Patent US5250255A successfully refreshed from Google Patents.
US5250255A
Expired / Lapsed
US
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Method for producing permanent magnet and sintered compact and production apparatus for making green compacts
Assignee: Intermetallics Co Ltd
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Filing: 1991-12-02
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Granted: 1993-10-05
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Expires: 2011-12-02
Abstract
Abstract Green compacts for sintered ceramic bodies and for sintered permanent magnets are produced by first preparing outside a die press machine a mold which contains a rubber portion in at least a side portion. The mold cavity is then filled with the fine powder which is to form the compact to a density which is at least 1.2 times the natural filling density of the powder. The filled rubber mold is then placed in the die press machine and compacted in the die press machine to produce the green compact. The natural filling density is obtained by allowing the powder to fall from a powder pan into the rubber mold until the powder reaches the top of the rubber mold, where the distance from the powder pan to the bottom of the rubber mold is 3.7 times the depth of the cavity of the rubber mold.
Inventors
- 👤 Masato Sagawa
- 👤 Hiroshi Nagata
- 👤 Hiroo Shirai
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 15:05
CPC Classifications
B; B22; B22F; B22F3/00; B22F3/22; B22F3/225; B22F3/003; B22F3/004; B22F3/02; B22F3/12; B22F3/1208; B22F3/1216; B22F3/1233; B30; B30B; B30B11/00; B30B11/008; B30B11/02; B30B11/025; B30B11/027; B30B15/00; B30B15/02; B30B15/022; B30B15/024; B30B15/30; B30B15/302; H; H01; H01F; H01F41/00; H01F41/02; H01F41/0253; H01F41/0266; B22F2003/026; B22F2998/00; B22F2999/00; B29; B29C; B29C43/00; B29C43/02; B29C43/04; B29C2043/046; B29C43/32; B29C43/34; B29C2043/3488; B29C2043/3494; B29C43/36; B29C43/3642; B29C2043/3652; B29C2043/3676; B29C2043/3689; B29C43/361
Claims Analysis
Total Claims: 170
Claim 1
Independent Claim
187 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the magnet powder, by means of vibrations pressing the magnet powder with pushing or both; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine under a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 2
Dependent Claim
187 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the magnet powder, by means of vibrations pressing the magnet powder with pushing or both; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine under a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 3
Dependent Claim
32 words
A production method for producing a green magnet compact according to claim 1, wherein the magnet powder is filled under gravity and by a vibrator, on which the rubber mold is placed.
Claim 4
Dependent Claim
33 words
A production method for producing a green magnet compact according to claim 1, wherein the magnet powder is filled under gravity and by a pusher which pushes the magnet powder filled under gravity.
Claim 5
Dependent Claim
55 words
A production method for producing a green magnet compact according to claim 1, the magnet powder is preliminarily weighed and then filled under gravity into the rubber mold, which has a guide frame on the upper surface of the rubber mold, until the magnet powder stacks higher than the upper surface of the rubber mold.
Claim 6
Dependent Claim
51 words
A production method for producing a green magnet compact according to claim 1, a feeder box for feeding the magnet powder is located on the rubber mold, and the magnet powder is stirred by a rotary blade mounted in the feeder box to fill the magnet powder into the rubber mold.
Claim 7
Dependent Claim
23 words
A production method for producing a green magnet compact according to claim 1, wherein the green magnet compact is sabsequently subjected to sintering.
Claim 8
Dependent Claim
26 words
A production method for producing a green magnet compact according to claim 1, wherein resin is filled together with the magnet powder at the high density.
Claim 9
Dependent Claim
29 words
A production method for producing a green magnet compact according to claim 1, wherein upper and lower peripheral edges of the inner wall of the rubber mold are tapered.
Claim 10
Dependent Claim
31 words
A production method for producing a green magnet compact according to claim 1, wherein the rubber mold has at least one of the top and bottom harder than said side portion.
Claim 11
Dependent Claim
64 words
A production method for producing a green magnet compact according to claim 1, wherein the rubber mold comprising at least a top and bottom, in which at least one of the top and the bottom has a thickness (t, units-mm) defined by t≦16h/D (h is thickness of a green compact, and D is a positive square root of cross-sectional area of the green compact).
Claim 12
Dependent Claim
31 words
A production method for producing a green magnet compact according to claim 1, wherein the rubber mold comprises a mandrel which is harder than the other portions of the rubber mold.
Claim 13
Dependent Claim
46 words
A production method for producing a green magnet compact according to claim 1, wherein the rubber mold is open at the top thereof or at the bottom thereof, and the open portion of the rubber mold is directly pressed by a punch of the die-press machine.
Claim 14
Dependent Claim
47 words
A production method for producing a green magnet compact according to claim 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, wherein the magnet powder is rare-earth magnet powder and is filled to a density of 1.78 times or more the natural filling density.
Claim 15
Dependent Claim
47 words
A production method for producing a green magnet compact according to claim 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, wherein the magnet powder is ferrite powder and is filled to a density of 1.67 times or more the natural filling density.
Claim 16
Dependent Claim
185 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; preliminarily compacting a magnet powder to a density which is at least 1.2 times a natural filling density of the magnet powder; inserting the preliminary compact of the magnet powder in the rubber mold outside the die-press machine; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine under a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 17
Dependent Claim
185 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; preliminarily compacting a magnet powder to a density which is at least 1.2 times a natural filling density of the magnet powder; inserting the preliminary compact of the magnet powder in the rubber mold outside the die-press machine; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine under a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 18
Dependent Claim
29 words
A production method for producing a green magnet compact according to claim 15, wherein the magnet powder is compacted under a pressure of 15 to 1000 kg/cm 2 .
Claim 19
Dependent Claim
46 words
A production method for producing a green magnet compact according to claim 15, wherein the preliminary compacting is carried out by using a punch and a die provided with a retractable bottom, and the precompact is fallen into the rubber mold by retracting the retractable bottom.
Claim 20
Dependent Claim
23 words
A production method for producing a green magnet compact according to claim 15, wherein the green magnet compact is subsequently subjected to sintering.
Claim 21
Dependent Claim
26 words
A production method for producing a green magnet compact according to claim 15, wherein resin is precompacted together with the magnet powder at the high density.
Claim 22
Dependent Claim
29 words
A production method for producing a green magnet compact according to claim 15, wherein upper and lower peripheral edges of the inner wall of the rubber mold are tapered.
Claim 23
Dependent Claim
31 words
A production method for producing a green magnet compact according to claim 1, wherein the rubber mold has at least one of the top and bottom harder than said side portion.
Claim 24
Dependent Claim
64 words
A production method for producing a green magnet compact according to claim 15, wherein the rubber mold comprising at least a top and bottom, in which at least one of the top and the bottom has a thickness (t, unit-mm) defined by t≦16h/D (h is thickness of a green compact, and D is a positive square root of cross-sectional area of the green compact).
Claim 25
Dependent Claim
30 words
A production method for producing green magnet compact according to claim 15, wherein the rubber mold comprises a mandrel which is harder than the other portions of the rubber mold.
Claim 26
Dependent Claim
46 words
A production method for producing a green magnet compact according to claim 15, wherein the rubber mold is open at the top thereof or at the bottom thereof, and the open portion of the rubber mold is directly pressed by a punch of the die-press machine.
Claim 27
Dependent Claim
47 words
A production method for producing a green magnet compact according to claim 15, 16, 17, 18, 19, 20, 21, 22, 23, or 24, wherein the magnet powder is a rare-earth magnet powder and is filled to a density of 1.78 times or more the natural filling density.
Claim 28
Dependent Claim
45 words
A production method for producing a green magnet compact according to claim 15, 16, 17, 18, 19, 20, 21, 22, 23, or 24, wherein the magnet powder is ferrite powder and is filled to a density of 1.67 times or more the natural filling density.
Claim 29
Dependent Claim
88 words
A production method for producing a green magnet compact according to claim 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 21, 22, 23, or 24, further comprising the steps of covering the upper open portion of the rubber mold with a cover; and, subsequently, prior to the compacting step in the die-press machine, applying an instantaneous magnetic field or static magnetic field more than 8 kOe to the magnet powder in the rubber mold covered with the cover.
Claim 30
Dependent Claim
36 words
A production method for producing a green magnet compact according to claim 27, wherein the magnet powder is rare-earth magnet powder and is filled to a density of 1.78 times or more the natural filling density.
Claim 31
Dependent Claim
35 words
A production method for producing a green magnet compact according to claim 27, wherein the magnet powder is ferrite powder and is filled to a density of 1.67 times or more the natural filling density.
Claim 32
Dependent Claim
211 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the magnet powder, by means of vibration, pressing the magnet powder with pushing or both; covering an upper open part of the rubber mold with a cover; applying an instantaneous magnetic field or stronger magnetic field more than 8 kOe to the magnet powder in the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine without a magnetic field; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 33
Dependent Claim
211 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the magnet powder, by means of vibration, pressing the magnet powder with pushing or both; covering an upper open part of the rubber mold with a cover; applying an instantaneous magnetic field or stronger magnetic field more than 8 kOe to the magnet powder in the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine without a magnetic field; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 34
Dependent Claim
32 words
A production method for producing a green magnet compact according to claim 30, wherein the magnet powder is filled under gravity and by a vibrator, on which the rubber mold is placed.
Claim 35
Dependent Claim
33 words
A production method for producing a green magnet compact according to claim 30, wherein the magnet powder is filled under gravity and by a pusher which pushes the magnet powder filled under gravity.
Claim 36
Dependent Claim
55 words
A production method for producing a green magnet compact according to claim 30, the magnet powder is preliminarily weighed and then filled under gravity into the rubber mold, which has a guide frame on the upper surface of the rubber mold, until the magnet powder stacks higher than the upper surface of the rubber mold.
Claim 37
Dependent Claim
51 words
A production method for producing a green magnet compact according to claim 30, a feeder box for feeding the magnet powder is located on the rubber mold, and the magnet powder is stirred by a rotary blade mounted in the feeder box to fill the magnet powder into the rubber mold.
Claim 38
Dependent Claim
52 words
A production method for producing a green magnet compact according to claim 30, wherein a feeder box for feeding the magnet powder is located on the rubber mold, and the magnet powder is stirred by a reciprocating blade mounted in the feeder box to fill the magnet powder into the rubber mold.
Claim 39
Dependent Claim
51 words
A production method for producing a green magnet compact according to claim 30, wherein a feeder box for feeding the magnet powder is located on the rubber mold, and the magnet powder is vibrated by a vibrator mounted in the feeder box to fill the magnet powder into the rubber mold.
Claim 40
Dependent Claim
44 words
A production method for producing a green magnet compact according to claim 30, wherein the magnet powder is conveyed by a conveyor, on whose lower side a vibrator is slidably attached to fill the magnet powder into the rubber mold at the high density.
Claim 41
Dependent Claim
50 words
A production method for producing a green magnet compact according to claim 30, wherein a screw rod, around which blades are spirally secured, is coaxially mounted in a container, and, the magnet powder is stirred in the container to enhance its density and is then dropped into the rubber mold.
Claim 42
Dependent Claim
45 words
A production method for producing a green magnet compact according to claim 30, wherein the magnet powder is conveyed by a conveyor, on whose both sides rolls are located to press the magnet powder, and the densified magnet powder is dropped into the rubber mold.
Claim 43
Dependent Claim
28 words
A production method for producing a green magnet compact according to claim 30, wherein the magnet powder is filled into the rubber mold under gravity and magnetic field.
Claim 44
Dependent Claim
23 words
A production method for producing a green magnet compact according to claim 30, wherein the green magnet compact is subsequently subjected to sintering.
Claim 45
Dependent Claim
26 words
A production method for producing a green magnet compact according to claim 30, wherein resin is filled together with the magnet powder at the high density.
Claim 46
Dependent Claim
29 words
A production method for producing a green magnet compact according to claim 30, wherein upper and lower peripheral edges of the inner wall of the rubber mold are tapered.
Claim 47
Dependent Claim
31 words
A production method for producing a green magnet compact according to claim 30, wherein the rubber mold has at least one of the top and bottom harder than said side portion.
Claim 48
Dependent Claim
64 words
A production method for producing a green magnet compact according to claim 30 wherein the rubber mold comprises at least a top and bottom, in which at least one of the top and the bottom has a thickness (t, units-mm) defined by t≦16h/D (h is thickness of a green compact, and D is a positive square root of cross-sectional area of the green compact).
Claim 49
Dependent Claim
31 words
A production method for producing a green magnet compact according to claim 30, wherein the rubber mold comprises a mandrel which is harder than the other portions of the rubber mold.
Claim 50
Dependent Claim
53 words
A production method for producing a green magnet compact according to claim 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, or 46 wherein the magnet powder is rare-earth magnet powder and is filled to a density of 1.78 times or more the natural filling density.
Claim 51
Dependent Claim
52 words
A production method for producing a green magnet compact according to claim 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 42, 42, 43, 44, 45, or 46 wherein the magnet powder is ferrite powder and is filled to a density of 2.41 times or more the natural filling density.
Claim 52
Dependent Claim
220 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press preliminarily compacting a magnet powder to a density which is at least 1.2 times a natural filling density of the magnet powder; inserting the prliminary compact of the magnet powder in the rubber mold outside the die-press machine; covering an upper open part of the rubber mold with a cover; applying an instantaneous magnetic field or stronger magnetic field than 8kOe to the magnet powder in the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine without a magnetic field or under a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 53
Dependent Claim
220 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press preliminarily compacting a magnet powder to a density which is at least 1.2 times a natural filling density of the magnet powder; inserting the prliminary compact of the magnet powder in the rubber mold outside the die-press machine; covering an upper open part of the rubber mold with a cover; applying an instantaneous magnetic field or stronger magnetic field than 8kOe to the magnet powder in the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine without a magnetic field or under a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 54
Dependent Claim
29 words
A production method of a green magnet compact according to claim 49, wherein the magnet powder is compacted under a pressure of from 15 to 1000 kg/cm 2 .
Claim 55
Dependent Claim
44 words
A production method of a green magnet compact according to claim 49 wherein the preliminary compacting is carried out by using a punch and a die provided with a retractable bottom, and the precompact is dropped into the rubber mold by retracting retractable bottom.
Claim 56
Dependent Claim
84 words
A production method of a green magnet compact according to claim 2, 3, 4, 3, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, or 51, wherein a back-up plate, consisting of harder elastic material than the rubber mold, is located between the rubber mold and one or both of the upper and lower punches.
Claim 57
Dependent Claim
35 words
A production method of a green magnet compact according to claim 52, wherein the magnet powder is rare-earth magnet powder and is filled to a density of 1.78 times or more the natural filling density.
Claim 58
Dependent Claim
34 words
A production method of a green magnet compact according to claim 52, wherein the magnet powder is ferrite powder and is filled to a density of 2.41 times or more the natural filling density.
Claim 59
Dependent Claim
79 words
A production method of a green magnet compact according to claim 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, or 51, wherein the magnet powder contains a rare-earth element, and is filled or precompacted in the rubber mold under an inert gas atomsphere.
Claim 60
Dependent Claim
35 words
A production method of a green magnet compact according to claim 55, wherein the magnet powder is rare-earth magnet powder and is filled to a density of 1.78 times or more the natural filling density.
Claim 61
Dependent Claim
34 words
A production method of a green magnet compact according to claim 55, wherein the magnet powder is ferrite powder and is filled to a density of 2.41 times or more the natural filling density.
Claim 62
Dependent Claim
225 words
A production method of a green magnet compact, characterized by repeatedly carrying out: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density at least 1.2 times a natural filling density of the magnet powder, by means of vibration, pressing the magnet powder with a pushing or both; covering an upper open portion of the rubber mold with a cover; applying instantaneous magnetic field or stronger static magnetic field than 8kOe to the magnet powder in the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine under a magnetic field or without a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 63
Dependent Claim
225 words
A production method of a green magnet compact, characterized by repeatedly carrying out: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density at least 1.2 times a natural filling density of the magnet powder, by means of vibration, pressing the magnet powder with a pushing or both; covering an upper open portion of the rubber mold with a cover; applying instantaneous magnetic field or stronger static magnetic field than 8kOe to the magnet powder in the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine under a magnetic field or without a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 64
Dependent Claim
35 words
A production method of a green magnet compact according to claim 58, wherein the magnet powder is rare-earth magnet powder and is filled to a density of 1.78 times or more the natural filling density.
Claim 65
Dependent Claim
34 words
A production method of a green magnet compact according to claim 58 wherein the magnet powder is ferrite powder and is filled to a density of 2.41 times or more the natural filling density.
Claim 66
Dependent Claim
233 words
A production method of a green magnet compact, comprising repeatedly carrying out: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; preliminarily compacting a magnet powder to a density at least 1.2 times a natural filling density of the magnet powder, by means of vibration, pressing the magnet powder with a pushing or both; inserting the preliminary compact of the magnet powder in the rubber mold outside the die-press machine; covering an upper open portion of the rubber mold with a cover; applying instantaneous magnetic field or stronger magnetic field than 8kO3 to the magnet powder in the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine under a magnetic field or without a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 67
Dependent Claim
233 words
A production method of a green magnet compact, comprising repeatedly carrying out: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; preliminarily compacting a magnet powder to a density at least 1.2 times a natural filling density of the magnet powder, by means of vibration, pressing the magnet powder with a pushing or both; inserting the preliminary compact of the magnet powder in the rubber mold outside the die-press machine; covering an upper open portion of the rubber mold with a cover; applying instantaneous magnetic field or stronger magnetic field than 8kO3 to the magnet powder in the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the magnet powder therein by a punch in the die-press machine under a magnetic field or without a magnetic field to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the magnet powder to fall under gravity from a powder pan into the rubber mold until the top of the magnet powder arrives at an upper frame which prevents the magnet powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 68
Dependent Claim
35 words
A production method of a green magnet compact according to claim 61, wherein the magnet powder is rare-earth magnet powder and is filled to a density of 1.78 times or more the natural filling density.
Claim 69
Dependent Claim
34 words
A production method of a green magnet compact according to claim 61, wherein the magnet powder is ferrite powder and is filled to a density of 2.41 times or more the natural filling density.
Claim 70
Dependent Claim
33 words
A production method of a green magnet compact according to claim 61, 62 or 63, wherein the rubber mold is transferred on the circuit which is located in a chamber having inert-gas atmosphere.
Claim 71
Dependent Claim
118 words
A production method of a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least side portion thereof and is open at a top thereof; filling a cavity of the rubber mold with a slurry containing maget powder and a solvent in the rubber mold in or outside a die-press machine is provided with an upper punch, a filter and a water suction channel formed in the upper punch; placing the filled rubber mold in the die-press machine; placing the filter between the upper punch and the open top of the rubber mold; compacting the filled rubber mold and the magnet powder therein, thereby sucking the solvent through the filter and the water-suction channel.
Claim 72
Dependent Claim
118 words
A production method of a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least side portion thereof and is open at a top thereof; filling a cavity of the rubber mold with a slurry containing maget powder and a solvent in the rubber mold in or outside a die-press machine is provided with an upper punch, a filter and a water suction channel formed in the upper punch; placing the filled rubber mold in the die-press machine; placing the filter between the upper punch and the open top of the rubber mold; compacting the filled rubber mold and the magnet powder therein, thereby sucking the solvent through the filter and the water-suction channel.
Claim 73
Dependent Claim
40 words
A production method of a green magnet compact according to claim 65 further comprising making the upper profile of the slurry filled in the rubber mold essentially the same as the profile of a lower punch of the upper punch.
Claim 74
Dependent Claim
19 words
A production method of a green magnet compact according to claim 66, wherein the slurry contains a defoaming agent.
Claim 75
Dependent Claim
43 words
A production method of a green magnet compact according to claim 65, 66 or 67, wherein prior or subsequent to filling the slurry in the rubber mold the inside of the cavity of the rubber mold is subjected to degassing treatment under vacuum.
Claim 76
Dependent Claim
29 words
A production method of a green magnet compact according to claim 68, wherein a bottom of a rubber mold is harder than the side portion of the rubber mold.
Claim 77
Dependent Claim
41 words
A production method of a green magnet compact according to claim 69, wherein prior or subsequent to filling the slurry in the rubber mold, the inside of the cavity of the rubber mold is subjected to a degassing treatement under vacuum.
Claim 78
Dependent Claim
63 words
A production method of a green magnet compact according to claim 1, wherein the rubber mold comprising at least a top and bottom, in which at least one of the top and the bottom has a thickness (t, unti-mm) defined by t≦16h/D (h is thickness of a green compact, and D is a positive square root of cross-sectional area of the green compact).
Claim 79
Dependent Claim
40 words
A production method of a green magnet compact according to claim 71, wherein prior or subsequent to filling the slurry in the rubber mold the inside of the cavity of the rubber mold is subjected to degassing treatment under vacuum.
Claim 80
Dependent Claim
41 words
A production method of a green magnet compact according to claim 65, 66 or 67, wherein said green compact is hollow, and said rubber mold is provided with a mandrel which is harder than the other portion of the rubber mold.
Claim 81
Dependent Claim
42 words
A production method of a green magnet according to claim 73, wherein prior or subs compact according to filling the slurry in the rubber mold, the inside of the cavity of the rubber mold is subjected to a degassing treatement under vacuum.
Claim 82
Dependent Claim
34 words
A production method of a green compact according to claim 65 repeatedly carrying out on a circuit the preparation of the rubber mold, filling of the slurry, placing the filled rubber mold, and compacting.
Claim 83
Dependent Claim
37 words
A production method of a green compact according to claim 75, repeatedly carrying out on a circuit the preparation of the rubber mold, filling of the slurry, placing the filled rubber mold, compacting and the degassing treatment.
Claim 84
Dependent Claim
31 words
A production method of a green compact according to claim 75 or 76, wherein at least one rubber mold is mounted on the circuit and circulates around positions of respective treatments.
Claim 85
Dependent Claim
32 words
A production method of a green compact according to claim 75 or 76, wherein at least one palette, on which the rubber mold is mounted, is conveyed through positions of respective treatments.
Claim 86
Dependent Claim
211 words
A production method of a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a fine powder of material except for Magnet material having average particle diameter of 50 μm or less and being essentially free of organic binder to a density which is at least 1.15 times a natural filling density of the fine powder, by means of vibration, pressing the fine powder with a pushing or both; placing the filled rubber mold in the die-press machine; compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the fine powder; and sintering the green compact; wherein the natural filling density is obtained by allowing the fine powder from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 87
Dependent Claim
211 words
A production method of a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a fine powder of material except for Magnet material having average particle diameter of 50 μm or less and being essentially free of organic binder to a density which is at least 1.15 times a natural filling density of the fine powder, by means of vibration, pressing the fine powder with a pushing or both; placing the filled rubber mold in the die-press machine; compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the fine powder; and sintering the green compact; wherein the natural filling density is obtained by allowing the fine powder from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 88
Dependent Claim
37 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein the fine powder is filled under gravity and by a vibrator, on which the rubber mold is placed.
Claim 89
Dependent Claim
63 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein weight of the fine powder is preliminarily weighed and then filled under gravity into the rubber mold, which has a guide frame on the upper surface of the rubber mold, until the fine powder stacks higher than the upper surface of the rubber mold.
Claim 90
Dependent Claim
56 words
A production method of a sintered compact having a density of 90% or more according to claim 79, a feeder box for feeding the fine powder is located on the rubber mold, and the fine powder is stirred by a rotary blade mounted in the feeder box to fill the fine powder into the rubber mold.
Claim 91
Dependent Claim
57 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein a feeder box for feeding the fine powder is located on the rubber mold, and the fine powder is stirred by a reciprocating blade mounted in the feeder box to fill the fine powder into the rubber mold.
Claim 92
Dependent Claim
56 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein a feeder box for feeding the fine powder is located on the rubber mold, and the fine powder is vibrated by a vibrator mounted in the feeder box to fill the fine powder into the rubber mold.
Claim 93
Dependent Claim
49 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein the fine powder is conveyed by a conveyor, on whose lower side a vibrator is slidably attached to fill the fine powder into the rubber mold at the high density.
Claim 94
Dependent Claim
55 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein a screw rod, around which blades are spirally secured, is coaxially mounted in a container, and, the fine powder is stirred in the container to enhance its density and is then dropped into the rubber mold.
Claim 95
Dependent Claim
50 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein the fine powder is conveyed by a conveyor, on whose both sides rolls are located to press the fine powder, and the densified fine powder is dropped into the rubber mold.
Claim 96
Dependent Claim
33 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein the fine powder is filled into the rubber mold under gravity and magnetic field.
Claim 97
Dependent Claim
34 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein upper and lower peripheral edges of the inner wall of the rubber mold are tapered.
Claim 98
Dependent Claim
72 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein the green compact has a flat shape having 2 or more of width/thickness ratio, and further the rubber mold having at least one of the top and the bottom harder than said side protion, wherein the width is defined as a positive square root of cross sectiona area of the sintered green compact.
Claim 99
Dependent Claim
72 words
A production method of a sintered compact having a density of 90% or more according to claim 79, wherein the green compact has a flat shape having 0.5 or less of width/thickness ratio, and further the rubber mold having at least one of the top and the bottom softer than said side protion, wherein the width is defined as a positive square root of cross sectiona area of the sintered green compact.
Claim 100
Dependent Claim
63 words
A production method of a sintered magnet compact according to claim 79, wherein the rubber mold comprising at least a top and bottom, in which at least one of the top and the bottom has a thickness (t, unti-mm) defined by t≦16h/D (h is thickness of a green compact, and D is a positive square root of cross-sectional area of the green compact).
Claim 101
Dependent Claim
30 words
A production method of a sintered magnet compact according to claim 79, wherein the rubber mold comprises a mandrel which is harder than the other portions of the rubber mold.
Claim 102
Dependent Claim
45 words
A production method 0 f a sintered magnet compact according to 79, wherein the rubber mold is open at the top thereof or at the bottom thereof, ant the open portion of the rubber mold is directly pressed by a punch of the die-press machine.
Claim 103
Dependent Claim
45 words
A production method 0 f a sintered magnet compact according to 79, wherein the rubber mold is open at the top thereof or at the bottom thereof, ant the open portion of the rubber mold is directly pressed by a punch of the die-press machine.
Claim 104
Dependent Claim
50 words
A production method of a sintered magnet compact according to claim 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, or 94, further comprising the steps of weighing the fine powder to provide a predetermined weight, and producing green compacts having said predetermined weight.
Claim 105
Dependent Claim
55 words
A production method for making a sintered magnet compact according to claim 95, further comprising the steps of dropping fine powder onto a tray through a vibrating mesh until a predetermined weight of the fine powder is obtained; and then dropping the predetermined weight of said fine powder from the tray into the rubber mold.
Claim 106
Dependent Claim
68 words
A production method of a sintered magnet compact according to claim 79, 80, 81, 82, 83, 84 ,85, 86, 87, 88, 89, 90, 91, 92, 93, or 94, further comprising the steps of filling the fine powder under gravity into the rubber mold; weighing the fine powder during its filling in the rubber mold under gravity; and stopping the filling under gravity when a predermined weight is obtained.
Claim 107
Dependent Claim
48 words
A production method of a sintered compact having a density of 90% or more according to claim 79, 80, 81, 82, 83 ,84, 85, 86, 87, 88, 89, 90, 91, 92, 93, or 94, wherein the side portion of the rubber mold consist of two or more parts.
Claim 108
Dependent Claim
72 words
A production method of a sintered compact having a density of 90% or more according to claim 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, or 94, wherein the side portion of the rubber mold consists the first material at the inner side thereof and the second material facing a die of the die-pressing machine, said first material being essentially harder than the second material.
Claim 109
Dependent Claim
48 words
A production method of a sintered compact having a density of 90% or more according to claim 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93 or 94, wherein the fine powder has an average particle diameter of 30 μm or less.
Claim 110
Dependent Claim
28 words
A production method of a sintered compact having a density of 90% or more according to claim 99, wherein the average particle deameter is 20 μm or less.
Claim 111
Dependent Claim
28 words
A production method of a sintered compact according to claim 99, wherein the fine powder is filled at a density of 1.3 times or more the natural density.
Claim 112
Dependent Claim
32 words
A production method of a magnet according to claim 110, wherein the fine powder is filled at a density of 60% or less or of a true density of the fine powder.
Claim 113
Dependent Claim
60 words
A production method of a sintered compost having a density of 90% or more according claim 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, or 94, wherein the material of the fine power is at least one selected from the group consisting of Fe, Co, Ni, Cu, Mo, Al, Ti, and their alloys.
Claim 114
Dependent Claim
27 words
A production method of a sintered compact having a density of 90% or more according to claim 104, wherein material of the fine powder is atomized iron.
Claim 115
Dependent Claim
28 words
A production method of a sintered compact having a density of 90% or more according to claim 100, wherein the material fine powder is atomized or melt-quenched aluminum.
Claim 116
Dependent Claim
51 words
A production method of a sintered compact having a density of 90% or more according to claim 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93 or 94, wherein further comprising a step of enlarging a clearance between the green compact and the rubber mold.
Claim 117
Dependent Claim
37 words
A production method of a sintered compact having a density of 90% or more according to claim 107, wherein the clearance enlarging step is carried out by imparting pressure to the inner surface of the rubber mold.
Claim 118
Dependent Claim
38 words
A production method of a sintered compact having a density of 90% or more according to claim 107, wherein the clearance enlarging step is carried out by decreasing pressure applied to the outer surface of the rubber mold.
Claim 119
Dependent Claim
235 words
A production method of a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber at least in a side portion thereof; weighing fine powder of material except for magnet material, having average particle size of 50 m or less and being essentially free of organic binder, to provide a predetermined amount; filling a cavity of the rubber mold with the fine powder to a density at least 1.15 times a natural filling density, outside a die-press machine; placing the filled rubber mold in the die-press machine; compacting the rubber mold and the fine powder by a punch of the die-press machine thereby obtaining a green compact; withdrawing the green compact from the rubber mold; and sintering the green compact; wherein the rubber mold is mounted on a conveying means for circulating the same around and intermittently moving the same between positions where said filling, compacting and withdrawing are carried out, and, further wherein the natural filling density is obtained by allowing the fine powder to fall under gravity into the rubber mold from a powder pan until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing from the rubber mold, the distance between the bottom end of the powder pan and the bottom of the rubber mold is 3.7 times the depth of cavity of the rubber mold.
Claim 120
Dependent Claim
235 words
A production method of a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber at least in a side portion thereof; weighing fine powder of material except for magnet material, having average particle size of 50 m or less and being essentially free of organic binder, to provide a predetermined amount; filling a cavity of the rubber mold with the fine powder to a density at least 1.15 times a natural filling density, outside a die-press machine; placing the filled rubber mold in the die-press machine; compacting the rubber mold and the fine powder by a punch of the die-press machine thereby obtaining a green compact; withdrawing the green compact from the rubber mold; and sintering the green compact; wherein the rubber mold is mounted on a conveying means for circulating the same around and intermittently moving the same between positions where said filling, compacting and withdrawing are carried out, and, further wherein the natural filling density is obtained by allowing the fine powder to fall under gravity into the rubber mold from a powder pan until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing from the rubber mold, the distance between the bottom end of the powder pan and the bottom of the rubber mold is 3.7 times the depth of cavity of the rubber mold.
Claim 121
Dependent Claim
233 words
A production method of a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber at least in a side portion thereof; weighing fine powder of material except for magnet material, having average particle size of 50 μm or less and being essentially free of organic binder, to provide a predetermined amount; filling a cavity of the rubber mold with the fine powder to a density at least 1.15 times a natural filling density, outside a die-press machine; placing the filled rubber mold in the die-press machine; compacting the rubber mold and the fine powder by a punch of the die-press machine thereby obtaining a green compact; withdrawing the green compact from the rubber mold; and sintering the green compact; wherein the rubber mold is mounted on a conveying means for linearly and intermittently conveying the rubber molds between positions where said filling, compacting and withdrawing are carried out, and, further wherein the natural filling density is obtained by allowing the fine powder to fall under gravity into the rubber mold from a powder pan until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing from the rubber mold, the distance between the bottom end of the powder pan and the bottom of the rubber mold is 3.7 times the depth of cavity of the rubber mold.
Claim 122
Dependent Claim
233 words
A production method of a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber at least in a side portion thereof; weighing fine powder of material except for magnet material, having average particle size of 50 μm or less and being essentially free of organic binder, to provide a predetermined amount; filling a cavity of the rubber mold with the fine powder to a density at least 1.15 times a natural filling density, outside a die-press machine; placing the filled rubber mold in the die-press machine; compacting the rubber mold and the fine powder by a punch of the die-press machine thereby obtaining a green compact; withdrawing the green compact from the rubber mold; and sintering the green compact; wherein the rubber mold is mounted on a conveying means for linearly and intermittently conveying the rubber molds between positions where said filling, compacting and withdrawing are carried out, and, further wherein the natural filling density is obtained by allowing the fine powder to fall under gravity into the rubber mold from a powder pan until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing from the rubber mold, the distance between the bottom end of the powder pan and the bottom of the rubber mold is 3.7 times the depth of cavity of the rubber mold.
Claim 123
Dependent Claim
32 words
A production method of a sintered it compact having a density of 90% or more according to claim 111, wherein the linear moving passage of the supporting means has a polygonal configuration.
Claim 124
Dependent Claim
29 words
A production method of a sintered compact having a density of 90% or more according to claim 112, where the linear moving passage of the supporting means is straight.
Claim 125
Dependent Claim
32 words
A production method of a sintered compact having a density of 90% or more according to claim 110, 111, 112 or 113, wherein a die is moved together with the rubber mold.
Claim 126
Dependent Claim
37 words
A production method of a sintered compact having a density of 90% or more according to claim 110, 111, 112 or 113, wherein the rubber mold is moved within a chamber, whose inner atmosphere is inert gas.
Claim 127
Dependent Claim
209 words
A production method for producing a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a fine powder of a material other than a magnet material having an average particle diameter of 50 μm or less to a density which is at least 1.15 times a natural filling density of the fine powder, by means of vibration, pressing the fine powder with pushing or both; placing the filled rubber mold in the die-press machine; compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the fine powder; and sintering the green compact; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 128
Dependent Claim
209 words
A production method for producing a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a fine powder of a material other than a magnet material having an average particle diameter of 50 μm or less to a density which is at least 1.15 times a natural filling density of the fine powder, by means of vibration, pressing the fine powder with pushing or both; placing the filled rubber mold in the die-press machine; compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the fine powder; and sintering the green compact; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold.
Claim 129
Dependent Claim
38 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein the fine powder is filled under gravity and by a vibrator, on which the rubber mold is placed.
Claim 130
Dependent Claim
62 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein the fine powder is preliminarily weighed and then filled under gravity into the rubber mold, which has a guide frame on the upper surface of the rubber mold, until the fine powder stacks higher than the upper surface of the rubber mold.
Claim 131
Dependent Claim
57 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein a feeder box for feeding the fine powder is located on the rubber mold, and the fine powder is stirred by a blade mounted in the feeder box to fill the fine powder into the rubber mold.
Claim 132
Dependent Claim
57 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein a feeder box for feeding the fine powder is located on the rubber mold, and the fine powder is vibrated by a vibrator mounted in the feeder box to fill the fine powder into the rubber mold.
Claim 133
Dependent Claim
50 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein the fine powder is conveyed by a conveyor, on whose lower side a vibrator is slidably attached to fill the fine powder into the rubber mold at the high density.
Claim 134
Dependent Claim
56 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein a screw rod, around which blades are spirally secured, is coaxially mounted in a container, and the fine powder is stirred in the container to enhance its density and is then dropped into the rubber mold.
Claim 135
Dependent Claim
52 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein the fine powder is conveyed by a conveyor, on both sides of which rolls are located to press the fine powder, and the densified fine powder is dropped into the rubber mold.
Claim 136
Dependent Claim
35 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein upper and lower peripheral edges of the inner wall of the rubber mold are tapered.
Claim 137
Dependent Claim
73 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein the green compact has a flat shape of a width/thickness ratio of 2 or more the rubber mold has at least one of the top and the bottom harder than said side portion, and wherein the width is defined as a positive square root of cross sectional area of the sintered green compact.
Claim 138
Dependent Claim
72 words
A production method for producing a sintered compact having a density of 90% or more according to claim 116, wherein the green compact has a flat shape of a width/thickness ratio of 0.5 or less the rubber mold has at least one of the top and the bottom softer than said side portion, wherein the width is defined as a positive square root of cross sectional area of the sintered green compact.
Claim 139
Dependent Claim
67 words
A production method for producing a sintered magnet compact according to claim 116, wherein the rubber mold comprises at least a top and bottom, in which at least one of the top and the bottom has a thickness t, units in mm, defined by t≦16h/D, wherein h is thickness of a green compact and D is a positive square root of cross-sectional area of the green compact.
Claim 140
Dependent Claim
31 words
A production method for producing a sintered magnet compact according to claim 116, wherein the rubber mold comprises a mandrel which is harder than the other portions of the rubber mold.
Claim 141
Dependent Claim
45 words
A production method of a sintered magnet compact according to claim 116, wherein the rubber mold is open at the top thereof or at the bottom thereof, and the open portion of the rubber mold is directly pressed by a punch of the die-press machine.
Claim 142
Dependent Claim
57 words
A production method of a sintered magnet compact according to any one of claims 116 through 127, further comprising the steps of filling the fine powder under gravity into the rubber mold; weighing the fine powder during its filling in the rubber mold under gravity; and stopping the filling under gravity when a predetermined weight is obtained.
Claim 143
Dependent Claim
38 words
A production method for producing a sintered compact having a density of 90% or more according to any one of claims 116 through 129, wherein the fine powder has an average particle diameter of 30 μm or less.
Claim 144
Dependent Claim
29 words
A production method for producing a sintered compact having a density of 90% or more according to claim 131, wherein the average particle diameter is 20 μm or less.
Claim 145
Dependent Claim
29 words
A production method for producing a sintered compact according to claim 131, wherein the fine powder is filled to a density of 1.3 times or more the natural density.
Claim 146
Dependent Claim
33 words
A production method for producing a magnet according to claim 133, wherein the fine powder is filled to a density of 60% or less or of a true density of the fine powder.
Claim 147
Dependent Claim
50 words
A production method for producing a sintered compact having a density of 90% or more according to any of claims 116 through 129, wherein the material of the fine powder is at least one selected from the group consisting of Fe, Co, Ni, Cu, Mo, Al, Ti, and their alloys.
Claim 148
Dependent Claim
29 words
A production method for producing a sintered compact having a density of 90% or more according to claim 135, wherein the material of the fine powder is atomized iron.
Claim 149
Dependent Claim
29 words
A production method for producing a sintered compact having a density of 90% or more according to claim 135, wherein the material fine powder is atomized or melt-quenched aluminum.
Claim 150
Dependent Claim
39 words
A production method for producing a sintered compact having a density of 90% or more according to any of claims 116 through 129, further comprising a step of enlarging a clearance between the green compact and the rubber mold.
Claim 151
Dependent Claim
232 words
A production method for producing a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber at least in a side portion thereof; weighing fine powder of a material other than a magnet material, having an average particle size of 50 μm or less to provide a predetermined amount; filling a cavity of the rubber mold with the fine powder to a density at least 1.15 times a natural filling density, outside a die-press machine; placing the filled rubber mold in the die-press machine; compacting the rubber mold and the fine powder by a punch of the die-press machine thereby obtaining a green compact; withdrawing the green compact from the rubber mold; and sintering the green compact; wherein the rubber mold is mounted on a conveying means for circulating the same around and intermittently moving the same between positions wherein said filling, compacting and withdrawing are carried out, and, further wherein the natural filling density is obtained by allowing the fine powder to fall under gravity into the rubber mold from a powder pan until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing from the rubber mold, the distance between the bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of cavity of the rubber mold.
Claim 152
Dependent Claim
232 words
A production method for producing a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber at least in a side portion thereof; weighing fine powder of a material other than a magnet material, having an average particle size of 50 μm or less to provide a predetermined amount; filling a cavity of the rubber mold with the fine powder to a density at least 1.15 times a natural filling density, outside a die-press machine; placing the filled rubber mold in the die-press machine; compacting the rubber mold and the fine powder by a punch of the die-press machine thereby obtaining a green compact; withdrawing the green compact from the rubber mold; and sintering the green compact; wherein the rubber mold is mounted on a conveying means for circulating the same around and intermittently moving the same between positions wherein said filling, compacting and withdrawing are carried out, and, further wherein the natural filling density is obtained by allowing the fine powder to fall under gravity into the rubber mold from a powder pan until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing from the rubber mold, the distance between the bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of cavity of the rubber mold.
Claim 153
Dependent Claim
230 words
A production method for producing a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber at least in a side portion thereof; weighing fine powder of a material other than a magnet material, having an average particle size of 50 μm or less to provide a predetermined amount; filling a cavity of the rubber mold with the fine powder to a density at least 1.15 times a natural filling density, outside a die-press machine. placing the filled rubber mold in the die-press machine; compacting the rubber mold and the fine powder by a punch of the die-press machine thereby obtaining a green compact; withdrawing the green compact from the rubber mold; and sintering the green compact, wherein the rubber mold is mounted on a conveying means for linearly and intermittently conveying the rubber molds between positions where said filling, compacting and withdrawing are carried out, and, further wherein the natural filling density is obtained by allowing the fine powder to fall under gravity into the rubber mold from a powder pan until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing from the rubber mold, the distance between the bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of cavity of the rubber mold.
Claim 154
Dependent Claim
230 words
A production method for producing a sintered compact having a density of 90% or more, comprising: preparing a rubber mold which comprises rubber at least in a side portion thereof; weighing fine powder of a material other than a magnet material, having an average particle size of 50 μm or less to provide a predetermined amount; filling a cavity of the rubber mold with the fine powder to a density at least 1.15 times a natural filling density, outside a die-press machine. placing the filled rubber mold in the die-press machine; compacting the rubber mold and the fine powder by a punch of the die-press machine thereby obtaining a green compact; withdrawing the green compact from the rubber mold; and sintering the green compact, wherein the rubber mold is mounted on a conveying means for linearly and intermittently conveying the rubber molds between positions where said filling, compacting and withdrawing are carried out, and, further wherein the natural filling density is obtained by allowing the fine powder to fall under gravity into the rubber mold from a powder pan until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing from the rubber mold, the distance between the bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of cavity of the rubber mold.
Claim 155
Dependent Claim
32 words
A production method for producing a sintered compact having a density of 90% or more according to claim 140, wherein the linear moving passage of the supporting means has a polygonal configuration.
Claim 156
Dependent Claim
32 words
A production method for producing a sintered compact having a density of 90% or more according to claims 139, 140 or 141, wherein a die is moved together with the rubber mold.
Claim 157
Dependent Claim
37 words
A production method for producing a sintered compact having a density of 90% or more according to claim 139, 140 or 141, wherein the rubber mold is moved within a chamber, whose inner atmosphere is inert gas.
Claim 158
Dependent Claim
241 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by means of stirring the magnet powder by a reciprocating blade mounted in a feeder box to fill the magnet powder into the rubber mold, said feeder box being located on the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 159
Dependent Claim
241 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by means of stirring the magnet powder by a reciprocating blade mounted in a feeder box to fill the magnet powder into the rubber mold, said feeder box being located on the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 160
Dependent Claim
240 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by means of vibrating the magnet powder by a vibrator mounted in a feeder box to fill the magnet powder into the rubber mold, said feeder box being located on the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 161
Dependent Claim
240 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by means of vibrating the magnet powder by a vibrator mounted in a feeder box to fill the magnet powder into the rubber mold, said feeder box being located on the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 162
Dependent Claim
247 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by means if imparting vibration to the magnet powder while the magnet powder is conveyed on a conveyor by a vibrator slidably attached to a lower side of the conveyor and then dropping the magnet powder into the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 163
Dependent Claim
247 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by means if imparting vibration to the magnet powder while the magnet powder is conveyed on a conveyor by a vibrator slidably attached to a lower side of the conveyor and then dropping the magnet powder into the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 164
Dependent Claim
239 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by means of stirring the magnet powder with blades which are spirally secured around a screw rod coaxially mounted in a container and then dropping the magnet powder into the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 165
Dependent Claim
239 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by means of stirring the magnet powder with blades which are spirally secured around a screw rod coaxially mounted in a container and then dropping the magnet powder into the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 166
Dependent Claim
238 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by densifying the magnet powder by rolls located on the sides of a conveyor on which the magnet powder is conveyed and dropping the densified magnet powder into the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 167
Dependent Claim
238 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder, by densifying the magnet powder by rolls located on the sides of a conveyor on which the magnet powder is conveyed and dropping the densified magnet powder into the rubber mold; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the fine powder therein by the punch in the die-press machine.
Claim 168
Dependent Claim
213 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder under gravity and a magnetic field; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the time powder therein by the punch in the die-press machine.
Claim 169
Dependent Claim
213 words
A production method for producing a green magnet compact, comprising: preparing a rubber mold which comprises rubber in at least a side portion thereof and which is located outside a die-press machine; filling a cavity in the rubber mold with a magnet powder to a density which is at least 1.2 times a natural filling density of the fine powder under gravity and a magnetic field; placing the filled rubber mold in the die-press machine; and compacting the filled rubber mold and the fine powder therein by a punch in the die-press machine to obtain a green compact of the magnet powder; wherein the natural filling density is obtained by allowing the fine powder to fall from a powder pan into the rubber mold until the top of the fine powder arrives at an upper frame which prevents the fine powder from overflowing the rubber mold, the distance between a bottom end of the powder pan and the bottom of the rubber mold being 3.7 times the depth of the cavity of the rubber mold; and wherein a magnetic field is applied to the filled rubber mold containing the magnet powder before or during the compacting of the filled rubber mold and the time powder therein by the punch in the die-press machine.
Claim 170
Dependent Claim
38 words
The production method of claim 144, 145, 146, 147, 148 or 149, wherein the magnetic field is applied to orient particles in the magnetic powder prior to the compacting of the rubber mold and the magnet powder therein.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-10-04 | 1997-04-05 | 1997-10-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-10-04 | 2001-04-05 | 2001-10-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-10-04 | 2005-04-05 | 2005-10-05 | $7700.00 | Window Closed / Lapsed |