub.20 117.71 7.25 763 765 1336 1627 (calculated) Ti.sub.16.67Zr.sub.16.67Hf.sub.16.67Al.sub.16.67Co.sub.16.67Ni.sub.16.67 123.85 7.77 756 797 1380 1550 (calculated) Ti.sub.25Zr.sub.25Hf.sub.25Co.sub.25 80.22 4.76 606 650 1229 1286 (calculated)
[0069]
[0070] Further, based on the DSC results, the T.sub.rg and
of the twelve MGs are also calculated. As shown in
[0071] Next, as examples, the amorphous structures of Zr.sub.25Hf.sub.25Al.sub.25Co.sub.25 RMG and Zr.sub.54Ni.sub.16Cu.sub.14Ti.sub.10Al.sub.6 BMG are examined across the micro-, nano- and atomic-scale through 3D atom probe tomography (APT) and aberration corrected transmission electron microscopy.
[0072] The above embodiments provide a variety of novel compositional complex metallic glasses with good mechanical properties (good castability and hardness) and thermal stability, e.g., for their wide supercool liquid region. In particular, the Zr-based BMGs have high hardness, good fluidity, good thermal stability and are easy to fabricate by one-time molding.
[0073] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The described embodiments of the invention should therefore be considered in all respects as illustrative, not restrictive.