Means For Molding Powdered Metal Patents (Class 425/78)
  • Patent number: 7037465
    Abstract: A powder compacting method includes the steps of: providing a powder material; loading the powder material into a cavity; uniaxially pressing the powder material, which has been loaded into the cavity, between two opposed press surfaces, thereby obtaining a compact, wherein at least one of the two press surfaces is deformed elastically under a compacting pressure when contacting with the powder material in the cavity; and unloading the compact from the cavity. According to this powder compacting method, even when the powder material has a non-uniform fill density distribution, a compact with a uniform density distribution can be obtained at a high productivity.
    Type: Grant
    Filed: November 5, 2001
    Date of Patent: May 2, 2006
    Assignee: Neomax Co., Ltd.
    Inventor: Atsushi Ogawa
  • Patent number: 7033155
    Abstract: A hydraulic press for compressing metallic powder or the like to form compacts, comprising a die-plate, an upper ram, and at least one lower ram which interact with a die-bore and are operable each by a dual-action hydraulic press cylinder, whereby a limited dead path length is provided for the return stroke in the force path between the press cylinder and the upper ram in which the upper ram is not carried along, and that a separate pressure generator producing a variable pressure is arranged in parallel with the force path via which a compression force is produced on the upper ram during the dead path length.
    Type: Grant
    Filed: August 22, 2002
    Date of Patent: April 25, 2006
    Assignee: Fette GmbH
    Inventors: Jürgen Hinzpeter, Ulrich Zeuschner, Ingo Schmidt, Thomas Pannewitz, Udo Baltruschat, Thorsten Ehrich, Ulf Hauschild
  • Patent number: 7033156
    Abstract: The present invention is a method and apparatus for the production of compacted powder elements. More specifically, the present invention is directed to the improvement of tooling for powder compaction equipment, and the processes for making such tooling. The improvement comprises the use of a ceramic tip or similar component in high wear areas of the tooling, particularly center pins. Moreover, the use of such ceramic components enables reworking and replacement of the worn tool components.
    Type: Grant
    Filed: December 16, 2002
    Date of Patent: April 25, 2006
    Inventor: Luka Gakovic
  • Patent number: 7028525
    Abstract: The device comprises a stamping member (2) arranged to be conveyed towards and hit a material body (1) with such a velocity that a rebound motion of the stamping member (2) is generated while a permanent deformation of the material body (1) is generated. The device has structure (3) for counteracting the rebound and generating at least one additional impact of the stamping member (2) against the material body (1) within a period, during which kinetic energy in the material body (1) generates an additional deformation in the body.
    Type: Grant
    Filed: November 19, 1999
    Date of Patent: April 18, 2006
    Assignee: Hydropulsor AB
    Inventors: Lars Troive, Yngve Bergström
  • Patent number: 7025929
    Abstract: The invention provides a method and apparatus for densifying the teeth of a powder metal preform gear. The die includes an aperture for receiving a body of the gear and a plurality of grooves for receiving the teeth of the gear. The grooves have a length and a variable width along the length. The grooves narrow tangentially relative to the aperture. The powder metal preform gear is urged through the die and the teeth are plastically and elastically deformed at a relatively narrow portion of the groove. After passing through the narrow portion of the groove and being compressed, the teeth can at least partially recover. The grooves defined by the die can be helical for forming a helical groove.
    Type: Grant
    Filed: April 8, 2004
    Date of Patent: April 11, 2006
    Assignee: PMG Ohio Corp.
    Inventors: Juan R. L. Trasorras, Eric T. Riley
  • Patent number: 7014440
    Abstract: A method and apparatus for manufacturing a rare earth magnet is disclosed. In a first step, a compact is produced by compacting rare earth alloy powder in a predetermined space in an orienting magnetic field. Next, a demagnetizing process is performed for the compact, and the compact is ejected from the predetermined space. Then, a additional demagnetizing process is performed for magnetic powder adhering to a surface of the compact by applying an magnetic field to the compact after the compact is ejected.
    Type: Grant
    Filed: June 12, 2003
    Date of Patent: March 21, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Shuhei Okumura, Akira Nakamura
  • Patent number: 7011510
    Abstract: A hot isostatic pressing apparatus (HIP apparatus) comprises a vertically cylindrical high-pressure vessel comprising a high-pressure cylinder 1 and upper and lower lids 2 and 3; a bottomed cylindrical casing 6 capable of housing workpieces 9 and a resistance-wire heater 11, a heat insulating structure 16 equipped with a gas flow regulating valve 15 and formed in a bottomed cylindrical shape on the outside of the casing 6 so as to cover the casing 6, and a heat sink 17 having a water cooling mechanism provided in the space defined by the heat insulating structure 16 and the inner surface of the high-pressure cylinder 1, which are provided within the high-pressure vessel; and a pressure medium gas stirring fan 12 for promoting the temperature uniformity of the space of the treatment chamber 7 for housing the workpieces 9, the stirring fan being arranged on the lower lid 3 side within the casing 6, whereby the cooling to a temperature range of 100° C.
    Type: Grant
    Filed: March 17, 2003
    Date of Patent: March 14, 2006
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Tomomitsu Nakai, Makoto Yoneda, Shigeo Kofune, Takao Fujikawa
  • Patent number: 7001166
    Abstract: An arrangement of a die-plate of a hydraulic press to press powdered material into shape wherein an upper ram and a lower ram interact with a bore of the die-plate wherein the die-plate is supported via vertically arranged supporting standards which, along with upper supporting portions which are cantilevered towards the axis of the die-bore, define upwardly facing bearing areas located close to the die-bore for the die-plate.
    Type: Grant
    Filed: October 18, 2002
    Date of Patent: February 21, 2006
    Assignee: Fette GmbH
    Inventors: Jürgen Hinzpeter, Ulrich Zeuschner, Ingo Schmidt, Thomas Pannewitz, Udo Baltruschat, Thorsten Ehrich, Ulf Hauschild
  • Patent number: 6997691
    Abstract: A tablet press machine (1) includes a fixed casing (2) which houses a compression assembly (3) comprising a power-driven rotor (4) that rotates about an axis (5), the rotor including a matrix disc (6) and another two discs (7, 8) on both sides of it, mounting two sets of reciprocating punches (9, 10) opposite and aligned with each other in pairs. The matrix disc (6) has a plurality of through matrixes (11) where the reciprocating punches (9, 10) forming each pair are mounted in such a way as to delimit between them an empty space (12) of variably size designed to contain a dosed quantity of powder to be compressed. Two sets of cams (13, 14) are associated with the compression assembly (3) and, as the rotor (4) rotates, impart on the punches (9, 10) a driving motion which moves them cyclically towards and away from each other in such a way as to compress the powder contained in the matrix (11) in the matrix disc (6).
    Type: Grant
    Filed: March 12, 2002
    Date of Patent: February 14, 2006
    Assignee: I.M.A. Industria Macchine Automatiche S.p.A.
    Inventors: Roberto Trebbi, Hans Kramer
  • Patent number: 6986866
    Abstract: A method and apparatus for the cross-hole pressing of cutting inserts is disclosed whereby a green part is fabricated using metallurgical powder and an opening is imparted within the green part by placing the metallurgical powder about an oval-shaped core rod. Using a press with a uni-axial press motion, a core rod is placed within the cavity of a mold and metallurgical powder placed around the core rod and thereafter compressed to form a green part. The subject invention is also directed to an article formed utilizing such a process and the uni-axial press used to produce such an insert.
    Type: Grant
    Filed: November 4, 2002
    Date of Patent: January 17, 2006
    Assignee: Kennametal Inc.
    Inventors: Richard J. Gubanich, Edward M. Dinco
  • Patent number: 6969244
    Abstract: The present invention aims to prevent heating and ignition of a material powder of a rare-earth alloy while reducing the oxygen content thereof so as to improve the magnetic properties of the rare-earth magnet. A rare-earth alloy powder is compacted by using a powder compacting apparatus including: an airtight container capable of storing a rare-earth alloy powder therein; an airtight feeder box moved between a powder-filling position and a retracted position; and an airtight powder supply device capable of supplying the rare-earth alloy powder from the container into the feeder box without exposing the rare-earth alloy powder to the atmospheric air.
    Type: Grant
    Filed: August 15, 2002
    Date of Patent: November 29, 2005
    Assignee: Neomax Co., Ltd.
    Inventors: Futoshi Kuniyoshi, Koki Tokuhara, Kunitoshi Kanno, Hitoshi Morimoto, Tomoiku Ohtani, Ryoji Ono
  • Patent number: 6955532
    Abstract: An apparatus and method of producing dense, near net shape components of advanced materials such as intermetallics, ceramics, and their composites. The method consists of two major steps combined into one. First step includes the preparation of semi-solid or liquid materials by means of combustion synthesis or self-propagating high-temperature synthesis. The second step includes the densification and near net shape forming of such combustion products by semi-solid metalworking or die casting techniques. The combination of combustion synthesis and semi-solid metalworking or die casting techniques provides a low cost, fast production method for many articles made of high temperature materials such as intermetallics, ceramics, and their composites.
    Type: Grant
    Filed: September 25, 2002
    Date of Patent: October 18, 2005
    Assignee: University of Rochester
    Inventors: Ping Zhu, James C. M. Li
  • Patent number: 6926861
    Abstract: A package to be mounted with semiconductor chips has a heat-radiating substrate having a thickness of smaller than 0.4 mm of a Cu—Mo composite as prepared by impregnating from 30 to 40% by mass of copper (Cu) melt into a green compact of molybdenum. The heat-radiating substrate is produced by preparing an Mo green compact through isostatic molding, mounting Cu on the Mo green compact, heating it to thereby impregnate copper into the Mo green compact to give a Cu—Mo composite, and rolling the Cu—Mo composite into a sheet substrate.
    Type: Grant
    Filed: September 29, 2003
    Date of Patent: August 9, 2005
    Assignee: Tokyo Tungsten Co., Ltd.
    Inventors: Norio Hirayama, Mitsuo Osada, Akira Ichida, Yoshinari Amano, Kiyoshi Asai, Hidetoshi Maesato, Tadashi Arikawa, Kenji Sakimae
  • Patent number: 6919041
    Abstract: A method for compacting powder materials into articles comprises placing a powder material in a shaping cavity of a mold, the cavity being defined by active and passive shaping surfaces of one-piece or composite shaping members of the mold; mutually moving the shaping members of the mold along a pressing axis, with the pressing force transferred from the shaping members of the mold to the powder material through the active shaping surfaces. Surfaces of the powder article, parallel to the pressing axis, are formed by the passive shaping surfaces of the one-piece or composite shaping members of the mold. According to the invention, surfaces of the powder article, parallel to the pressing axis, are formed using parts of at least one passive shaping surface, located on the one-piece or composite shaping members split along the pressing axis.
    Type: Grant
    Filed: December 16, 2002
    Date of Patent: July 19, 2005
    Assignee: Tomsky Polytekhnichesky Universitet
    Inventors: Edgar Sergeevich Dvilis, Oleg Leonidovich Khasanov, Vitaly Mikhailovich Sokolov, Jury Petrovich Pokholkov
  • Patent number: 6902698
    Abstract: A press apparatus for producing dimensionally accurate pressed articles from a particulate material including a frame (70, 73), which can be connected via respective lower and upper connecting devices (71, 72) to a lower and upper platens of a press, a die holding plate (5) arranged in the frame and preferably rigidly connected with the lower connecting device, in which the die holding plate is displaceable relative to a base body (0), a plurality of punch carriers (1-4), at least one of which is supported on the frame between the die holding plate and the base body so as to be displaceable relative thereto into charging and pressing positions by piston/cylinder drives, and supports (12, 22, 32, 42), which in the final press position support the punch carriers relative to the base body.
    Type: Grant
    Filed: July 19, 2002
    Date of Patent: June 7, 2005
    Assignee: Dorst Technologies GmbH & Co. KG.
    Inventors: Walter Rau, Johann Meyer
  • Patent number: 6890168
    Abstract: A biaxial press molding system includes a cam apparatus having cams facing each other, and a biaxial press apparatus, disposed between the cams and installed to be capable of sliding contacting the cams, for forming a biaxial pressure to a molding object by converting rotational motion of the cams to linear reciprocating motion. Thus, a repulsive force generated during pressing concentrates only on the rotation shaft, so that an optimal design of the frame and a light system are possible. The upper and lower pressure continuously applied to a pressed object can be changed and the maximum pressure can be freely maintained, increased and decreased by forming upper and lower portions at the frictional surfaces of the cams facing each other. Also, a fine control of pressure is possible, the pressure can be appropriately distributed according to part of the pressed object, and mass production of accurate molding products is possible by controlling the pressing point of time.
    Type: Grant
    Filed: March 3, 2001
    Date of Patent: May 10, 2005
    Inventor: Young-Jung Kim
  • Patent number: 6881048
    Abstract: The present invention is a method of loading a desired amount of powder material into a mold which comprises a tubular body having a bore extending therethrough to define a mold cavity. The method comprises the steps of: providing the mold with a lower press core fitted in the lower end of the bore; bringing the mold with said lower press core fitted therein to a powder filling position; displacing the lower press core relative to the mold so as to determine the depth of the top surface of the lower press core from the top surface of the mold; filling an amount of powder material into the mold and strickling off any excessive amount of powder material to the level of the top surface of the mold; pressing at a desired pressure the amount of powder material in the mold to form a powder compact; and displacing the powder compact with the lower press core relative to the mold so as to bring the powder compact to a desired position in the mold.
    Type: Grant
    Filed: March 30, 2000
    Date of Patent: April 19, 2005
    Assignee: Sumitomo Coal Mining Co., Ltd.
    Inventor: Masao Tokita
  • Patent number: 6868778
    Abstract: This invention relates to a system and method for loading a plurality of powder materials into a magnetic compaction tool. The system and method employ a powder loader which guides the plurality of powder materials into predetermined locations in the magnetic compaction tool so that when the tool is electromagnetically energized, the plurality of powder materials are compacted to form a part having a plurality of densified metals formed by the plurality of powder materials.
    Type: Grant
    Filed: September 14, 2001
    Date of Patent: March 22, 2005
    Assignee: IAP Research, Inc.
    Inventors: Edward Arlen Knoth, Bhanu Chelluri, Edward John Schumaker
  • Patent number: 6861028
    Abstract: A manufacturing method for high-density iron-based powder compacts is disclosed. The temperature of the die is adjusted at ordinary temperature or at a predetermined temperature by preheating. A lubricant for die lubrication prepared by mixing at least two different lubricants having melting points higher than a predetermined temperature of the compaction pressure is sprayed at the upper part of the die and is introduced into the die and adhered by electrification to the surface of the die. The resulting die is filled with an iron-based mixed powder including a lubricant and molding is performed at ordinary temperature or at a temperature raised by heating.
    Type: Grant
    Filed: March 27, 2001
    Date of Patent: March 1, 2005
    Assignee: Kawasaki Steel Corporation
    Inventors: Yukiko Ozaki, Satoshi Uenosono, Shigeru Unami
  • Publication number: 20040265405
    Abstract: A hot press tool for use in a hot press process is formed of at least one material selected from a group consisting of materials characterized by formula Mn+1AXn, wherein
    Type: Application
    Filed: June 30, 2003
    Publication date: December 30, 2004
    Inventors: Devrim Akyuz, Tamer El-Raghy
  • Patent number: 6827567
    Abstract: Powder mixture is supplied into a die under a state that a center pin is located lower than the top surface of the die, after which the center pin is lifted up to a given molding position where an annular molding space is defined between the center pin and the die. The powder mixture is then compressed from upper and lower sides with an upper plunger and a lower plunger to form a pellet. The center pin and the lower plunger are simultaneously lifted up to remove the pellet out of the die.
    Type: Grant
    Filed: January 25, 2001
    Date of Patent: December 7, 2004
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Minoru Kouda, Shigeharu Hattori, Saburo Nakatsuka, Hiroshi Takebayashi, Toshio Sanukiya
  • Patent number: 6811887
    Abstract: This invention relates to a transformer and more particularly, to a system and method for making a transformer utilizing dynamic magnetic compaction. A coil is placed in a conductive container, and a conductive powder material, such as ferrite, is placed in the container and surrounds the coil and the turns of the coil. A power supply energizes a capacitor which subsequently provides a high energizing current to a second, energizing coil within which the container, material and inner coil are situated, thereby causing the container, powder materials and coil to be compacted to provide an electrical component, such as a transformer, motor, commutator, rotor or choke.
    Type: Grant
    Filed: August 12, 2002
    Date of Patent: November 2, 2004
    Assignee: IAP Research, Inc.
    Inventors: John P. Barber, David P. Bauer, Edward A. Knoth, Duane C. Newman
  • Patent number: 6779995
    Abstract: In a rare earth metal-based alloy powder supplying apparatus, a rare earth metal-based alloy powder is supplied from a feeder box having an opening in its bottom surface into a cavity by moving the feeder box to above the cavity. The apparatus includes a bar-shaped member which is moved horizontally and in parallel in the bottom of the feeder box. A plurality of the bar-shaped members may be provided horizontally at distances. The apparatus further includes a powder replenishing device for sequentially replenishing the alloy powder into the feeder box in an amount corresponding to a decrement in amount resulting from the supplying of the alloy powder from the feeder box to the cavity, an inert gas supply device for filling an inert gas into said powder feeder box, and a plate member made of a fluorine-contained resin and mounted on the bottom surface of the feeder box.
    Type: Grant
    Filed: August 6, 2002
    Date of Patent: August 24, 2004
    Assignee: Neomax Co., Ltd.
    Inventors: Seiichi Kohara, Shuhei Okumura, Akira Nakamura
  • Patent number: 6776595
    Abstract: A tool for applying grout into a recess between adjacent tile surfaces comprises a body for gripping by the user formed with an elongate, resilient channel member adapted for retaining a line of grout and delivering the grout directly into the recess by aligning and pressing of the channel member over the recess. A finishing portion can be formed on the same body or a separate body for compressing and shaping the grout after delivery into the recess. The tool of the present invention avoids wasting of grout and increases the speed of application without sacrificing the appearance or integrity of the grout joint.
    Type: Grant
    Filed: November 30, 2001
    Date of Patent: August 17, 2004
    Assignee: Vancouver Tool Corporation
    Inventor: Andrew Terrance Kevin Dewberry
  • Patent number: 6767505
    Abstract: A gas operated part forming die apparatus has compact high tonnage presses which are operated by high pressure gas generated within chambers and controlled to operate high pressure pistons and dies for compressing particulate material into dense formed parts. Combustion chambers are filled with pressurized mixtures of combustible gases and diluents. Elongated chambers have insulating walls and spaced electrodes. Some contain liquid or particulate ablatable materials or ablatable liners. Others extend fuzes between the electrodes and are filled with pressurized gases. Gas is removed from the particulate material. Die cavities may be precompressed during filing of chambers with pressurized gas. Igniting the combustible gases or creating arcs between the electrodes produces rapidly expanding high pressure resultant gases for driving pistons and movable dies and rapidly compressing die cavities. Pressures in the chambers are contained, or pistons are restrained until releasing and driving the pistons.
    Type: Grant
    Filed: July 12, 2001
    Date of Patent: July 27, 2004
    Assignee: Utron Inc.
    Inventors: F. Douglas Witherspoon, Dennis W. Massey, T. Arul Mozhi, David L. Kruczynski, John M. Ryan
  • Patent number: 6764289
    Abstract: A manufacturing fixture (11) for manufacturing a permanent magnet (24) for an actuator motor (20) of a disk drive (10) is provided herein. The manufacturing fixture (11) includes a fixture cavity (102) which receives the magnet powder (48) and an orientating device (108) which generates flux lines (110) which extend across the fixture cavity (102). The fixture cavity (102) includes a cavity axis (118), a cavity transition (116) and a cavity perimeter (124). Importantly, the flux lines (110) extend substantially transverse to the cavity axis (118) near the cavity transition (116) and the cavity perimeter (124) and substantially parallel with the cavity axis (118) intermediate the cavity transition (116) and the cavity perimeter (124). This allows for a magnet (24) having higher magnetic flux densities at the sides (54) (56) (58), and higher average magnetic flux densities in the magnet (24).
    Type: Grant
    Filed: September 3, 1999
    Date of Patent: July 20, 2004
    Assignee: Maxtor Corporation
    Inventors: Albert Hartman, Wendy Lorimer
  • Publication number: 20040137100
    Abstract: The present teachings describe various aspects of a pressing device for manufacturing of shaped compacts from pulverized or granulated material. In one aspect, the pressing device includes a frame structure, which, via a lower connection device adapter-like, can be connected to a lower press frame means of a press and a die holding plate arranged in the frame structure. Moreover, the pressing device may further include a base body arranged within the frame structure, the die holding plate, and the base body being arranged in the frame structure relatively movable one to each other, a plurality of punch carriers, at least one part of them being mounted on the frame structure being movable in press direction relatively to the die holding plate and relatively to the base body, and supporting devices which support the punch carriers relative to the base body in the final press position.
    Type: Application
    Filed: November 21, 2003
    Publication date: July 15, 2004
    Inventors: Michael Thomas Silbermann, Walter Rau, Johann Meyer
  • Patent number: 6758662
    Abstract: Disclosed is a die for compacting a powdered material. The die has a die body having a penetrating die cavity to which a couple of punches are adapted to apply for pressing the powdered material to be supplied to form a compact, and a die holder having a bore into which the die body is shrink fitted. The die cavity is provided with a coating composed of a material which is selected from the group consisting of titanium carbide, titanium nitride, alumina, titanium cyanide, hafnium nitride, chromium nitride, tungsten carbide and DLC, and the die holder is composed of a steel material which is prepared by tempering at a temperature higher than a treatment temperature at which the coating is provided on the die cavity. The die cavity is tapered at a ratio within a range of 1/5,000 to 1/1,000.
    Type: Grant
    Filed: October 19, 2001
    Date of Patent: July 6, 2004
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Yoshimi Sugaya, Makoto Iwakiri
  • Patent number: 6733260
    Abstract: A powder box, an arrangement for a powder box comprising an insert and a method for filling powder into a cavity formed in a die. Gas is supplied to a powder box, which is movable toward and away from a position just above the cavity. The gas is supplied through a permeable plate, which is arranged on at least one insert and which faces the interior of the powder box, so that particles of the powder in the powder box are movable relative to each other. The fluidisation of the powder shortens the filling time and results in an even particle size distribution in the cavity.
    Type: Grant
    Filed: October 8, 2002
    Date of Patent: May 11, 2004
    Assignee: Höganäs AB
    Inventors: Paul Skoglund, Sven Allroth, Hilmar Vidarsson
  • Patent number: 6699430
    Abstract: A method of producing a substantially regular cylindrical body that consists of a deformable material, especially a sintered metal blank. The blank is provided with an interior helical recess. The blank is first produced with a substantially linear course of the interior recess, for example by extrusion. The body is cut to a defined length and is subjected to a rolling movement by a friction surface while being supported across its entire length on a support. The speed of the rolling movement changes in a linear and continuous manner across the length of the body, thereby regularly twisting the body.
    Type: Grant
    Filed: March 11, 2002
    Date of Patent: March 2, 2004
    Inventor: Arno Friedrichs
  • Publication number: 20040018107
    Abstract: A selective inhibition of sintering (SIS) technique may be used to fabricate a three-dimensional (3-D) dense metal object from a binderless metal powder. A number of layers of metal powder are provided on a build tank. For each layer, regions of the layer are sinter-inhibited, e.g., by depositing a sinter-inhibiting material such as a ceramic slurry, a metal salt, or oxidizing metal particles in the powder using chemicals or a concentrated heat source. Each layer may be compacted before the next layer is provided. A final compact may then be sintered. Unwanted sintered sections may be removed from the compact at boundaries formed by the sinter-inhibited (unsintered) regions, and the object extracted.
    Type: Application
    Filed: June 30, 2003
    Publication date: January 29, 2004
    Inventor: Behrokh Khoshnevis
  • Patent number: 6663828
    Abstract: A method and an apparatus for sintering a compact of particulate material for a ceramic or of particles of a metal, or a ceramic precursor film, wherein the sintering is performed by heating and burning the compact or the ceramic precursor film while applying centrifugal force to the compact or the ceramic precursor film.
    Type: Grant
    Filed: December 21, 2001
    Date of Patent: December 16, 2003
    Assignees: National Institute of Advanced Industrial Science and Technology, Sinto V-Cerax, Ltd.
    Inventors: Koji Watari, Mamoru Aizawa, Syoji Uchimura, Hirohide Ishiguro, Hideki Morimitsu
  • Patent number: 6663826
    Abstract: A method for preparing flat foils having a high density includes the steps of mixing a powdered material with a binder to form a green sheet. The green sheet is exposed to a high intensity radiative source adapted to emit radiation of wavelengths corresponding to an absorption spectrum of the powdered material. The surface of the green sheet is heated while a lower sub-surface temperature is maintained. An apparatus for preparing a foil from a green sheet using a radiation source is also disclosed.
    Type: Grant
    Filed: July 12, 2000
    Date of Patent: December 16, 2003
    Assignee: Ut-Battelle, LLC
    Inventors: Craig A. Blue, Vinod K. Sikka, Evan K. Ohriner
  • Patent number: 6656416
    Abstract: A powder pressing apparatus comprises a powder feeding apparatus. The powder feeding apparatus includes a container having a bottom portion provided with a powder holding portion formed with openings, and an impactor. The impactor is hit against the container to give an impulsive force, thereby feeding the powder contained in the container into the cavity formed in a die via the openings. The powder fed in the cavity is pressed, and the obtained compact is sintered into a sintered magnet. The powder feeding apparatus may include a feeder box containing the powder, and the feeder box may be provided therein with a rod member, and an opening of the feeder box may be provided with a linear member. In this case, the powder is fed into the cavity while moving the rod member in the horizontal direction in the feeder box, when the feeder box is above the cavity.
    Type: Grant
    Filed: September 6, 2001
    Date of Patent: December 2, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Akira Nakamura, Atsuo Tanaka, Shouichi Matsugami, Tadahiro Iwasaki, Yoshiro Takano
  • Patent number: 6656410
    Abstract: A method of applying highly viscous paste-like build materials in layers in a solid freeform fabrication apparatus to form three-dimensional objects. A viscosity modifier is first introduced into the build material to establish a low viscosity state and then the material is dispensed in layers on a working surface. The viscosity modifier is then removed from the build material preferably by evaporation, and the layer is selectively solidified to form the three-dimensional object. The method substantially eliminates the undesirable effects of induced shear stress imposed on lower layers when attempting to apply uniform layers of highly viscous materials in solid freeform fabrication techniques. The method allows for the use of highly viscous paste-like materials that can include upwards of 50% by weight of metallic, ceramic, mineral, or polymer powders. Preferably the binder is a photocurable resin or thermocurable material which is selectively solidified to form the three-dimensional objects.
    Type: Grant
    Filed: January 17, 2002
    Date of Patent: December 2, 2003
    Assignee: 3D Systems, Inc.
    Inventors: Charles W. Hull, Kenneth J. Newell
  • Patent number: 6649124
    Abstract: A powder pressing apparatus comprises a die formed with a plurality of cavities. None of the cavities overlap with another in the direction of pushing the compacts. The magnetic field generator includes a pair of yokes sandwiching the die. The yokes and the die have their respective upper surfaces generally in a same plane. A die lubricant is applied to the die but not to a region on which the compacts are to be slid. A rare-earth alloy powder in a feeder box is supplied into each of the cavities. The powder in the cavities is oriented, pressed, and the formed compacts and the yokes are demagnetized. The compacts are pushed and slid off the die on an anti-wear layer, by a flexible pushing member provided in a front portion of the feeder box. The compacts are sintered into rare-earth magnets, which are suitable for a coreless motor.
    Type: Grant
    Filed: July 11, 2001
    Date of Patent: November 18, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Seiichi Kohara, Shinji Kidowaki, Tsutomu Harada
  • Patent number: 6645426
    Abstract: Material powder 17 is filled in a cavity 16 which is composed of a die 12 having a die hole 11 in a shape matching the contour of a green compact and a lower punch 13. The material powder 17 is temporarily compressed by an upper punch 14 and the lower punch 13 to obtain a preform 18. A punch-out pin 15a is inserted into the preform 18 to punch out a shape of a through-hole 3. The preform 18 is pressurized and compressed by both of the upper and lower punches 14, 13 to obtain a green compact 19. The punch-out pin 15a is pulled out from the green compact 19 and the green compact 19 is taken out from the cavity 16. Further, the green compact 19 is sintered and a pair of leg parts 24 connected continuously at a base part 23 and an undercut part 25 between the leg parts 24 are formed by cutting off a part of a peripheral wall 26 of a through-hole 25a.
    Type: Grant
    Filed: January 18, 2002
    Date of Patent: November 11, 2003
    Assignees: Kobayashi Industry Co., Ltd., Hitachi Powdered Metals Co., Ltd.
    Inventors: Toshiro Yoshihara, Mitsuhiro Sato, Tadao Masuda
  • Patent number: 6623263
    Abstract: A variable speed powder compacting press includes a generally horizontal table with a powder compacting die cavity defined in the table. A movable compacting punch is disposed in the die cavity and can move upwardly towards the die cavity opening to compact powder disposed in the cavity. A sliding anvil is disposed on the horizontal table and has a powder dispensing portion, a compacting portion, and a pick up portion. The anvil is movable between a filling position wherein the dispensing portion is above the cavity, a compacting position wherein the compacting portion is above the cavity, and a pick up position wherein the pick up position is above the cavity. A rotary drive operates to move the compacting punch and the sliding anvil in a coordinated manner. A safety cover can cover a portion of the table and the sliding anvil during operation of the machine. An interlock determines if the safety cover is in a closed position.
    Type: Grant
    Filed: September 4, 2001
    Date of Patent: September 23, 2003
    Assignee: PTX-Pentronix, Inc.
    Inventors: Paul G. Faiman, Bruce A. Wagner
  • Patent number: 6610246
    Abstract: A powder material is put into a cylindrical mold and electrodes are brought into contact with the side surface of the mold and a current is applied to sinter the material in the mold while a pressure is applied to the material. In this process, local temperature difference is kept as small as possible. A pair of electrodes are brought into contact with the side circumferential surface of a cylindrical mold (25) filled with a powder material (28) to which a pressure is applied and a current is applied to the mold (25) to heat the powder material (28) in the mold (25) and a sintered body is obtained. In order to sinter the material by the current application through the pair of electrodes, two pairs of electrodes (19a, 19b, 19c, 19d) which face each other are all brought into contact with the side surface of the mold (25) and the current is supplied through the electrodes (19) alternately.
    Type: Grant
    Filed: June 28, 2002
    Date of Patent: August 26, 2003
    Assignee: Akane Co., Ltd.
    Inventor: Kenichi Sunamoto
  • Patent number: 6599468
    Abstract: The present invention provides a powder compacting apparatus including: a die having a through hole forming a cavity; a first punch and a second punch for pressing a rare-earth alloy magnetic powder filled in the cavity; and a magnetic field generator for applying an orientation magnetic field parallel to a pressing direction through the rare-earth alloy magnetic powder in the cavity, wherein at least one of the first and second punches and has a curved pressing surface, and the pressing surface is given a shape such as to suppress the movement of particles of the rare-earth alloy magnetic powder along the pressing surface during the pressing step.
    Type: Grant
    Filed: March 28, 2001
    Date of Patent: July 29, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Shuichi Okuyama, Tsutomu Harada, Takashi Tajiri
  • Patent number: 6596224
    Abstract: A powder bed (32) is built up by repeated deposition of a slurry that contains powder. Layers are made by depositing a liquid dispersion of the desired powdered material, which then slip-casts into the forming powder bed to make a new layer (34). The slurry may be deposited in any suitable manner, such as by raster or vector scanning, or by a plurality of simultaneous jets that coalesce before the liquid slip-casts into the bed, or by individual drops, the deposits of which are individually controlled, thereby generating a regular surface for each layer.
    Type: Grant
    Filed: March 1, 2000
    Date of Patent: July 22, 2003
    Assignee: Massachusetts Institute of Technology
    Inventors: Emanuel M. Sachs, Michael J. Cima, Michael A. Caradonna, Jason Grau, James G. Serdy, Patrick C. Saxton, Scott A. Uhland, Jooho Moon
  • Publication number: 20030113222
    Abstract: A powder box, an arrangement for a powder box comprising an insert and a method for filling powder into a cavity formed in a die. Gas is supplied to a powder box, which is movable toward and away from a position just above the cavity. The gas is supplied through a permeable plate, which is arranged on at least one insert and which faces the interior of the powder box, so that particles of the powder in the powder box are movable relative to each other. The fluidisation of the powder shortens the filling time and results in an even particle size distribution in the cavity.
    Type: Application
    Filed: October 8, 2002
    Publication date: June 19, 2003
    Inventors: Paul Skoglund, Sven Allroth, Hilmar Vidarsson
  • Patent number: 6569364
    Abstract: An interface F between upper mandrels and lower mandrels are moved to a predetermined position in a cavity with the upper mandrels and the lower mandrels slidingly moving toward the lower punch while the upper mandrels and the lower mandrels remain in contact with each other, in a manner such that pressure is not applied to powdered dielectric material disposed in the cavity. The powdered dielectric material in the cavity is compressed by an upper punch and the lower punch while the upper mandrels and the lower mandrels remain in contact with each other, thereby forming a dielectric block.
    Type: Grant
    Filed: June 4, 2001
    Date of Patent: May 27, 2003
    Assignee: Murata Manufacturing Co. Ltd.
    Inventors: Wataru Yanase, Yukio Higuchi
  • Patent number: 6565345
    Abstract: The invention relates to an extrusion device (1) for compacting metal parts, in particular shavings (3), for example made of Fe, Cu, Mg or alloys of these elements or other low melting metals or their alloys, into homogenous extrusion mouldings with at least one extrusion unit with an extrusion die (5) formed by a die housing (9) which forms a die cavity (8) and has a guide arrangement for an extrusion element (7) adjustable by a drive device (6), and with an inlet opening (28) for the shavings (3) in the die housing (9), whereby a compression channel (18) is arranged opposite a front face of the extrusion element (7) facing the mould cavity (8) and adjacent to the mould cavity (8) in the direction of a passage surface (15) for a material strand (2).
    Type: Grant
    Filed: August 12, 1999
    Date of Patent: May 20, 2003
    Assignee: TCG Unitech AG
    Inventor: Helmut Schwaiger
  • Patent number: 6562288
    Abstract: Disclosed are a method for manufacturing cutting blades with a shortened manufacturing process and an apparatus for manufacturing cutting blades with a single manufacturing facility, as well as a cutting blade having cutting segments in which diamond particles are uniformly distributed.
    Type: Grant
    Filed: December 12, 2000
    Date of Patent: May 13, 2003
    Inventor: Rin Soon Park
  • Patent number: 6558594
    Abstract: Powder mixture is supplied into a die under a state that a center pin is located lower than the top surface of the die, after which the center pin is lifted up to a given molding position where an annular molding space is defined between the center pin and the die. The powder mixture is then compressed from upper and lower sides with an upper plunger and a lower plunger to form a pellet. The center pin and the lower plunger are simultaneously lifted up to remove the pellet out of the die.
    Type: Grant
    Filed: January 25, 2001
    Date of Patent: May 6, 2003
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Minoru Kouda, Shigeharu Hattori, Saburo Nakatsuka, Hiroshi Takebayashi, Toshio Sanukiya
  • Patent number: 6558144
    Abstract: The present invention relates to a metal powder compression tool for forming compacts for sintering, including a first punch (15) adapted to compress powder located in a die (10). The clearance between the punch and the die is greater than the radial expansion of the punch under the desired compression effort, and lower than the mean size of the powder grain.
    Type: Grant
    Filed: April 13, 2000
    Date of Patent: May 6, 2003
    Assignee: Federal-Mogul Sintered Products, S.A.
    Inventors: Henri Gueydan, Pierre Blanchard
  • Patent number: 6548014
    Abstract: A suspension application apparatus for applying a suspension containing powder particles of an oxide dispersed in a liquid to a plate for magnet sintering, the oxide having a specific gravity greater than the liquid. The apparatus includes: a container for storing the suspension; a stirrer for stirring the suspension stored in the container; a transport path through which the suspension is transported from the container to the plate; and a homogenizer for homogenizing the suspension by applying a mechanical force to at least part of the suspension flowing through the transport path.
    Type: Grant
    Filed: June 21, 2001
    Date of Patent: April 15, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Hiroyuki Kumokita, Katsumi Okayama, Tsuyoshi Wada
  • Patent number: 6533997
    Abstract: An isostatic press for hot isostatic pressing having a pressure vessel (1) in which a furnace chamber (2) is arranged with a space (3) between the furnace chamber (2) and the walls of the pressure vessel (2). The furnace chamber (2) has a heat-insulating mantle and heat-insulating top wall and bottom wall, and passageways (5, 6) are arranged in the walls of the furnace chamber (2). A gas outlet means is arranged in the interior of the furnace chamber (2). Gas is removed directly from the furnace chamber (2) by the gas outlet means. Advantages include that treated articles (11) are cooled rapidly, as cooling takes place during the same time as decompression. Articles (11) may also be rapidly cooled to a temperature at which they are easily handled.
    Type: Grant
    Filed: May 31, 2001
    Date of Patent: March 18, 2003
    Assignee: Flow Holding GmbH (SAGL) Limited Liability Company
    Inventor: Carl Bergman
  • Patent number: 6531090
    Abstract: A method for manufacturing a magnet using an apparatus including a die, a first punch, and a second punch for compacting magnet powder is disclosed. Magnet powder is compacted with the first and second punches to produce a compact of the magnet powder. The distance between the first and second punches is increased to reduce the pressure applied to the compact from the first and second punches. Lowering of the die is started after the decrease of the pressure is started and before it is halted. The compact is completely ejected from the die before the pressure becomes zero.
    Type: Grant
    Filed: February 15, 2001
    Date of Patent: March 11, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventor: Atsushi Ogawa