Method and apparatus for producing a powder compact

Abstract: The present invention relates to a method and an apparatus for producing a powder compact in which a recess (3) formed by die (d) and a lower punch (p1) inserted into said die is loaded with rubber mold (m) provided with a cavity (m') shaped according to the desired configuration of the compact, and subsequently, a powder is packed in the cavity of the rubber mold, and an upper punch (p2) is placed on die (d) to press the rubber mold with powder in the space formed by the die, the lower punch and the upper punch, thereby producing a powder compact. Because of the construction in which the upper punch is not inserted into the die but contacted at its bottom with the top of the die thereby carrying out the die pressing, the positioning of the indexed table does not have to be so accurate as in the prior art. The time for positioning is therefore shortened and the productivity is enhanced.

Description: The present invention relates to methods and apparatuses for producing a powder compact using powders for the production of permanent magnets, soft magnetic materials, electric and electronic materials, tool materials, and various parts used in a variety of industrial fields, wherein the powder packed in a rubber mold is pressed by utilizing pressure of the punches of a die press machine and deformation of rubber so as to produce a powder compact, which pressing is hereinafter referred to as "rubber mold die pressing." One of the known pressing technologies is the Rubber Mold Die Pressing method disclosed in Japanese Unexamined Patent Publication No. 55-26601. In this method, a rubber mold is loaded in a die secured to the table of a die press machine, and the cavity provided in the rubber mold is filled with a rare-earth cobalt alloy powder, and subsequently, the upper punch is lowered to carry out the die pressing. By using a rubber mold as a pressure medium, this method made it possible to produce rare-earth cobalt magnets with improved magnetic properties as high as those by transverse die pressing. Japanese Unexamined Patent Publication No. 4-363010 (EP-A-0 488 334) defines a method and an apparatus of the preambles of claims 1 and 6 and discloses another rubber mold die pressing method intended for mass-production of powder compacts, wherein the steps of powder-packing in the rubber mold, densification of the powder in the rubber mold, die pressing, and removal of green Compacts from the rubber mold are carried out on an indexed table which turns intermittently. PROBLEMS TO BE SOLVED BY THE INVENTION Referring to the prior rubber mold die pressing methods mentioned above, as well as to Fig. 8 illustrating the apparatus to implement said methods, the problems that the present invention intends to solve are now described as follows. 1 in Fig. 8 is an indexed table which turns intermittently driven by an appropriate means provided in base table 2. A desired number of dies M, which number is determined according to the number of steps for the production of compacts, are placed on indexed table 1. In Fig. 8, only a die M placed at the die pressing stage is shown, while the dies assigned for other stages are omitted. Die M comprises a cylindrical die d (hereinafter simply referred to as "die") fixed to indexed table 1 and lower punch p1 with a height less than die d which is inserted into said die. In recess 3 (hereinafter referred to as "die cavity") formed by die d and lower punch p1 inserted in said die, rubber mold m is loaded. Rubber mold m is provided with a recess (hereinafter referred to as "rubber cavity") which is designed in accordance with the desired configuration of the compact to be made. Rubber cavity m' is filled with a powder in the previous process on indexed table 1. Then, die M whose cavity 3 is loaded with rubber mold m with powder is transferred to the die pressing stage by the intermittent turning of indexed table 1 as shown in Fig. 8. p2 denotes the upper punch inserted into die d attached to the end of cylinder rod 5 of a fluid cylinder 4, and 6 is a magnetic field generator coil which is connected with cylinder rod 5 or the like. When a magnetic powder is oriented to produce permanent magnets, cylinder rod 5 or the like is provided with the magnetic field generator coil. 7 is a horizontal frame to install fluid cylinder 4 therein and is mounted on vertical frames 8 and 8' placed on the floor. In the conventional die press machine constructed as above, after the positioning of upper punch p2 and die cavity 3, upper punch p2 is inserted into die d, and then fluid cylinder 4 works to push down upper punch p2 so that rubber mold m filled with powder is pressed in the space formed by die d, lower punch p1 both of which are secured to the base of the die press machine and upper punch p2. Due to the downward movement of upper punch p2 and inward shrinking of rubber cavity m ' , the thickness of rubber mold m is reduced, thereby producing a powder compact from the powder packed in the rubber mold. The conventional rubber mold die pressing method must include an accurate positioning for die M to be transferred to the die pressing stage by the intermittent turning of indexed table 1, because upper punch p2 needs to be inserted into die cavity 3. Accordingly, the intermittent turning system of indexed table 1 must be provided with the function of accurate positioning, which makes the apparatus very complex and expensive. Also, such an apparatus requires frequent checks and maintenance, which leads to high prices of the products. If a clearance exists between the outer circumference of upper punch p2 and the inner circumference of die d, rubber mold m gets caught by this clearance upon pressing, which causes many troubles such as damages in the rubber mold, ascending of the rubber mold when pulling out the upper punch from the die, and cracks and fractures in the compact due to unnecessary force the rubber mold incurs. For the reasons above, upper punch p2 and die d must be made as precisely as possible. However, the more precisely the upper punch and the die are fabricated, the more accurate positioning must be carried out by the intermittent turning system of indexed table 1. The need for more accurate positioning complicates said turning system and the construction of the die press machine, which causes more disorders, and therefore requires more frequent maintenance. In the apparatus above, with upper punch p2 lowered, rubber mold m is pressed in the space formed by die d, lower punch p1 and upper punch p2, where the thickness of rubber mold m is reduced and rubber cavity m ' shrinks inward, while due to the compression of rubber mold by the lowering of upper punch p2, rubber mold m works to press the inner wall of die d, causing generation of a great frictional force between rubber mold m and die d. The great frictional force generated between die d and rubber mold m affects the compressing power applied to the powder filling the rubber cavity. Especially when rubber cavity m ' is deep, while the upper part of the rubber cavity receives sufficient compressing power, the part deep into the rubber cavity cannot get said power enough. As a result, the powder compact is not uniform in density, and is likely to break in the part insufficiently pressed. A molding apparatus for producing an anisotropic ferrite magnet is known from JP-A-6137901. A slurry powdered material is filled into the molding space of a die in the molding apparatus. The powdered material is then compressed between the die and an upper punch. In order to increase the difference in magnetic characteristics between both flat surfaces of the flat magnet to be produced and to improve the magnetic characteristic on the flat surface sides, a nonmagnetic plate is provided between the powdered material and the surface of the upper punch on the molding space side which is in contact with the powdered material. Further, the thickness of the nonmagnetic plate is increased from the periphery of the upper punch toward the central perpendicular of the molding space while keeping the contact surface of the plate with the powdered material flat. It is an object of the present invention to solve the problems mentioned above that the conventional powder compacting methods suffer, as well as to provide methods and apparatus for producing a powder compact with superior productivity and easier maintenance. This object is solved in accordance with the present invention by a method comprising the features of claim 1 and by an apparatus comprising the features of claim 6. Detailed embodiments of the inventive method and apparatus are described in the dependent claims. Several examples of this invention are hereinafter described with reference to Figs. 1 to 7. However, the present invention is not at all limited to these examples. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 illustrates in vertical elevation and partly in section a die press machine comprising a die and the upper punch and others located at the die pressing stage in an indexed table. Fig. 2 illustrates in vertical elevation and partly in section another embodiment of the the die press machine of this invention comprising a die and the upper punch and others located at the die pressing stage in an indexed table similar to that in Fig. 1. Fig. 3 illustrates partly in section a front view of a die pressing apparatus comprising a die and the upper punch and others located at the die pressing stage in an indexed table similar to that in Fig. 1. Fig. 4 is a plan view of a rubber mold for shaping a plurality of powder compacts at one time pressing. Fig. 5 is an enlarged sectional view taken along the line I - I of Fig. 4. Fig. 6 is an elevational view of a modification of the die press machine in Fig. 2 comprising a die and the upper punch and others located at the die pressing stage in an indexed table. Fig. 7 is an elevational view of another modification of the die press machine in Fig. 2 comprising a die and the upper punch and others located at the die pressing stage in an indexed table. Fig. 8 illustrates partly in section a front view of a conventional die press machine comprising a die and the upper punch and others located at the die pressing stage in an indexed table. Fig.1 illustrates in vertical elevation and partly in section an apparatus for die pressing comprising die M and upper punch p2 and others which are located at the die pressing stage of indexed table 1. The same reference numerals as those in Fig. 8 are used for the parts colon with the conventional apparatus in Fig. 8. Lower punch p1 comprises: 1) spacers 11 and 11' for adjusting the depth of die cavity 3 which are placed on supplemental support plate 10 fixed to indexed table 1 with bolts 9 and 9 ' ; 2) the body 12 of the lower punch ; and 3) attachment tool for back-up ring 14 inserted into the body 12 of lower punch on whose top a back-up ring or plate (hereinafter referred to as "back-up ring") 13 is attached. After spacers 11 and 11' , body 12 of the lower punch and attachment tool 14 are assembled, bolt 15 inserted into through hole 9'' provided in supplemental support plate 10 is screwed into screw hole 14 ' , thereby securing lower punch p1 to indexed table 1. The bottom of die d into which lower punch p1 is inserted is provided with groove d' . Between groove d' and supplemental support plate 10, springs 16 are provided so as to surround lower punch p1. As springs 16, not only compressive springs made of nonmagnetic stainless steel, but also rubber cushions using hard urethane rubber, flush springs, fluid cylinders functioning as a spring and various other springs may be used. Particularly preferred springs are flush springs with a great spring coefficient which allow easy adjustment of the length and said coefficient and the like. In particular, flush springs made of nonmagnetic steel are preferable because they do not generate shock due to the magnetic attraction upon application of a pulsed magnetic field. As is described above, rubber mold m with rubber cavity m' filled with powder is loaded in die cavity 3 which is formed by die d and lower punch p1 inserted into said die. Upper punch p2 is placed on the top surface, d '' , of die d and constructed to be larger than the top surface area of die cavity 3 so that it covers the die cavity. That is, in the present invention, the upper punch is not inserted into the die cavity, but placed on d '' , the top surface of the die. 17 is the back-up ring comprising hard rubber or the like which is attached to the bottom of upper punch p2 as the need arises. The back-up ring 17 prevents rubber mold m from sticking out from the clearance between d'' and the bottom of upper punch p2, thereby enhancing the life of the rubber mold m. When attaching back-up ring 17 to the bottom of upper punch p2, back-up ring 17 should be made larger than the top surface area of die cavity 3 so that it covers die cavity 3 or the boundary between die d and rubber mold m. In the latter case, at the area surrounded by back-up ring 17 in the bottom of upper punch p2, the material of upper punch p2 is exposed. When this area contacts with rubber mold m at pressing, the frictional force generated there may be so great that it impedes necessary deformation of rubber mold m. To prevent such a problem, the surface of this area should be finished as smooth as possible, for example, by coating. As shown in Fig. 1, when die M incorporating rubber mold m with rubber cavity m' which is filled with powder previously to the die pressing is transferred to the position for the die pressing by the intermittent turning of indexed table 1, upper punch p2 is moved down and placed on d'' , the top of the die d. While further lowering the upper punch, die d is moved down along with upper punch p2 resisting springs 16 provided between die d and supplemental support plate 10. As the lowering of upper punch p2 and die d reduces the space formed by die d, lower punch p1 and upper punch p2 i.e., die cavity 3, rubber cavity m' shrinks inward so that the powder filling the cavity is compressed to form a powder compact. As has been discussed, in the die pressing process of the present invention, upper punch p2 is not inserted into die d, but simply placed on the top surface of the die, d '' . As a result, the positioning of indexed table 1 does not have to be so accurate as in the conventional die pressing, which saves the time for positioning and improves the productivity. Furthermore, the present invention simplifies the construction of the apparatus for producing a powder compact because it is not necessary for the apparatus to be equipped with such a precise system for the positioning as needed before. This simplification leads to cost-down of the apparatus and facilitation of the maintenance, as well as reduction of the production costs. Owing to the structure of the apparatus in which upper punch p2 is not inserted into die d, rubber mold m does not get caught in the clearance between the outer wall of upper punch p2 and the inner wall of die d. The problems such as cracks in rubber mold m and damages to the compacts can therefore be prevented. In addition, because die d moves down along with upper punch p2, the friction generated between rubber mold m and die d can be reduced. Accordingly, rubber mold m deforms uniformly in the direction perpendicular to the moving direction of upper punch p2, and such deformation promotes the pseudoisostatic compaction of the powder packed in the rubber cavity. A powder compact with a uniform packing density can therefore be obtained. Fig. 2 illustrates another embodiment of the die pressing apparatus in vertical elevation and partly in section, showing die M and upper punch p2 and others located at the die pressing stage of indexed table 1. In this embodiment, lower punch p1 is fixed with bolt 15 to slider 18 which is inserted in through hole 1 ' provided in indexed table 1 in a vertically slidable manner. At the upper and lower ends of slider 18, upper flange 18a and lower flange 18b are provided. Between groove 18c in lower flange 18b and indexed table 1, compressive springs 19 are provided surrounding slider 18. These springs 19 are intended to usually help slider 18 move downward. 20 is a pressure applier such as a fluid cylinder and a mechanical pressure applier provided with a vertically movable piston 20 ' . Due to the pressure from this pressure applier, piston 20' moves up and down so that it also moves lower punch p1 vertically. When pressing the powder in rubber cavity m' , first, upper punch p2 is lowered until its bottom gets in contact or nearly in contact with the top surface of die d i.e.,d '' , and then the lowering is stopped. Subsequently, pressure applier 20 is energized to move piston 20 ' so that piston 20 ' pushes up lower punch p1 secured to slider 18, resisting springs 16 and compressive springs 19. Die d stops ascending when contacted with the bottom of upper punch p2 , while lower punch p1 continues to move upward pushed by piston 20 ' . As a result, as the space or die cavity 3 which is formed by die d, lower punch p1 and upper punch p2 reduces its depth, rubber cavity m' shrinks inward. Thus a powder compact is obtained from the powder filling the rubber cavity. This embodiment in Fig. 2 is provided with a magnetic field generator coil 6. However, when the magnetic alignment of the powder is not necessary and accordingly this coil 6 can be omitted, die pressing may be carried out with upper punch p2 secured and only by lifting lower punch p1 with pressure applier 20. 21 indicated in a chain line is a cover made of rubber attached to back-up ring 17 and is designed to be inserted into rubber cavity m ' . Such a cover 21 may not necessarily be provided. However, for certain configurations of the compact, cover 21 should preferably be used, because the pressure becomes more uniform i.e.,isostatic with cover 21 than without it, and generation of cracks in the compact can therefore be prevented. Cover 21 is made of a elastic rubber as used for rubber mold m. Since rubber expands in the horizontal direction when pressed, it can fill the gap between the side wall of cover 21 and rubber cavity m ' even if the gap is considerably large. Therefore, the powder is kept in the rubber cavity without flowing out upon pressing. In addition, rubber is so easy to deform that it deforms itself to fit into die d, even if die d is swerved from the right position. Accordingly, there is no particular need for strict positioning of the cover. A part of the inner wall of rubber mold m may occasionally be recessed so that cover 21 can fit into the recess 21' ( indicated in a chain line in Figs. 2 and 6). The embodiment in Fig. 2 has the same effects as those of the embodiment in Fig. 1. Fig. 3 illustrates an embodiment other than those Figs. 1 and 2, in elevation and partly in section, showing die M and upper punch p2 and others located at the die pressing stage of indexed table 1. Differently from the examples above, in Fig. 3, die d is fixed to indexed table 1 with bolts 22 and 22' . A column part p1' constituting the lower part of lower punch p1 penetrates indexed table 1 through hole 1 '' and protrudes downward. 23 is a piston provided under column p1 ' of lower punch p1, which moves up and down driven by a pressure applier ( not shown ). 24 is a back-up ring attached to lower punch p1 so as to prevent rubber mold m from getting caught between die d and lower punch p1, which is provided when the need arises. 25 is a pressure support table provided under indexed table 1 with a desired space between, which supports indexed table 1 at the die pressing so as to reduce the pressure applied to indexed table 1. This may be provided when necessary. When pressing the powder filling rubber cavity m ' , first, upper punch p2 is lowered until it gets in contact or nearly contact with with d '' , the top surface of die d, and then the lowering of upper punch p2 is stopped. As piston 23 is moved up along die d fixed to indexed table 1 so as to lift lower punch p1, the space formed with die d, lower punch p1 and upper punch p2 is shrunk i.e., the depth of die cavity 3 is reduced. As a result, rubber cavity m ' of rubber mold m loaded in die cavity 3 shrinks inward pressing the powder so as to produce a powder compact. The embodiment in Fig. 3 is different from those in Figs. 1 and 2, because die d is fixed to indexed table 1. In this embodiment, although it may not be possible to reduce the frictional force generated between die d and rubber mold m, the positioning of indexed table 1 does not have to be so accurate because upper punch p2 is not inserted into die d but simply placed on d'' , the top surface of the die. Therefore, such effects as saving the time for positioning and improvement of the productivity may be expected. When using a rubber mold m with a relatively small height to produce a thin compact, because the unevenness of the pressure applied to the powder resulting from the frictional force between die d and rubber mold m does not seriously affect the uniformity of the powder density in the compact, the apparatus shown in Fig. 3 may be used. 26 is a cover made of rubber attached to the bottom of back-up ring 27 in the same manner as cover 21 in the embodiment shown above. Fig.4 is a plan view of rubber mold m provided with a plurality of rubber cavities m' . Fig. 5 is a cross section taken on line I - I , comprising lower punch p1, upper punch p2 and die d. Fig. 4 illustrates rubber mold m with several rubber cavities m' which is used to produce several powder compacts at one pressing, in which rubber cavities m' are filled with powder and then pressed with an apparatus as shown in Figs. 1, 2, and 3. As a result, as shown in Fig.5, the depth of the space formed by die d, lower punch p1 and upper punch p2 i.e. ,the depth of die cavity 3 is reduced and rubber cavity m ' is shrunk inward, thereby producing a plurality of powder compacts. Fig. 6 is a different version of the die press machine shown in Fig. 2, in which lower punch p1 is provided with a concave part 26 in its outer surface to which a convex part 27 provided in the lower interior of die d is fitted. By fitting concave part 26 provided in the outer surface of lower punch p1 to convex part 27 in the lower interior of die d , die d can be prevented from getting out of die M. Concave part 26 can be formed in the outer surface of lower punch p1 by making the wall thickness of lower punch p1 excluding its upper section and the same of the upper spacer 11 ' thinner than usual, while forming the lower spacer 11 to have the usual wall thickness. Therefore, when fitting die d to lower punch p1, first, die d is fitted to the body 12 of lower punch p1 and the upper spacer 11 ' , and then the lower spacer 11 is attached thereto. It will be obvious to those skilled in the art that the constitution as described above in which convex part 27 provided in the lower interior of die d is fitted into concave part 26 provided in the outer surface of lower punch p1 can also be applied to the die press machine shown in Fig. 1. Fig. 7 illustrates a modification of the apparatus in Fig.1 in which the upper end of lower punch p1 is extended penetrating rubber mold m so that its top is higher than d'' ,the top of die d. This apparatus is intended to produce hollow compacts. Meanwhile, upper punch p2 is provided with a through hole or a recess p2 ' so that p1'' , the upper end of lower punch p1 ' , is fitted therein. 28 is a cover made of the same rubber as rubber mold m. In this embodiment, the same process as that in Fig. 1 is carried out to produce a hollow compact : Upper punch p2 is lowered so that the end of lower punch p1 i.e. p1'' is fitted into through hole or recess p2 ' in upper punch p2, when upper punch p2 is placed on d '' , the top surface of die d. While upper punch p2 is further lowered, the space formed by die d, lower punch p1 and upper punch p2 and containing rubber mold m, that is, die cavity 3, reduces its depth as well as rubber cavity m ' shrinks inward, thereby producing a hollow, cylindrical powder compact from the powder filling rubber cavity m' . This structure may of course be applied to the die press apparatuses in Figs. 2, 3 and 6. EFFECTS OF THE INVENTION With the constitution being as described, the present invention has the effects as follows : Because of the constitution in which the pressing is carried cut not by inserting the upper punch into the die but by contacting the bottom of the upper punch with the top of the die, the positioning of the indexed table is not required to be so accurate, which saves the time for positioning and improve the productivity. Because the intermittent turning system of the indexed table does not have to include devices for very accurate positioning, the structure of the apparatus can be simplified, which leads to cost-down and easy maintenance of the apparatus resulting in reduction of the production costs. The problem that the rubber mold gets caught between the outer wall of the upper punch and the inner wall of the die does not arise in the constitution in which the upper punch is contacted at its bottom with the top of the die. Damages to the rubber mold and products can therefore be prevented. Furthermore, since the structure of the present invention is intended to make the die and the rubber mold move relatively to each other, the frictional force between the rubber mold and the die is reduced enabling the rubber mold to deform uniformly in the direction perpendicular to the moving direction of the upper punch. Such a deformation promotes the pseudoisostatic compaction of the powder in the rubber cavity, and as a result, a uniformly densified powder compact is obtained.

Claims: A method for producing a powder compact comprising the steps of: (a) loading a rubber mold (m) provided with a cavity (m') which is shaped according to the desired configuration of the compact into a recess (3) formed by a die (d) and a lower punch (p1) inserted into said die (d), said die (d) being suported on an indexed turntable; (b) filling the cavity (m') of the rubber mold (m) with a powder; characterized by the steps of (c) placing an upper punch (p2) on the die (d); and (d) pressing the rubber mold (m) filled with the powder in the space formed by the die (d), the lower punch (p1) and the upper punch (p2) to obtain a powder compact. A method for producing a powder compact according to claim 1, wherein step (d) is carried out such that the die (d) and the rubber mold (m) are moved relatively to each other. A method for producing a powder compact according to claim 1 or 2, wherein the lower punch (p1) is secured and the upper punch (p2) is placed on the die (d), and in the space formed by the die (d), the lower punch (p1) and the upper punch (p2), the rubber mold (m) with powder is pressed by lowering the upper punch (p2), thereby obtaining a powder compact from the powder filling the rubber mold (m). A method for producing a powder compact according to claim 1 or 2, wherein the upper punch (p2) is secured and placed on the die (d), and in the space formed by the die (d) the lower punch (p1) and the upper punch (p2), the rubber mold (m) with powder is pressed by lifting the lower punch (p1), thereby obtaining a powder compact from the powder filling the rubber mold (m). A method for producing a powder compact according to claim 1 or 2, wherein the upper punch (p2) is placed on the die (d), and while the lower punch (p1) is lifted, the upper punch (p2) is lowered so that in the space formed by the die (d), the lower punch (p1) and the upper punch (p2), the rubber mold (m) with powder is pressed, thereby obtaining a powder compact from the powder filling the rubber mold (m). An apparatus for producing a powder compact comprising a die (d) supported on an indexed turntable (1), a lower punch (p1) inserted into said die (d), a rubber mold (m) loaded in a recess (3) formed by the die (d) and the lower punch (p1) inserted into said die (d), and an upper punch (p2), characterized in that the upper punch (p2) is arranged to be placed on the die (d). An apparatus for producing a powder compact according to claim 6, wherein a supporting device is provided which holds the die (d) through springs such that the die (d) is movable relative to the rubber mold (m). An apparatus for producing a powder compact according to claim 6 or 7, wherein a driving device for lowering the upper punch (p2) is provided above the die (d). An apparatus for producing a powder compact according to claim 6 or 7, wherein a driving device for lifting the lower punch (p1) is provided below the die (d). An apparatus for producing a powder compact according to claim 6 or 7, wherein a driving device for lowering the upper punch (p2) and a driving device for lifting the lower punch (p1) are provided above the die (d) and below the die (d), respectively.

Inventors: ITATANI OSAMU, NAGATA HIROSHI, SAGAWA MASATO, ITATANI, OSAMU, NAGATA, HIROSHI, SAGAWA, MASATO, ITATANI, OSAMU, C/O INTERMETALLICS CO., LTD., NAGATA, HIROSHI, C/O INTERMETALLICS CO., LTD., SAGAWA, MASATO, C/O INTERMETALLICS CO., LTD.
Applicants: INTERMETALLICS CO LTD, INTERMETALLICS CO., LTD.
Application year: 1993
Main classification: B30B15
IPC codes: B30B11, B30B15, H01F41, B22F3