JP2009091651A - Die apparatus for metal powder injection molding - Google Patents

Die apparatus for metal powder injection molding Download PDF

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JP2009091651A
JP2009091651A JP2008198552A JP2008198552A JP2009091651A JP 2009091651 A JP2009091651 A JP 2009091651A JP 2008198552 A JP2008198552 A JP 2008198552A JP 2008198552 A JP2008198552 A JP 2008198552A JP 2009091651 A JP2009091651 A JP 2009091651A
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punch
cavity
raw material
mold
metal powder
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JP5183346B2 (en
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Zenzo Ishijima
善三 石島
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Resonac Corp
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Hitachi Powdered Metals Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/004—Filling molds with powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/03—Press-moulding apparatus therefor

Abstract

<P>PROBLEM TO BE SOLVED: To provide a die apparatus for injection molding which facilitates the supply of a raw material for efficiently producing a molded part having a thin part. <P>SOLUTION: A die for metal powder injection molding is disclosed in which a plastic raw material M composed of metal powder and a binder is injection-filled into a cavity provided at the inside of a die composed of a fixed die 10 and a movable die 20 from a gate 51 provided at least either the fixed die or movable die. At least either the fixed die or movable die is split into a plurality of dies, the plastic raw material composed of the metal powder and the binder is injected-filled into the cavity, and thereafter, the dies split into two or more are driven, consequently the volume of the cavity is made fixed to deform the cavity, and further, the plastic raw material filled into the cavity is deformed at a fixed volumes to mold a molded body P. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、金属粉末とバインダーからなる可塑性の原料を、金型内部に設けられたキャビティに射出充填して所望の形状の成形体を成形する金属粉末射出成形用金型装置に係わり、特に、肉厚の薄い部位を有する成形体の成形に好適な技術に関する。   The present invention relates to a metal powder injection molding die apparatus for forming a molded body of a desired shape by injection-filling a plastic raw material comprising a metal powder and a binder into a cavity provided inside the die, and in particular, The present invention relates to a technique suitable for molding a molded body having a thin portion.

粉末冶金法は、金属粉末または金属粉末に非金属粉末を配合した粉末を所定の形状および寸法に固める成形工程により得られた成形体を、融点よりも低い温度で加熱して粉末粒子を強固に結合する焼結工程を経て金属製品を製造する技術であり、複雑形状部品をニアネットシェイプに大量生産できることや、溶製法では得られない複合材料を得られる等の利点により、その適用が拡大している。   In the powder metallurgy method, a powder obtained by molding a metal powder or a metal powder mixed with a non-metal powder into a predetermined shape and size is heated at a temperature lower than the melting point to strengthen the powder particles. It is a technology for manufacturing metal products through a combined sintering process, and its application has expanded due to advantages such as the ability to mass-produce complex shaped parts in a near net shape and the ability to obtain composite materials that cannot be obtained by the melting method. ing.

このような粉末冶金法は、原料粉末をダイのキャビティ内に充填し、これをパンチで加圧して圧粉成形した後、得られた成形体を焼結する押型成形法と、原料粉末を多量のバインダーとともに混練して可塑性をもたせた原料をモールド内のキャビティに加圧充填し、得られた成形体を加熱してバインダーを除去した後、焼結する射出成形法に大別される。   In such a powder metallurgy method, a raw material powder is filled in a cavity of a die, pressed with a punch and compacted, and then an obtained molding is sintered. It is roughly classified into an injection molding method in which a raw material kneaded with a binder is plastic-filled into a cavity in a mold and the obtained molded body is heated to remove the binder and then sintered.

押型成形法では、原料粉末の流動性および金型に対する潤滑性のため、１質量％以下程度の成形潤滑剤を原料粉末に混入する場合があるが、成形潤滑剤の使用量が少ないため、焼結工程の初めの段階で揮発除去することが容易で、脱脂工程が短くて済むという利点がある。押型成形法では、原料粉末のダイへの充填は、フィーダ（粉箱）と呼ばれる粉末供給装置より原料粉末をダイ等で形成される空間に落とし込む方法で行われるが、この方法では充填量にばらつきが発生することが避けられない。また、肉厚が薄い製品を押型成形法で得ようとすると、キャビティの小さい空隙に原料粉末を充填する必要があるため、原料粉末の粒径が小さいものを用いる必要がある。この場合には、原料粉末の流動性が低下するとともに充填性が低下して、安定した原料粉末の供給が行えない。このため、押型成形法により製品を製造する場合には、ある程度の大きさの製品であることが必要となる。   In the injection molding method, a molding lubricant of about 1% by mass or less may be mixed into the raw material powder because of the fluidity of the raw material powder and the lubricity with respect to the mold. There is an advantage that it is easy to volatilize and remove at the initial stage of the binding process, and the degreasing process can be shortened. In the injection molding method, the raw material powder is filled into the die by a method of dropping the raw material powder into a space formed by a die or the like from a powder feeder called a feeder (powder box). Is inevitable. In addition, if an attempt is made to obtain a product with a small wall thickness by the injection molding method, it is necessary to fill the raw material powder into a cavity having a small cavity, and therefore it is necessary to use a material powder having a small particle size. In this case, the fluidity of the raw material powder is lowered and the filling property is lowered, so that stable raw material powder cannot be supplied. For this reason, when a product is manufactured by an injection molding method, the product needs to have a certain size.

射出成形法は、原料が可塑性を有するため上記の押型法では成形できないアンダーカット等（オーバーハングした部位）を有する形状にも成形できるという利点がある。また、原料が可塑性を有するため上記の押型成形法に比してキャビティの小さい空隙に原料粉末を充填できるという利点も有する。しかしながら、原料の流動性を確保するため、原料粉末に３０〜７０体積％の熱可塑性樹脂等のバインダーを添加して混練する必要がある。この場合、成形体に多量のバインダーを含有しているため、これを除去する脱バインダー工程に時間がかかるという欠点がある。また、肉厚が極めて薄い製品を得ようとすると、原料を充填するキャビティの空隙が微少であるため、高圧で原料を充填する必要がある。ところが、高圧で原料を射出して充填すると、流動しやすいバインダーのみが微少空隙に流れてしまい、金属粉末を均一に充填することが難しい。このため、射出成形法により肉厚が薄い製品を製造する場合でも、ある程度の薄さまでの製品にしか対応できない。   The injection molding method has an advantage that it can be molded into a shape having an undercut or the like (overhanged portion) that cannot be molded by the above-described mold method because the raw material has plasticity. In addition, since the raw material has plasticity, it has an advantage that the raw material powder can be filled in a void having a small cavity as compared with the above-described press molding method. However, in order to ensure the fluidity of the raw material, it is necessary to add and knead 30 to 70% by volume of a binder such as a thermoplastic resin to the raw material powder. In this case, since the molded body contains a large amount of binder, there is a drawback that it takes time to remove the binder. In addition, when trying to obtain a product with a very thin wall thickness, since the voids in the cavity for filling the raw material are very small, it is necessary to fill the raw material at a high pressure. However, when the raw material is injected and filled at a high pressure, only the binder that easily flows flows into the minute voids, and it is difficult to uniformly fill the metal powder. For this reason, even when a product with a thin wall thickness is manufactured by an injection molding method, it can only deal with products up to a certain thickness.

このような状況の下、押型成形法と射出成形法の長所を兼ね備えた成形法が提案されている（特許文献１等）。特許文献１等に開示された技術は、原料粉末に通常の押型成形法で与える以上の多量のバインダー等を与えた原料を用いて押型成形する方法である。特許文献１によれば、射出成形法では原料を均一に充填できないような微少空隙にも原料を充填でき、肉厚が極めて薄い製品の製造に対応可能である。また、射出成形法に比してバインダーの添加量が少なく、その分脱バインダー時間を短くできるため、射出成形法で製造する場合よりも安価に製造可能である。   Under such circumstances, there has been proposed a molding method that combines the advantages of the injection molding method and the injection molding method (Patent Document 1, etc.). The technique disclosed in Patent Document 1 and the like is a method in which a raw material powder is subjected to an injection molding using a raw material provided with a larger amount of binder or the like than that provided by a normal injection molding method. According to Patent Document 1, raw materials can be filled even in minute voids that cannot be filled uniformly by the injection molding method, and it is possible to cope with the manufacture of a product with a very thin wall thickness. Further, since the amount of binder added is small compared to the injection molding method and the binder removal time can be shortened by that amount, it can be manufactured at a lower cost than the case of manufacturing by the injection molding method.

特開２００６−３４４５８１号公報JP 2006-344581 A

特許文献１の製造方法において、原料は、一般の押型法で扱えるように、ある程度の大きさの造粒粉末として、フィーダ等の粉末供給装置による充填方法を用いて供給される。しかしながら、肉厚が極めて薄い製品を成形する場合、キャビティの空隙が微小であるため、一般の押型法で用いる粉末供給装置に適した粉末の大きさに造粒すると、粒径が大きいため均一かつ緻密に造粒粉末を充填することが難しい。一方、造粒粉末の粒径を小さくすると、原料粉末の流動性が低下する。従って、好適な大きさの造粒粉末に調整することは容易ではない。   In the production method of Patent Document 1, the raw material is supplied as a granulated powder of a certain size using a filling method by a powder supply device such as a feeder so that it can be handled by a general stamping method. However, when molding an extremely thin product, the cavity has a very small gap. Therefore, when granulated to a powder size suitable for a powder feeding apparatus used in a general stamping method, the particle size is large and uniform. It is difficult to fill the granulated powder precisely. On the other hand, when the particle size of the granulated powder is reduced, the fluidity of the raw material powder is lowered. Therefore, it is not easy to adjust the granulated powder to a suitable size.

特許文献１では、所定の量を充填出来るように原料を１回の充填量に相当する量のペレットとしてまとめ、ペレット単位で原料を供給することを好ましい態様としている。しかしながら、この場合、ペレット作製工程が追加されて工数が増える。また、均質な製品を製造するためには、このペレット作製工程において得られるペレットを均質に管理する必要があり、この管理の手間が増える。さらに、ペレットを作製する際、軟化し易いように原料を加熱するため、ペレットを作製するための余分な熱エネルギーが必要となる。   In Patent Document 1, the raw materials are collected as pellets in an amount corresponding to one filling amount so that a predetermined amount can be filled, and the raw materials are supplied in units of pellets. However, in this case, the number of steps is increased by adding a pellet manufacturing process. In addition, in order to produce a homogeneous product, it is necessary to uniformly manage the pellets obtained in this pellet manufacturing process, and this management effort increases. Furthermore, when the pellet is manufactured, the raw material is heated so as to be easily softened, so that extra thermal energy for manufacturing the pellet is required.

そこで、本発明は、肉厚が極めて薄い製品をより効率的に製造するため、原料の供給が容易な射出成形用金型装置を提供するものであり、原料である粉末の造粒が容易であり、原料からペレットを作製する工程を追加して管理項目を増やしたり、成形過程における余分な熱エネルギーを必要としない技術を提供することを目的としている。   Therefore, the present invention provides an injection mold apparatus in which raw material can be easily supplied in order to more efficiently produce a product having an extremely thin wall thickness, and it is easy to granulate the raw material powder. The purpose is to provide a technique that does not require extra heat energy in the molding process, or adds a process for producing pellets from raw materials to increase management items.

本発明の金型装置は、固定金型と可動金型とからなる金型内部に設けられたキャビティに、固定金型および可動金型の少なくとも一方に設けられたゲートより、金属粉末とバインダーからなる可塑性の原料を射出充填する金属粉末射出成形用金型において、固定金型と可動金型のうち少なくとも一方が複数の金型に分割され、キャビティに、金属粉末とバインダーからなる可塑性の原料を射出充填した後、複数に分割された金型を駆動することにより、キャビティの容積を一定にしてキャビティを変形させるとともに、キャビティに充填された可塑性の原料を体積一定で変形させて成形体を成形できるようにしたことを特徴とする。上記構成の金型装置にあっては、キャビティに射出充填された原料の体積を一定にして、原料の一部を押し出しして成形体を成形するため、キャビティの小さい隙間に原料を充填する必要がない。従って、原料である粉末の粒径の影響を小さくすることができ、粉末の造粒が容易である。また、一定量の原料を金型内に充填できるため、ペレット作製工程が不要である。   The mold apparatus according to the present invention includes a metal powder and a binder from a gate provided in at least one of a fixed mold and a movable mold in a cavity provided in a mold including a fixed mold and a movable mold. In a metal powder injection mold for injection-filling a plastic raw material, at least one of a fixed mold and a movable mold is divided into a plurality of molds, and a plastic raw material composed of metal powder and a binder is placed in a cavity. After injection filling, by driving a mold divided into multiple parts, the cavity is deformed while keeping the volume of the cavity constant, and the molded material is formed by deforming the plastic raw material filled in the cavity at a constant volume. It is possible to do it. In the mold apparatus configured as described above, the volume of the raw material injected and filled in the cavity is made constant, and a part of the raw material is extruded to form a molded body. Therefore, it is necessary to fill the raw material into a small gap in the cavity. There is no. Therefore, the influence of the particle diameter of the raw material powder can be reduced, and the powder can be easily granulated. In addition, since a certain amount of raw material can be filled in the mold, a pellet manufacturing step is unnecessary.

本発明の金型装置において、固定金型と可動金型のうち少なくとも一方に、キャビティ内部に突出する突出パンチと後退する後退パンチとに分割した金型を設けることが好ましい。この場合、キャビティに金属粉末とバインダーからなる可塑性の原料を射出充填した後、突出パンチをキャビティ内に突出させるとともに、後退パンチをキャビティより後退させて、キャビティに射出充填された原料の体積を一定にして、原料の一部を押し出しして成形体を成形する。   In the mold apparatus of the present invention, it is preferable that at least one of the fixed mold and the movable mold is provided with a mold divided into a projecting punch projecting into the cavity and a retracting punch retracting. In this case, after the plastic raw material consisting of metal powder and binder is injected and filled into the cavity, the protruding punch is protruded into the cavity and the retreating punch is retracted from the cavity, so that the volume of the raw material injected and filled into the cavity is constant. Then, a part of the raw material is extruded to form a molded body.

具体的には、キャビティは、可塑性の原料の射出充填時に例えば略円柱状とされ、後退パンチは例えば円筒状であり、後退パンチを設けた金型の内周面と摺動自在に嵌合する。突出パンチは例えば円柱状であり、後退パンチの内周面と摺動自在に嵌合する。後退パンチを設けた金型のキャビティによりコップ状成形体の外周を、後退パンチを設けていない金型によりコップ状成形体の底部を、後退パンチによりコップ状成形体の縁部を、突出パンチによりコップ状成形体の内周面および底部をそれぞれ成形する。   Specifically, the cavity is, for example, substantially cylindrical when the plastic raw material is injected and filled, and the receding punch is, for example, cylindrical, and is slidably fitted to the inner peripheral surface of the mold provided with the receding punch. . The projecting punch has, for example, a cylindrical shape and is slidably fitted to the inner peripheral surface of the receding punch. The outer periphery of the cup-shaped molded body is formed by the cavity of the mold provided with the reverse punch, the bottom of the cup-shaped molded body is formed by the mold not provided with the backward punch, the edge of the cup-shaped molded body is formed by the backward punch, and the protruding punch The inner peripheral surface and the bottom of the cup-shaped molded body are respectively molded.

後退パンチの肉厚は、例えば０．０５〜０．２６ｍｍである。本発明の金型装置により薄肉製品を成形するにあたり、原料として、金属粉末に、熱可塑性樹脂とワックスからなるバインダーを４０〜６０体積％添加して、加熱混練した可塑性の原料を用いることができる。   The thickness of the receding punch is, for example, 0.05 to 0.26 mm. In forming a thin product with the mold apparatus of the present invention, a plastic raw material obtained by adding 40 to 60% by volume of a binder made of a thermoplastic resin and a wax to a metal powder and heating and kneading can be used as a raw material. .

本発明の射出成形用金型装置によれば、原料である粉末の造粒が容易であり、原料からペレットを作製する工程を追加して管理項目を増やしたり、成形過程における余分な熱エネルギーの必要がない。これらより、肉厚が極めて薄い製品をより効率的に製造できるという優れた効果を奏する。   According to the mold apparatus for injection molding of the present invention, it is easy to granulate powder as a raw material, and the number of management items can be increased by adding a process for producing pellets from the raw material, or excess heat energy in the molding process can be increased. There is no need. As a result, it is possible to produce a product having an extremely thin wall thickness more efficiently.

以下、薄肉の製品の一例として冷陰極蛍光ランプ用電極の製造を例にとり、図面を参照して本発明の金型装置の構成と動作を説明するとともに、本金型装置を用いた成形体の成形方法について説明する。   Hereinafter, as an example of a thin product, taking the production of an electrode for a cold cathode fluorescent lamp as an example, the configuration and operation of the mold apparatus of the present invention will be described with reference to the drawings, and a molded body using the mold apparatus will be described. A forming method will be described.

図１に示すように、冷陰極蛍光ランプは、ガラス管１内に、端子２で外部に接続された電極３が両端に配置された構造をしており、このガラス管１の内面に蛍光体４を塗布するとともに、希ガスと微量の水銀からなる封入ガス５を封入して構成されている。この両端の電極３に高電界を加えて低圧の水銀蒸気中でグロー放電を発生させ、この放電により励起された水銀が紫外線を発生するとともに、この紫外線によりガラス管１内面の蛍光体４を励起して発光させる。近年、ここで用いられる電極３としては、ホローカソード効果を得るため、図２に示すような底部３ａと円筒部３ｂからなる有底円筒状に形成したものが用いられている。この場合、端子２は有底円筒状電極３の底部３ａにろう付け等で接着されるが、端子２と電極３とが一体形状となっているものもある。   As shown in FIG. 1, the cold cathode fluorescent lamp has a structure in which electrodes 3 connected to the outside by terminals 2 are arranged at both ends in a glass tube 1, and a phosphor is formed on the inner surface of the glass tube 1. 4 and a sealed gas 5 composed of a rare gas and a small amount of mercury are sealed. A high electric field is applied to the electrodes 3 at both ends to generate a glow discharge in a low-pressure mercury vapor. The mercury excited by the discharge generates ultraviolet rays, and the ultraviolet rays on the inner surface of the glass tube 1 are excited by the ultraviolet rays. To emit light. In recent years, as the electrode 3 used here, in order to obtain a hollow cathode effect, an electrode formed in a bottomed cylindrical shape including a bottom portion 3a and a cylindrical portion 3b as shown in FIG. 2 is used. In this case, the terminal 2 is bonded to the bottom portion 3a of the bottomed cylindrical electrode 3 by brazing or the like, but there are some in which the terminal 2 and the electrode 3 are integrated.

このような構成の冷陰極蛍光ランプは、近年、液晶ディスプレイのバックライト用光源として用いられており、また、最近では、液晶テレビやカーナビゲーションシステムの液晶ディスプレイ等にも適用され、その需要が拡大している。さらに、一つの製品に使用される冷陰極蛍光ランプの本数は、１５インチ以下の液晶ディスプレイ等では、テレビ用で４〜６本、モニタ用で１〜２本であるが、大型モニタやテレビ用では必要な輝度を得るために複数本の冷陰極蛍光ランプが使用される。このため、冷陰極蛍光ランプの需要は急激に拡大している。   In recent years, the cold cathode fluorescent lamp having such a configuration has been used as a light source for backlights of liquid crystal displays, and has recently been applied to liquid crystal displays for liquid crystal televisions and car navigation systems, and the demand for such cold cathode fluorescent lamps has expanded. is doing. Furthermore, the number of cold cathode fluorescent lamps used in one product is 4-6 for TVs and 1-2 for monitors for liquid crystal displays of 15 inches or less, but for large monitors and TVs. In order to obtain the required brightness, a plurality of cold cathode fluorescent lamps are used. For this reason, the demand for cold cathode fluorescent lamps is rapidly expanding.

上記のような冷陰極蛍光ランプにおいては、近年、液晶ディスプレイ等の低消費電力化、高輝度・高精細化等の性能向上の要求に対応するため、陰極降下電圧の低下、耐スパッタ性等の電極材料の特性向上が求められている。そして、そのような特性向上のために、より薄肉の電極が求められている。   In the cold cathode fluorescent lamp as described above, in order to meet the demand for performance improvement such as low power consumption, high brightness and high definition of liquid crystal displays in recent years, reduction of cathode fall voltage, spatter resistance, etc. There is a need for improved properties of electrode materials. In order to improve such characteristics, thinner electrodes are required.

図３は、本発明の金型装置の構成と動作を説明する模式図である。金型装置は、コップ状成形体の底面を成形する金型面１１を有する固定金型１０と、コップ状成形体の外周面を成形する内周面２１を有する可動金型２０と、コップ状成形体の縁部を成形する端面３１を有する円筒状の後退パンチ３０と、コップ状成形体の底部を成形する端面４１およびコップ状成形体の内周面を形成する外周面４２を有する円柱状の突出パンチ４０から構成されている。   FIG. 3 is a schematic diagram illustrating the configuration and operation of the mold apparatus of the present invention. The mold apparatus includes a fixed mold 10 having a mold surface 11 that molds the bottom surface of a cup-shaped molded body, a movable mold 20 having an inner peripheral surface 21 that molds an outer peripheral surface of the cup-shaped molded body, and a cup shape. A cylindrical receding punch 30 having an end surface 31 for forming the edge of the formed body, a columnar shape having an end surface 41 for forming the bottom of the cup-shaped formed body and an outer peripheral surface 42 for forming the inner peripheral surface of the cup-shaped formed body. Projecting punch 40.

固定金型１０と可動金型２０は、一般の射出成形に用いる金型と同様に、各々の端面を密着させて配置され型締めされ、成形体の取り出しにあたっては、可動金型２０が図示していない駆動装置により型開きする。固定金型１０にはゲート５１およびスプルー６１が、可動金型２０にはゲート５２およびスプルー６２がそれぞれ対に形成されている。なお、本実施形態においては、ゲートおよびスプルーを固定金型１０と可動金型２０の両者に形成したが、いずれか一方にのみ形成してもよい。   The fixed mold 10 and the movable mold 20 are arranged with their end faces in close contact with each other and clamped in the same manner as a mold used for general injection molding, and the movable mold 20 is shown when taking out the molded body. The mold is opened by the drive that is not. The fixed mold 10 is formed with a gate 51 and a sprue 61, and the movable mold 20 is formed with a gate 52 and a sprue 62, respectively. In the present embodiment, the gate and the sprue are formed in both the fixed mold 10 and the movable mold 20, but may be formed only in either one.

突出パンチ４０は図示していないシリンダ等の駆動装置により、進退可能に構成されている。後退パンチ３０は図示していないスプリング等により保持され、あるいは別の駆動装置により、突出パンチ４０の突出、後退に応じて進退可能に構成されている。後退パンチ３０の内周面は突出パンチ４０の外周面と摺動自在に嵌合し、後退パンチ３０の外周面は可動金型２０の内周面２１と摺動自在に嵌合しており、固定金型１０に対向している。   The protruding punch 40 is configured to be advanced and retracted by a driving device such as a cylinder (not shown). The retreating punch 30 is held by a spring or the like (not shown), or is configured to be advanced or retracted according to the protrusion or retraction of the protruding punch 40 by another drive device. The inner peripheral surface of the reverse punch 30 is slidably fitted to the outer peripheral surface of the protruding punch 40, and the outer peripheral surface of the reverse punch 30 is slidably fitted to the inner peripheral surface 21 of the movable mold 20. It faces the fixed mold 10.

上記構成の金型装置は、次のようにして動作する。すなわち、原料Ｍの充填時においては、図３（ａ）に示すように、固定金型１０の金型面１１、可動金型２０の内周面２１、後退パンチ３０の端面３１、突出パンチ４０の端面４１とにより所望の容積のキャビティを形成する。このキャビティにスプルー６１，６２およびゲート５１，５２を介して可塑性の原料Ｍを射出して充填する。   The mold apparatus having the above-described configuration operates as follows. That is, when filling the raw material M, as shown in FIG. 3A, the mold surface 11 of the fixed mold 10, the inner peripheral surface 21 of the movable mold 20, the end surface 31 of the retreating punch 30, and the protruding punch 40 A cavity having a desired volume is formed by the end face 41 of the above. A plastic raw material M is injected and filled into the cavity through the sprues 61 and 62 and the gates 51 and 52.

このようにしてキャビティに原料Ｍが充填された後、図３（ｂ）に示すように、突出パンチ４０をキャビティ内に進入させて（図中の下向き矢印の方向）原料Ｍを押圧し、突出パンチ４０の端面４１によりコップ状成形体の底部３ａを形成する。このとき、後退パンチ３０を後退させることにより（図中の上向き矢印の方向）、可動金型２０の内周面２１と、後退パンチ３０の端面３１と、突出パンチ４０の外周面４２とにより形成される円筒状のキャビティに原料Ｍを後方押し出しして、電極の円筒部３ｂを形成する。このため、キャビティの小さい隙間に原料Ｍを充填する必要がなく、原料Ｍである粉末の粒径の影響を小さく出来るため、造粒が容易となる。また、スプルー６１，６２よりキャビティ内に充填した原料Ｍが漏れ出してキャビティ内の原料Ｍの容積が減ることがないように、ゲート５１，５２からキャビティ内では原料Ｍを射出時の圧力において維持する必要がある。さらに、原料Ｍに背圧を加えながら後退パンチ３０を後退させて成形すると、成形体の円筒部３ｂの縁部の高さが均一に成形できるとともに、原料Ｍの密度がキャビティ内に均一に作用して、成形後に得られる成形体の密度が均一となるため好ましい。   After the cavity is filled with the raw material M in this way, as shown in FIG. 3B, the protruding punch 40 is caused to enter the cavity (in the direction of the downward arrow in the figure) to press the raw material M and protrude. The bottom surface 3a of the cup-shaped molded body is formed by the end face 41 of the punch 40. At this time, the backward punch 30 is moved backward (in the direction of the upward arrow in the drawing) to form the inner peripheral surface 21 of the movable mold 20, the end surface 31 of the backward punch 30, and the outer peripheral surface 42 of the protruding punch 40. The raw material M is extruded backward into a cylindrical cavity to form the cylindrical portion 3b of the electrode. For this reason, it is not necessary to fill the raw material M in a small gap of the cavity, and the influence of the particle size of the powder that is the raw material M can be reduced, so that granulation is facilitated. Further, the raw material M is maintained at the pressure at the time of injection from the gates 51 and 52 in the cavity so that the raw material M filled in the cavity does not leak from the sprues 61 and 62 and the volume of the raw material M in the cavity is reduced. There is a need to. Further, when the back punch 30 is retreated while applying back pressure to the raw material M, the edge of the cylindrical portion 3b of the formed body can be uniformly formed, and the density of the raw material M acts uniformly in the cavity. And since the density of the molded object obtained after shaping | molding becomes uniform, it is preferable.

上記の充填工程および成形工程においては、原料Ｍは軟化して流動性がある状態で用いられるが、成形完了後の抜き出し工程時において、原料Ｍが軟化したままであると成形体の形状が保持できず、抜き出し時もしくは抜き出し後に型くずれが生じる。このため、抜き出し工程は、バインダー中に含まれる熱可塑性樹脂の軟化点以下の温度に冷却した後に行う。このようにすることで有底円筒状成形体が硬化し、抜き出し時および抜き出し後も成形時の形状が保持され、取扱いも容易になる。   In the above filling process and molding process, the raw material M is used in a softened and fluid state, but the shape of the molded body is maintained if the raw material M remains soft during the extraction process after completion of molding. This is not possible, and the mold is deformed at the time of extraction or after extraction. For this reason, an extraction process is performed after cooling to the temperature below the softening point of the thermoplastic resin contained in a binder. By doing so, the bottomed cylindrical molded body is cured, and the shape at the time of molding is maintained even during and after the extraction, and the handling becomes easy.

上記の温度に冷却されて成形体Ｐが固化したら、図３（ｃ）に示すように、可動金型２０を固定金型１０との密着状態より開放して、固定金型１０と離間する方向に移動させるとともに、突出パンチ４０を図面上方に退避させ、最後に後退パンチ３０を成形体Ｐの円筒部３ｂの縁部から離間する方向に退避させて、成形体Ｐを成形金型より抜き出す。成形体Ｐの抜き出しが容易になるよう、固定金型１０の金型面１１に抜き出しピンを設けておいてもよい。   When the molded body P is cooled to the above temperature and solidified, as shown in FIG. 3C, the movable mold 20 is released from the close contact state with the fixed mold 10 and separated from the fixed mold 10. The projecting punch 40 is retracted upward in the drawing, and finally the retracting punch 30 is retracted in a direction away from the edge of the cylindrical portion 3b of the molded body P, and the molded body P is extracted from the molding die. An extraction pin may be provided on the mold surface 11 of the fixed mold 10 so that the molded body P can be easily extracted.

上記により得られる成形体Ｐはコップ状成形体Ｐ１とランナＰ２からなり、図３（ｄ）に示すように、ランナＰ２を除去することによりコップ状成形体Ｐ１が得られる。このとき、成形体Ｐは、金属粉末がバインダにより結着されただけのきわめて脆いものであるため、手作業で容易にコップ状成形体Ｐ１とランナＰ２に分離することができる。また、このランナＰ２の除去作業をより一層容易にするため、一般の射出成形法において行われているように、固定金型１０のゲート５１または可動金型２０のゲート５２として、ゲートの断面積の小さいゲートを用いることは好ましい。これにより、ゲート部分で容易に分離することができる。 Moldings P obtained by the above consists cup-shaped molded product P 1 and the runner P 2, as shown in FIG. 3 (d), a cup-shaped molded product P 1 is obtained by removing the runner P 2. In this case, the molded body P, since the metal powder is of only very fragile is bound with a binder, it can be readily separated into a cup-shaped article P 1 and runner P 2 manually. Further, in order to make the removal of the runner P 2 even easier, the gate is cut off as the gate 51 of the fixed mold 10 or the gate 52 of the movable mold 20 as is performed in a general injection molding method. It is preferable to use a gate having a small area. Thereby, it can isolate | separate easily in a gate part.

上記の本発明の金型装置によれば、射出成形法で成形することが難しい、肉厚が０．０５〜０．２６ｍｍの薄肉製品を成形することが可能である。このような薄肉製品を成形するためには、後退パンチの肉厚を０．０５〜０．２６ｍｍとすればよい。また、上記の本発明の金型装置によれば、特許文献１のようなペレット作製工程が不要であるため工数を低減することができる。また、均一量の原料をキャビティ内に充填できるため、ペレットを均質に管理する手間を省くことができる。さらに、加熱して作製するペレットが不要なため、原料の成形に必要な熱エネルギーを削減することができ、より効率的に薄肉の製品を製造できるという優れた効果を奏する。   According to the above-described mold apparatus of the present invention, it is possible to mold a thin product having a thickness of 0.05 to 0.26 mm, which is difficult to be molded by an injection molding method. In order to form such a thin product, the thickness of the receding punch may be 0.05 to 0.26 mm. Further, according to the above-described mold apparatus of the present invention, the number of steps can be reduced because the pellet manufacturing process as in Patent Document 1 is unnecessary. In addition, since a uniform amount of raw material can be filled in the cavity, it is possible to save the trouble of managing the pellets uniformly. Furthermore, since the pellets produced by heating are unnecessary, it is possible to reduce the heat energy required for forming the raw material, and to produce an excellent effect that a thin product can be manufactured more efficiently.

上記の本発明の金型装置を用いて冷陰極蛍光ランプ用電極を製造する場合には、原料として、モリブデン粉末および／またはタングステン粉末を主原料とする金属粉末に、熱可塑性樹脂とワックスからなるバインダーを４０〜６０体積％添加して、加熱混練したものを用いることができる。   When manufacturing an electrode for a cold cathode fluorescent lamp using the above-described mold apparatus of the present invention, a metal powder mainly composed of molybdenum powder and / or tungsten powder as a raw material is made of a thermoplastic resin and a wax. What added 40-60 volume% of binders and knead | mixed by heating can be used.

金属粉末として、モリブデン粉末またはタングステン粉末のみで用いることができ、モリブデン粉末とタングステン粉末を、体積比で、Ｍｏ：Ｗ＝１０：９０〜９０：１０の範囲で混合して用いてもよい。また、モリブデン粉末、タングステン粉末、およびこれらの混合粉末のうちのいずれかに５質量％以下のニッケル粉末を添加して用いてもよい。さらに、チタン炭化物、モリブデン炭化物、タングステン炭化物、バナジウム炭化物、ジルコニウム炭化物、ニオブ炭化物、タンタル炭化物、ハフニウム炭化物等の金属炭化物粉末を１〜５０体積％の範囲で添加してもよい。これらの金属粉末や金属炭化物粉末は、粒径が１０μｍ以下のものが適している。また粉末の形状としては、凹凸の少ないものが適しており、主原料となるモリブデン粉末の場合はタップ密度が３．０Ｍｇ／ｍ３以上となる粉末、タングステン粉末の場合はタップ密度が、５．６Ｍｇ／ｍ３以上となる粉末が適している。 As the metal powder, only molybdenum powder or tungsten powder can be used, and molybdenum powder and tungsten powder may be mixed and used in a volume ratio of Mo: W = 10: 90 to 90:10. Moreover, you may add and use 5 mass% or less nickel powder to any of molybdenum powder, tungsten powder, and these mixed powders. Furthermore, metal carbide powders such as titanium carbide, molybdenum carbide, tungsten carbide, vanadium carbide, zirconium carbide, niobium carbide, tantalum carbide, hafnium carbide and the like may be added in an amount of 1 to 50% by volume. These metal powders and metal carbide powders having a particle size of 10 μm or less are suitable. Further, as the shape of the powder, those having less irregularities are suitable. In the case of molybdenum powder as a main raw material, the powder has a tap density of 3.0 Mg / m 3 or more, and in the case of tungsten powder, the tap density is 5. A powder of 6 Mg / m 3 or more is suitable.

バインダーは、原料に可塑性を付与する熱可塑性樹脂および、金属粉末と金型（ダイおよびパンチを含む）との間の摩擦を低減するワックスからなるものが好適である。熱可塑性樹脂としては、ポリスチレン、ポリエチレン、ポリプロピレン、ポリアセタール、ポリエチレンビニルアセテート等が用いられ、ワックスとしては、パラフィンワックス、ウレタンワックス、カルナバワックス等が用いられる。また熱可塑性樹脂とワックスは、２０：８０〜６０：４０の範囲で構成すると好適なバインダーとなる。このようなバインダーは、原料をキャビティの微小な空隙に流動させるため４０体積％以上が必要であるが、６０体積％を超えてバインダーを添加すると、原料の成形後に行われる脱バインダー工程が長時間となって製造コストが増加する。このことから、バインダーの添加量は４０〜６０体積％とすると好適である。   The binder is preferably made of a thermoplastic resin that imparts plasticity to the raw material and a wax that reduces friction between the metal powder and the mold (including the die and punch). As the thermoplastic resin, polystyrene, polyethylene, polypropylene, polyacetal, polyethylene vinyl acetate, or the like is used. As the wax, paraffin wax, urethane wax, carnauba wax, or the like is used. Moreover, when the thermoplastic resin and the wax are configured in the range of 20:80 to 60:40, they are suitable binders. Such a binder requires 40% by volume or more in order to cause the raw material to flow into the minute voids of the cavity. However, if the binder is added in excess of 60% by volume, the debinding step performed after forming the raw material takes a long time. As a result, the manufacturing cost increases. Therefore, it is preferable that the amount of binder added is 40 to 60% by volume.

また、上記のようにして得られたコップ状成形体は、特許文献１と同様に、バインダー成分の熱分解温度に加熱する脱バインダー工程、および金属粉末どうしを金属的に拡散結合させる焼結工程を経て冷陰極蛍光ランプ用電極となる。このようにして得られる冷陰極蛍光ランプ用電極は、主原料としてモリブデンおよび／またはタングステンを用いているため、陰極降下電圧の低下、耐スパッタ性等の特性が向上している。上記の製造方法によると、電極の小型化が可能であるとともに、より一層効率よく製造できるため、電極を安価に供給できる。従って、本発明の金属粉末射出成形用金型装置及びこれを用いた製造方法は、冷陰極蛍光ランプ用電極の製造に適している。   In addition, the cup-shaped molded body obtained as described above has a debinding step of heating to the thermal decomposition temperature of the binder component and a sintering step of metallicly bonding the metal powders together as in Patent Document 1. After that, it becomes an electrode for a cold cathode fluorescent lamp. Since the cold cathode fluorescent lamp electrode thus obtained uses molybdenum and / or tungsten as the main raw material, characteristics such as reduction in cathode fall voltage and resistance to sputtering are improved. According to the above manufacturing method, the electrode can be miniaturized and can be manufactured more efficiently, so that the electrode can be supplied at low cost. Therefore, the metal powder injection mold apparatus and the manufacturing method using the same of the present invention are suitable for manufacturing a cold cathode fluorescent lamp electrode.

なお、上記は冷陰極蛍光ランプ用電極の製造例として、薄肉のコップ状成形体を製造する場合の金型装置および成形方法について説明したが、本発明の金型装置および成形方法によれば、図４で示されるカム形状等の成形体も成形可能である。   In addition, although the above demonstrated the mold apparatus and molding method in the case of manufacturing a thin cup-shaped molded body as an example of manufacturing a cold cathode fluorescent lamp electrode, according to the mold apparatus and the molding method of the present invention, Molded bodies such as cam shapes shown in FIG. 4 can also be molded.

また、上記では可動金型のみを複数の金型に分割し、可動金型に突出パンチおよび後退パンチを設けたが、本発明はこれに限定されない。例えば、図５および図６に示すように、固定金型１０および可動金型２０の両方を複数の金型に分割し、固定金型１０に底面形成パンチ５０を設け、可動金型２０に突出パンチ４０および後退パンチ３０を設けてもよい。この場合、底面形成パンチ５０によりコップ状成形体の底面を成形する。また、固定金型１０の内周面および底面形成パンチ５０、可動金型２０の内周面２１、後退パンチ３０の端面３１、突出パンチ４０の端面４１により所望の容積のキャビティが形成される。   In the above description, only the movable mold is divided into a plurality of molds, and the movable mold is provided with the protruding punch and the backward punch. However, the present invention is not limited to this. For example, as shown in FIG. 5 and FIG. 6, both the fixed mold 10 and the movable mold 20 are divided into a plurality of molds, a bottom surface forming punch 50 is provided in the fixed mold 10, and protrudes from the movable mold 20. A punch 40 and a receding punch 30 may be provided. In this case, the bottom surface of the cup-shaped molded body is formed by the bottom surface forming punch 50. A cavity having a desired volume is formed by the inner peripheral surface and bottom surface forming punch 50 of the fixed mold 10, the inner peripheral surface 21 of the movable mold 20, the end surface 31 of the retreating punch 30, and the end surface 41 of the protruding punch 40.

さらに、上記では後方押し出しにより原料の成形を行ったが、本発明における原料の押し出し形態はこれに限定されない。例えば、図５に示すように、キャビティに原料Ｍを充填した後、後退パンチ３０を後退させ（図中の上向き矢印の方向）、同時に底面形成パンチ５０をキャビティ内に進入させて（図中の上向き矢印の方向）、原料Ｍを前方押し出しして成形してもよい。さらに、図６に示すように、キャビティに原料Ｍを充填した後、突出パンチ４０をキャビティ内に進入させ（図中の下向き矢印の方向）、後退パンチ３０を後退させ（図中の上向き矢印の方向）、底面形成パンチ５０をキャビティ内に進入させて（図中の上向き矢印の方向）、原料Ｍを成形してもよい。このとき、原料Ｍは前方押し出しと後方押し出しを同時に行う複合押し出しにより成形される。また、上記と同様に、これらの成形工程は原料Ｍが軟化して流動性のある状態で行われる。   Furthermore, in the above, the raw material was formed by backward extrusion, but the raw material extrusion form in the present invention is not limited to this. For example, as shown in FIG. 5, after filling the cavity with the raw material M, the receding punch 30 is retracted (in the direction of the upward arrow in the figure), and at the same time, the bottom surface forming punch 50 is entered into the cavity (in the figure). The direction of the upward arrow) may be formed by extruding the raw material M forward. Further, as shown in FIG. 6, after filling the cavity with the raw material M, the projecting punch 40 is moved into the cavity (in the direction of the downward arrow in the figure), and the backward punch 30 is retracted (in the direction of the upward arrow in the figure). Direction), the bottom surface forming punch 50 may enter the cavity (the direction of the upward arrow in the figure), and the raw material M may be molded. At this time, the raw material M is formed by a composite extrusion that simultaneously performs forward extrusion and backward extrusion. Further, similarly to the above, these forming steps are performed in a state where the raw material M is softened and fluid.

冷陰極蛍光ランプの構造の一例を示す断面図である。It is sectional drawing which shows an example of the structure of a cold cathode fluorescent lamp. 冷陰極蛍光ランプ用電極の一例の断面図である。It is sectional drawing of an example of the electrode for cold cathode fluorescent lamps. 本発明のコップ状成形体を成形するための金型装置の構成と、その動作を説明する断面図であり、図３（ａ）は原料の充填工程、図３（ｂ）は成形工程、図３（ｃ）は抜き出し工程、および図３（ｄ）はランナ除去工程を示す断面図である。It is sectional drawing explaining the structure of the metal mold | die apparatus for shape | molding the cup-shaped molded object of this invention, and its operation | movement, Fig.3 (a) is a filling process of a raw material, FIG.3 (b) is a shaping | molding process, FIG. 3 (c) is a sectional view showing an extraction process, and FIG. 3 (d) is a sectional view showing a runner removal process. 本発明の金属粉末射出成形用金型装置により得られる他の製品形状の例を示す模式図である。It is a schematic diagram which shows the example of the other product shape obtained by the metal mold | die apparatus for metal powder injection molding of this invention. 本発明の金型装置の他の一例を示す断面図であり、図５（ａ）は原料の充填工程、図５（ｂ）は成形工程を示す断面図である。It is sectional drawing which shows another example of the metal mold | die apparatus of this invention, Fig.5 (a) is a raw material filling process, FIG.5 (b) is sectional drawing which shows a formation process. 本発明の金型装置の他の一例を示す断面図であり、図６（ａ）は原料の充填工程、図６（ｂ）は成形工程を示す断面図である。It is sectional drawing which shows another example of the metal mold | die apparatus of this invention, Fig.6 (a) is a raw material filling process, FIG.6 (b) is sectional drawing which shows a formation process.

符号の説明Explanation of symbols

１０…固定金型、２０…可動金型、３０…後退パンチ、４０…突出パンチ、５０…底面形成パンチ、Ｍ…可塑性原料、Ｐ…成形体
DESCRIPTION OF SYMBOLS 10 ... Fixed metal mold | die, 20 ... Movable metal mold | die, 30 ... Retraction punch, 40 ... Projection punch, 50 ... Bottom surface formation punch, M ... Plastic raw material, P ... Molded object

Claims (5)

固定金型と可動金型とからなる金型内部に設けられたキャビティに、前記固定金型および前記可動金型の少なくとも一方に設けられたゲートより、金属粉末とバインダーからなる可塑性の原料を射出充填する金属粉末射出成形用金型において、
前記固定金型と前記可動金型のうち少なくとも一方が複数の金型に分割され、
前記キャビティに、金属粉末とバインダーからなる可塑性の原料を射出充填した後、前記複数に分割された金型を駆動することにより、前記キャビティの容積を一定にして前記キャビティを変形させるとともに、前記キャビティに充填された可塑性の原料を体積一定で変形させて成形体を成形することを特徴とする金属粉末射出成形用金型装置。 A plastic material made of metal powder and a binder is injected into a cavity provided inside a fixed die and a movable die from a gate provided in at least one of the fixed die and the movable die. In filling metal powder injection mold,
At least one of the fixed mold and the movable mold is divided into a plurality of molds,
After the plastic raw material composed of metal powder and binder is injected and filled into the cavity, the cavity is deformed while the volume of the cavity is constant by driving the plurality of molds. A mold apparatus for metal powder injection molding, wherein a molded material is formed by deforming a plastic raw material filled in a fixed volume. 前記固定金型と前記可動金型のうち少なくとも一方に、前記キャビティ内部に突出する突出パンチと後退する後退パンチとに分割した金型を設けるとともに、
前記キャビティに金属粉末とバインダーからなる可塑性の原料を射出充填した後、前記突出パンチを前記キャビティ内に突出させるとともに、前記後退パンチを前記キャビティより後退させて、キャビティに射出充填された原料の体積を一定にして、原料の一部を押し出しして成形体を成形することを特徴とする請求項１に記載の金属粉末射出成形用金型装置。 At least one of the fixed mold and the movable mold is provided with a mold divided into a projecting punch projecting into the cavity and a retreating punch that retreats,
After injection filling the cavity with a plastic raw material consisting of metal powder and binder, the protruding punch is protruded into the cavity, and the retracting punch is retracted from the cavity, and the volume of the raw material injected into the cavity is filled. 2. A mold apparatus for metal powder injection molding according to claim 1, wherein a molding is formed by extruding a part of the raw material with a constant value. 前記キャビティは、可塑性の原料の射出充填時に略円柱状とされ、
前記後退パンチが、円筒状であり、前記後退パンチを設けた金型の内周面と摺動自在に嵌合し、
前記突出パンチが、円柱状であり、前記後退パンチの内周面と摺動自在に嵌合し、
前記後退パンチを設けた金型のキャビティでコップ状成形体の外周を、前記後退パンチを設けていない金型でコップ状成形体の底部を、前記後退パンチでコップ状成形体の縁部を、前記突出パンチでコップ状成形体の内周面および底部を、それぞれ成形することを特徴とする請求項２に記載の金属粉末射出成形用金型装置。 The cavity is substantially cylindrical at the time of injection filling of the plastic raw material,
The receding punch is cylindrical, and is slidably fitted to the inner peripheral surface of the mold provided with the receding punch,
The protruding punch is cylindrical, and is slidably fitted to the inner peripheral surface of the receding punch,
The outer periphery of the cup-shaped formed body is formed by a cavity of the mold provided with the retreat punch, the bottom of the cup-shaped formed body is formed by the mold not provided with the retreat punch, and the edge of the cup-shaped formed body is formed by the retreat punch. The metal powder injection molding die apparatus according to claim 2, wherein an inner peripheral surface and a bottom portion of the cup-shaped molded body are respectively molded by the protruding punch. 前記後退パンチの肉厚が０．０５〜０．２６ｍｍであることを特徴とする請求項３に記載の金属粉末射出成形用金型装置。   4. The metal powder injection molding die apparatus according to claim 3, wherein the thickness of the receding punch is 0.05 to 0.26 mm. 前記可塑性の原料が、金属粉末に、熱可塑性樹脂とワックスからなるバインダーを４０〜６０体積％添加して、加熱混練した原料から構成されていることを特徴とする請求項１〜４のいずれかに記載の金属粉末射出成形用金型装置。   5. The plastic material according to any one of claims 1 to 4, wherein the plastic material is composed of a raw material obtained by adding 40 to 60% by volume of a binder composed of a thermoplastic resin and a wax to a metal powder, followed by heating and kneading. The metal powder injection molding die apparatus described in 1.
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