JP3155385B2 - Apparatus and method for manufacturing multilayer brush - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and a method for manufacturing a multi-layer brush in which raw material powders of two or more different materials are laminated.

[0002]

2. Description of the Related Art Generally, in a DC motor, a DC generator, or the like, an arbitrary commutator is short-circuited with a brush to perform commutation. However, the current change at the time of rectification is greatly delayed due to the inductance of the armature coil and the like, and the current change becomes large at the end of the rectification. Therefore, a large reactance voltage is generated by the inductance of the short-circuit coil. This causes a spark discharge between the brush and the commutator, roughening the commutator surface and forming an uneven surface. For this reason, there arises a problem that the amount of wear of the brush device is increased, the life thereof is significantly reduced, and the vibration noise of the brush itself is also increased.

In particular, when a high-performance magnet is used to reduce the size of a motor or the like and the thickness of the magnet is reduced, the distance between the armature and the stator yoke is reduced. For this reason, the magnetic resistance of the armature is reduced, and the inductance of the short-circuit coil is increased, so that the above-mentioned problem appears more remarkably.

For this reason, various methods for performing non-spark rectification have been conventionally performed. As a typical example, a proposal disclosed in Japanese Patent Application Laid-Open No. 4-46546 is known. In this proposal, the brush front end is made of low resistance material,
The rear end is formed by using a high-resistance material to reduce spark generation.

[0005] Further, as a method of manufacturing this kind of two-layer brush, Japanese Patent Application Laid-Open No. 2-86081 and Japanese Patent Application Laid-Open No. 2-860 are disclosed.
A proposal disclosed in, for example, Japanese Patent Publication No. 83 is known. In these proposals, two layers filled and stacked in a forming die are used.
A two-layer brush is manufactured by pressing various kinds of raw material powders or brushes with upper and lower punches.

[0006]

However, in the above-described conventional two-layer brush, the commutation characteristics do not approach an ideal commutation curve depending on the rotational position of the rotor, and particularly the boundary between the low-resistance material and the high-resistance material. However, there is a drawback in that it is difficult to completely suppress the generation of sparks because the current changes rapidly. For this reason, the present applicant has proposed a multilayer brush free of such disadvantages (Japanese Patent Application No. Hei 4-23).
No. 5231 "Brush device").

FIG. 12 is a perspective view showing the structure of a two-layer brush proposed by the present applicant. This two-layer brush 100
Is a first layer 1 bounded by one diagonal of a square cross section
02 and the second layer 104. First layer 10
Reference numeral 2 denotes a low resistance portion formed such that the commutator contact surface gradually narrows from the upstream side to the downstream side in the rotor rotation direction. The second layer 104 is a high-resistance portion formed such that the commutator contact surface gradually widens from the upstream side to the downstream side in the rotor rotation direction. FIG. 13A is a diagram showing an assembled state of the two-layer brush shown in FIG. The state where the two-layer brush 100 is assembled perpendicularly to the rotation direction of the armature 110 is shown. FIG. 13 (b)
FIG. 2A is a diagram showing a cross section taken along line AA of FIG.
2 shows that the second layer 104 gradually narrows from the upstream side to the downstream side in the rotational direction, and the second layer 104 gradually widens in the opposite direction.

By using such a two-layer brush 100, the brush resistance changes smoothly with the progress of commutation, and no abrupt current change occurs during the entire commutation period, so that no spark is generated. Good rectification can be performed.

When the two-layer brush 100 is to be manufactured by the manufacturing method disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 2-86083, a two-layer brush having a boundary surface parallel to the upper and lower surfaces is pressed by upper and lower punches. This requires post-processing such as cutting after once manufacturing, which is troublesome and prolongs the manufacturing time. In addition, there is a problem that material is wasted and the cost is increased.

FIG. 14 is a diagram showing a state in which a two-layer brush 100 having a boundary surface inclined with respect to the upper and lower surfaces is cut out of a two-layer brush having a boundary surface parallel to the upper and lower surfaces. By removing the corners of the brush, the two-layer brush 100 is cut out, and the removed corners are completely wasted, which directly leads to higher costs. In addition, the work and time required for the deletion are extra.

Further, by expanding the two-layer brush 100 for one-way rotation, a three-layer brush for two-way rotation can be obtained.

FIG. 15 is a perspective view showing the structure of a three-layer brush proposed by the present applicant. This three-layer brush 120
The first layer 122 having a triangular prism shape provided on the upstream side in the normal rotation direction so that the commutator contact surface gradually narrows from the upstream side to the downstream side in the commutator normal rotation direction; A triangular prism-shaped second provided on the downstream side in the forward rotation direction so as to gradually narrow from the downstream side in the forward rotation direction to the upstream side in the commutator forward direction
Layer 124 and the first and second layers 122 and 124
A third layer 1 having a triangular prism shape formed to be located between
26. First and second layers 122, 12
Reference numeral 4 denotes a low resistance part, and the third layer 126 is a high resistance part.

By using such a three-layer brush 120, when the rotor rotates forward, the first layer 122 is mainly used.
Current flows through the commutator so as to cancel the short-circuit current of the armature coil, and when the rotor reverses, the current flows through the commutator mainly to cancel the short-circuit current of the armature coil through the second layer 124. Because of the flow, the commutation is completed at a relatively early stage in either forward rotation or reverse rotation.
In addition, since the brush resistance changes smoothly with the progress of rectification, abrupt current change does not occur during the entire period of rectification, and good rectification without sparks can be performed.

The three-layer brush 120 described above is
Interface between first layer 122 and third layer 126 and second layer 1
Since the boundary surface between the second layer 24 and the third layer 126 is not parallel, there is a problem that it cannot be manufactured by the manufacturing method disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 2-86083.

Therefore, an object of the present invention is to provide a multilayer brush which can manufacture an inexpensive brush by eliminating post-processing such as cutting, and without drastically changing the conventional process, without wasting material. An object of the present invention is to provide a brush manufacturing apparatus and a brush manufacturing method.

[0016]

Means for Solving the Problems In order to solve the above problems, apparatus for producing a multilayer brush of the present invention, a punch which pressing surface is inclined relative to the horizontal, inclined relative to the horizontal arrangement has a molding space that is, pre-equipped with a molding die which constitutes a mold with Kipa inch, and the molding space
After sequentially filling two or more kinds of raw material powders in layers,
A multi-layer brush is formed by pressurizing the multi-layer brush.

Further, the method for producing a multilayer brush of the present invention comprises:
In the method for manufacturing a multilayer brush having an inclined interlayer boundary surface, two or more kinds of raw material powders constituting the multilayer brush are sequentially charged into a molding die having an inclined molding space in a layered form and then filled. the raw material powder of the above species were pressed by punch, characterized by integrating the raw material powder by press molding.

Further, the method for manufacturing a multi-layer brush of the present invention comprises:
A method for manufacturing a multi-layer brush having an inclined interlayer interface , comprising: a first raw material powder having a horizontal surface and an inclined surface;
The formed first brush is applied to the forming brush formed on the molding die.
Arranged so that the inclined surface is located in the mold space,
After charging the second raw material powder onto the first brush in the molding space , the pressing surface is perpendicular to the pressing direction.
By pressing the punch, characterized by integrating the first and second raw material powders so as to have an interlayer boundary surface that the inclined by pressure molding.

Further, the method for manufacturing a multi-layer brush of the present invention comprises:
After the first raw material powder is put into a molding die having a molding space, the first raw material powder is pressed by a first upper punch and a lower punch, one of which pressing surfaces is inclined, to form a first raw material powder. After the brush is temporarily formed and the second raw material powder is put on the first brush in the forming space, the pressing surface is inclined in a different direction from the first upper punch and the lower punch. 2, the second brush is preliminarily formed by pressing with the upper punch and the lower punch, and after the third raw material powder is charged onto the second brush in the molding space, both pressing surfaces are pressed. By pressing with a third upper punch and a lower punch perpendicular to the direction, the first, second and third raw material powders are pressed and integrated so as to have the inclined interlayer interface. It is characterized by doing.

Further, the method for manufacturing a multilayer brush according to the present invention comprises:
A method of manufacturing a multi-layer brush having an inclined interlayer boundary surface, wherein a first and a second pressing are performed on a lower punch having a V-shaped concave shape in a forming die having a vertical forming space. 2 are sequentially charged and filled, and then the filled first and second raw material powders are pressed by the lower punch and the upper punch having a V-shaped concave pressing surface. Are pressure molded and integrated.

[0021]

Apparatus for manufacturing a multilayer brush the present invention, the molding space formed molding the die Ri Contact is disposed inclined with respect to the horizontal direction, the inclined molding space this 2
More than one kind of raw material powder is selectively and sequentially charged. Therefore, when the first raw material powder is supplied, the upper surface of the first raw material powder becomes substantially a horizontal surface due to its own weight, and the second raw material powder is supplied and laminated thereon. After that, for punching and molding
By pressing the raw material powders stacked by the dies and pressing them together, a multilayer brush having an inclined interlayer boundary surface is integrally formed.

According to the manufacturing apparatus and manufacturing method for a multilayer brush of the present invention, two or more kinds of raw material powder after filling was poured into sequential layers, is possible to manufacture a multi-layer brush is pressed by punch Therefore, post-processing such as cutting is not required, and the conventional process is not largely changed.

In the method for manufacturing a multilayer brush according to the present invention, the first brush having a horizontal surface and an inclined surface is used.
The first raw material powder is temporarily formed, and this temporarily formed
The first brush is inclined into the forming space of the forming die.
Is placed upward. Thereafter, the first brush
Adding a second raw material powder above, by the pressing surface is pressed by vertical punch relative to the pressing direction, to compression molding two layers brush boundary surface is inclined.

Further, the first raw material powder is provisionally formed using the first upper and lower punches having one of the pressing surfaces inclined in a V-shape, and then the second raw material powder is applied to the provisionally formed brush. In addition, when the pressing surface is pressed by the second upper and lower punches perpendicular to the pressing direction, the interlayer boundary surface becomes V-shaped.
The three-layer brush inclined in a letter shape is pressed.

According to the above-described method for manufacturing a multilayer brush,
By tilting the pressing surface of either the upper punch or the lower punch in one direction or in a V-shape, an inclined interlayer boundary surface of the two-layer brush or the three-layer brush is formed. By using upper and lower punches perpendicular to the above, a two-layer brush or a three-layer brush can be manufactured. Therefore, the inclined interlayer boundary surface is provisionally formed by pressure molding, and post-processing such as cutting is not required. In addition, it is only necessary to change the pressing surface shape of the upper and lower punches and to add a temporary forming step, and it is not necessary to largely change the conventional step.

In the method of manufacturing a multilayer brush according to the present invention, after the above-described provisional molding, the second raw material powder is charged,
A three-layer brush in which the interlayer boundary surface is inclined by again performing temporary forming using the upper and lower punches in which one of the pressing surfaces is inclined, and finally pressing the upper and lower punches in which the pressing surface is perpendicular to the pressing direction. Under pressure.

According to this method of manufacturing a multi-layer brush, the inclined two-layer boundary surfaces of the three-layer brush are formed by separate temporary forming steps, and it is not necessary to perform a post-process such as cutting.

In the method for manufacturing a multilayer brush according to the present invention, each pressing surface uses an upper and lower punch having a V-shaped concave shape, and the first raw material powder is put on the lower punch. Then, the upper surface of the first raw material powder itself becomes substantially horizontal due to its own weight, on which the second raw material powder is charged and laminated. After that, the stacked raw material powders are pressed and engaged by the upper and lower punches.

Therefore, at the stage of laminating the raw material powders, the pressing surfaces of the upper and lower punches, which are the outer surfaces of the brush, and the boundary surface are inclined, and it is not necessary to perform post-processing such as cutting after that.
In particular, in the present invention, it is only necessary to change the shape of the upper and lower punching pressing surfaces, so that it is not necessary to change the conventional process.

[0030]

Embodiments of the present invention will be described below in detail with reference to the drawings.

First Embodiment FIG. 1 is a view showing a cross-sectional structure of a manufacturing apparatus according to an embodiment for manufacturing the two-layer brush 100 shown in FIG.

This manufacturing apparatus includes a molding die 10, an upper punch 12 and a lower punch 14 constituting a compression mold, and feeders 20, 30 for charging two types of raw material powders for brush molding. It is configured.

The molding die 10 has a molding space 18 for pressurizing the raw material powder of the brush. The upper punch 12 and the lower punch 14 move along the molding space 18 so that the raw material powder is removed. Press from two directions. Further, the molding space 18 is inclined so that the upper punch 1
The molding die 10 is arranged so that the pressing direction of the lower punch 2 and the lower punch 14 is inclined with respect to the horizontal plane.

One feeder 20 is for charging one of the raw material powders of the two-layer brush, and has a raw material powder reservoir 24 for feeding the raw material powder into a filling space 22 in the feeder 20 and a raw material discharge device 26. It has. The raw material powder discharging device 26 has a mechanism for feeding raw material powder from the raw material powder reservoir 24 to the filling space 22 using, for example, compressed air.

Similarly, the other feeder 30 is for charging the other material powder of the two-layer brush, and has a material powder reservoir 34 for feeding the material powder into the filling space 32 in the feeder 30 and a material powder reservoir 34. A discharge device 36 is provided. The raw material powder discharging device 36 has a mechanism for feeding raw material powder from the raw material powder reservoir 34 to the filling space 32 by using, for example, compressed air.

The inclination angle of the molding space 18 in the molding die 10 (the angle between the pressing direction of the upper and lower punches 12 and 14 and the horizontal plane) is shown in FIG.
The pressing surface of the upper and lower punches 12 and 14 is perpendicular to the pressing direction.

FIG. 2 is an explanatory view of the manufacturing process, and shows each process of forming the two-layer brush 100 in detail.
Hereinafter, a process of manufacturing the two-layer brush 100 using the above-described manufacturing apparatus will be described in detail with reference to FIG.

Step 1: First, the filling space 22 of the feeder 20 is filled with an appropriate amount of the first raw material powder of the two-layer brush 100. This filling is performed by feeding the first raw material powder in the raw material powder reservoir 24 into the filling space 22 by the raw material powder discharging device 26.

Further, in parallel with or following the filling operation of the first raw material powder, the feeder 3
A suitable amount of the second raw material powder of the two-layer brush 100 is filled in the 0 filling space 32. This filling is performed by feeding the second raw material powder in the raw material powder reservoir 34 into the filling space 32 by the raw material powder discharging device 36.

Step 2: Next, the feeder 20 is moved along the upper surface of the forming die 10, and the filling space 22 in the feeder 20 is matched with the forming space 18 of the forming die 10, and the feeder 20 is filled. The first raw material powder is put into the molding space 18 (see FIG. 2A). The top surface of the charged first raw material powder becomes substantially horizontal due to the weight of the powder. After the input of the first raw material powder is completed, the feeder 20 returns to the original position.

Depending on the type of the raw material powder and the size of the brush, the upper surface of the first raw material powder may not be horizontal due to its own weight. In this case, the molding die 10 may be subjected to impact or vibration. By adding, the upper surface can be made horizontal.

Step 3: Next, the feeder 30 is moved along the upper surface of the molding die 10, and the filling space 32 in the feeder 30 is matched with the molding space 18 of the molding die 10 to fill the feeder 30. The prepared second raw material powder is introduced into the molding space 18 (see FIG. 2B). This second
Of the second raw material powder is superimposed on the first raw material powder whose upper surface is substantially horizontal, so that the boundary between the first raw material powder and the second raw material powder is kept horizontal while the second raw material powder is maintained. Are laminated. The upper surface of the second raw material powder is also substantially horizontal due to its own weight. After the end of the feeding of the second raw material powder, the feeder 30 returns to the original position.

Step 4: Next, the upper punch 12 is lowered into the molding space 18 of the molding die 10 (see FIG. 2C). At this time, the lower punch 14 is raised, and the lower punch 14 and the lower punch 14 press and engage the two types of raw material powders filled in the steps 1 to 3 (FIG. 2D). reference).

Step 5: Thereafter, the lower punch 14 is further raised to take out the brush that has been pressed and engaged (see FIG. 2 (e)). The layer brush 100 is completed.

By devising the cross-sectional shape of the two-layer brush 100, the pressing force can evenly reach the end of the brush. As shown in FIG. 3, if the vertical dimension of the cross section of the two-layer brush 100 is a and the horizontal dimension is b, a
By relatively shortening the dimension in the pressing direction so that / b <1 or a / b becomes substantially equal to 1, the pressing force can evenly reach the brush end.

As described above, in the present embodiment, the entirety of the molding die 10 and the upper and lower punches 12, 14 and the like are arranged at a predetermined angle and are inclined.
After filling the first raw material powder and the second raw material powder into the inside 8 so that the boundary surface is substantially horizontal, these two types of raw material powders are engaged under pressure.

Accordingly, the two-layer brush 100 can be formed only by one pressing step, and the conventional step does not need to be changed significantly. Further, since the two-layer brush 100 formed in this manner already has an inclined boundary surface in the forming process, post-processing such as cutting is not required, and waste of material can be eliminated. Further, since there is no need to perform post-processing such as cutting or separately press-mold the first layer 102 and the second layer 104, it is possible to manufacture an inexpensive brush with reduced cost.

Second Embodiment FIG. 4 is a view showing a sectional structure of a manufacturing apparatus of a second embodiment for manufacturing the two-layer brush 100.

The manufacturing apparatus of this embodiment includes a molding die 40, an upper punch 42, and a lower punch 44 constituting a compression mold.
And a feeder 50 for charging two types of raw material powders for brush molding.

The molding die 40 has a molding space 48 for pressurizing the raw material powder of the brush. The upper punch 42 and the lower punch 44 move along the molding space 48 to remove the raw material powder. The point of pressing from two directions is the same as in the manufacturing apparatus of the first embodiment.

The feeder 50 is for charging two types of raw material powders, and the raw material powder reservoir 54 and the raw material discharge device 56 for feeding the two types of raw material powders into the filling space 52 in the feeder 50. And two passage valves 58,
59 are provided. The raw material powder reservoir 54 has two storage areas for accommodating the respective raw material powders, and each storage area has two passages provided at different heights in the feeder 50 and a separate passage for this passage. It is connected to the filling space 52 via passage valves 58 and 59 provided at the distal end. Therefore, when sending one raw material powder to the filling space 52, one of the passage valves 58 is opened, and the raw material discharge device 56 is opened.
Feeds the raw material powder into the filling space 52 through a passage connected to the passage valve 58. When the other raw material powder is sent to the filling space 52, the other passage valve 59 is opened,
The raw material powder discharging device 56 feeds the raw material powder into the filling space 52 through a passage connected to the passage valve 59. The opening and closing of these two passage valves 58 and 59 is performed by the passage valve opening / closing device 5.
7

Using the feeder 50, two types of raw material powders are sequentially filled into the molding space 48 in the molding die 40. At this time, each of the raw material powders is filled such that the boundary surface between the first raw material powder and the second raw material powder is horizontal, as in the first embodiment described above. Next, the two kinds of the filled raw material powders are press-engaged by raising the lower punch 44 and descending the upper punch 42, and then taking out the press-engaged brush and firing it to form a two-layer brush 100. Get.

Third Embodiment FIG. 5 is a view showing a sectional structure of a manufacturing apparatus of a third embodiment for manufacturing the two-layer brush 100.

The manufacturing apparatus of this embodiment includes a forming die 60, an upper punch 62, and a lower punch 64 which constitute a compression mold.

The upper punch 62 also functions as a feeder for charging two types of raw material powder for brush molding, and opens and closes when the two types of raw material powder are charged into the forming space 68. A valve 70, an auxiliary punch 72 for pushing the valve 70 into the molding space 68,
A spring 74 for pushing back the valve 70, a raw material powder reservoir 76 for feeding the first raw material powder into the molding space 68 via the valve 70, and a raw material discharge device 78
And a raw material powder reservoir 8 for charging the second raw material powder
0, and a material powder discharging device 82.

When the first raw material powder is charged, only one raw powder discharging device 78 operates, and when the second raw powder is charged, only the other raw powder discharging device 82 operates.

In the state where the valve 70 is closed,
The lower surface of the valve 70 projects slightly into the molding space 68 from the lower surface of the upper punch 62. Otherwise, a protrusion corresponding to the valve 70 will be formed on the formed brush, and when the brush device is assembled, the brush will not slide smoothly.
A stopper 84 is mounted on the upper surface of the molding die 60, and serves to protect the molding die 60 when the upper punch 62 collides with the molding die 60.

Using the upper punch 62 having a function as a feeder, two kinds of raw material powders are successively formed into a molding die 6.
The space 68 for molding in the space 0 is filled. At this time, each raw material powder is filled so that the boundary surface between the first raw material powder and the second raw material powder is substantially horizontal.
This is the same as the embodiment. Next, the two kinds of the filled raw material powders are press-engaged by raising the lower punch 64 and lowering the upper punch 62, and then taking out the press-engaged brush and firing it to form a two-layer brush 100. Get.

As described above, also in the second and third embodiments, the lamination is performed so that the boundary between the first raw material powder and the second raw material powder is substantially horizontal in the inclined molding spaces 48, 68. Thereafter, the two-layer brush 10 is pressed and engaged.
0 can be obtained. Therefore, as in the first embodiment, post-processing such as cutting is not required, so that waste of material can be eliminated and the cost of the brush can be reduced.

Fourth Embodiment FIG. 6 is a diagram showing a cross-sectional structure of a manufacturing apparatus according to a fourth embodiment for manufacturing the two-layer brush 100.

The manufacturing apparatus of this embodiment includes a molding die 110, an upper punch 112, and a lower punch 1 which constitute a compression mold.
14 and feeders 120 and 130 for charging two types of raw material powders for brush molding.

The molding die 110 has a molding space 118 for pressurizing the raw material powder of the brush, and the upper punch 112 and the lower punch 1 along the molding space 118.
14 moves and presses the raw material powder from two directions. Also,
The molding dies 110 are arranged so that the molding space 118 is perpendicular to the horizontal plane, that is, the pressing direction of the upper punch 112 and the lower punch 114 is perpendicular to the horizontal plane. Therefore, the manufacturing apparatus of the present embodiment can use a general manufacturing apparatus for brush molding, and requires little change of manufacturing equipment.

One feeder 120 corresponds to the feeder 20 of the first embodiment described above. The feeder 120 is provided with a raw powder reservoir 124 and a raw powder discharge device 126 for feeding the raw powder into the filling space 122 in the feeder 120. Have.

Similarly, the other feeder 130 corresponds to the feeder 30 of the first embodiment, and stores a raw powder reservoir 134 for feeding raw powder into a filling space 132 in the feeder 130 and a raw powder discharge device 136. It has.

The lower punch 114 is disposed below the molding space 118 so that the pressing surface is horizontal. The upper punch 112 is disposed above the molding space 118 so as to face the lower punch 114, but the pressing surface thereof is not horizontal, and the two-layer brush 100 shown in FIG.
Are inclined by the angle between the boundary surface and the lower surface.

It should be noted that the brush manufacturing apparatus of the present embodiment has an upper punch 116 having a horizontal pressing surface in addition to the upper punch 112.
, And the two upper punches 112 and 116 are appropriately replaced and used.

FIG. 7 is an explanatory view of the manufacturing process of the two-layer brush in the present embodiment, and shows each process in detail. Hereinafter, the two-layer brush 1 is manufactured using the manufacturing apparatus shown in FIG.
The steps of manufacturing the “00” will be described in detail with reference to FIG.

Step 1: First, the filling space 122 of the feeder 120 is filled with an appropriate amount of the first raw material powder of the two-layer brush 100. In this filling, the first raw material powder in the raw material powder reservoir 124 is filled with a raw material
By sending it to

Next, the feeder 120 is connected to the molding die 11.
0, and the filling space 122 in the feeder 120 is made to coincide with the molding space 118 of the molding die 110, and the first raw material powder is introduced into the molding space 118 (FIG. 7A). reference). After the input of the first raw material powder is completed, the feeder 120 returns to the original position.

Step 2: Next, the upper punch 112 is lowered into the molding space 118 of the molding die 110 to temporarily form the brush using only the first raw material powder (see FIG. 7B). Since the pressing surface of the lower punch 114 is horizontal and the pressing surface of the upper punch 112 is inclined at a predetermined angle with respect to the horizontal, a brush having a right-angled triangular cross section (the first brush in FIG. Layer 102) is manufactured.

Since this step is a tentative forming step, the forming pressure may be low and the triangular cross section may be maintained.

Step 3: Next, the feeder 130 is moved along the upper surface of the molding die 110, and the filling space 132 in the feeder 130 is moved to the molding space 11 of the molding die 110.
8, the feeder 130 is filled with the second
Of the raw material powder is injected into the molding space 118 (FIG. 7C).
reference). After the input of the second raw material powder is completed, the feeder 130 returns to the original position.

The filling space 132 in the feeder 130
The second raw material powder is filled in parallel with the above-mentioned step 1 or step 2 or after step 2 is completed.

Step 4: Next, the upper punch 112 is replaced with an upper punch 116 having a horizontal pressing surface, the replaced upper punch 116 is lowered into the forming space 118 of the forming die 110, and the lower punch 114 is raised. (See FIG. 7D). At this time, since the second raw material powder is filled on the temporarily formed first raw material powder, two types of raw material powders are pressed and engaged by the lower punch 114 and the lower punch 114 raised. You.

Thereafter, the lower punch 114 is further raised to take out the brush that has been pressed and engaged, and the taken-out brush is fired in a predetermined firing step, so that the two-layer brush 100 is finally completed.

In this embodiment, the upper punch 112
Was replaced with the upper punch 116, but the upper punch 1
A mold having the upper mold 12 and a mold having the upper punch 116 are separately prepared. After the provisional molding in the step 3 is completed, the temporarily molded brush is transferred to the mold having the upper punch 116. You may do it.

Also, as shown in FIG.
When the vertical dimension of the cross section of a is a and the horizontal dimension is b, a / b
If <1 or a / b is made substantially equal to 1, the point that the pressing force evenly reaches the brush end is the first point described above.
This is the same as the embodiment.

As described above, in the present embodiment, after the first raw material powder is temporarily formed using the upper punch 112 having the inclined pressing surface, the second raw material powder is pressed and engaged. I have. Therefore, it is only necessary to add a temporary forming step to a general conventional brush pressing step. Further, since the two-layer brush 100 formed in this manner already has an inclined boundary surface in the forming process, post-processing such as cutting is not required, and waste of material can be eliminated.

Fifth Embodiment Next, a fifth embodiment for manufacturing the two-layer brush 100 will be described.

The basic structure of the manufacturing apparatus of this embodiment is the same as that of the fourth embodiment shown in FIG. 6. By changing the shape of the upper and lower punches, the following manufacturing process of this embodiment is realized. are doing. Except for the upper and lower punches, the structure in FIG. 6 is used as it is, and a detailed description thereof will be omitted.

FIG. 8 is an explanatory diagram of the manufacturing process of the two-layer brush of this embodiment. As shown in the figure, the upper punch 212 and the lower punch 214 have pressing surfaces such that when they are combined, the external shape of the two-layer brush 100 is formed.
Specifically, the pressing surface of the upper punch 212 is formed so as to face the upper surface and the left side surface of the two-layer brush 100 shown in FIG. 12, and the boundary surface between the first layer 102 and the second layer 104 is formed. It is horizontal. Similarly, the lower punch 214 is formed such that the pressing surface thereof is opposed to the lower surface and the right side surface of the two-layer brush 100 shown in FIG. 12, and the boundary surface between the first layer 102 and the second layer 104 is horizontal. It is formed so that it becomes.

Hereinafter, such upper and lower punches 212 and 21 will be described.
The steps in the case of manufacturing the two-layer brush 100 using the manufacturing apparatus having No. 4 will be described in detail with reference to FIG.

Step 1: First, the feeder 120 in which the filling space 122 is filled with the first raw material powder in an appropriate amount is moved along the upper surface of the molding die 110, and the first raw material powder is put into the molding space 118. (See FIG. 8A). The top surface of the charged first raw material powder becomes substantially horizontal due to the weight of the powder. After the input of the first raw material powder is completed, the feeder 120 returns to the original position.

Step 2: Next, the feeder 130 in which the filling space 132 is filled with an appropriate amount of the second raw material powder is moved along the upper surface of the molding die 110, and the second raw material powder is put into the molding space 118. (See FIG. 8B). After the input of the second raw material powder is completed, the feeder 130 returns to the original position.

Step 3: Next, the upper punch 212 is lowered into the molding space 118 of the molding die 110 (FIG. 8).
(C)). At this time, the lower punch 214 is raised,
The two kinds of raw material powders filled in the steps 1 and 2 are press-engaged by the lower punch 212 and the lower punch 214.

After that, the lower punch 214 is further raised to take out the brush that has been pressed and engaged, and the taken-out brush is fired in a predetermined firing step, so that the two-layer brush 100 is finally completed.

As described above, in this embodiment, the pressing surfaces of the upper punch 212 and the lower punch 214 are
In addition to matching the outer shape of each layer of No. 0 and making the boundary surface of each layer horizontal at the time of brush molding, the first
After the first raw material powder is filled, the second raw material powder is filled, and these two types of raw material powders can be press-engaged in a single pressurizing step.

The two-layer brush 10 thus formed
0 is similar to each of the above-described embodiments in that a post-process such as cutting is unnecessary because the surface has an inclined boundary in the forming process.

Sixth Embodiment Next, a sixth embodiment will be described. The brush manufacturing apparatus of this embodiment has the same basic structure as the manufacturing apparatus of the fourth embodiment shown in FIG. 6, and is characterized in that a different upper punch is used. Further, in each of the embodiments described above, the two-layer brush 100 is manufactured. In this embodiment, the three-layer brush 120 shown in FIG. 15 is manufactured. Except for the upper punch, the structure shown in FIG.
The detailed description is omitted.

FIG. 9 is an explanatory diagram of a manufacturing process of the three-layer brush of this embodiment. As shown in the figure, the upper punch 228 of the present embodiment has a pressing surface whose first layer 12 shown in FIG.
It is inclined toward the center to form a boundary between the second and third layers 126 and a boundary between the second layer 124 and the third layer 126. That is, the upper punch 228 and the lower punch 11
4, the pressing surface of the upper punch 228 forms a V-shaped recess so that the gap between the upper and lower punches becomes the first layer 122 and the second layer 124 in FIG. are doing.

Hereinafter, a process for manufacturing the three-layer brush 120 using the above-described manufacturing apparatus will be described in detail with reference to FIG.

Step 1: First, the feeder 120 in which the filling space 122 is filled with the first raw material powder in an appropriate amount is moved along the upper surface of the molding die 110, and the first raw material powder is put into the molding space 118. (See FIG. 9A). After the input of the first raw material powder is completed, the feeder 120 returns to the original position.

Step 2: Next, the upper punch 228 is lowered into the molding space 118 of the molding die 110 (FIG. 9).
(B)). At this time, the lower punch 114 is raised,
The first punch 122 and the second punch 122 shown in FIG.
4 are simultaneously formed.

Step 3: Next, the feeder 130 in which the filling space 132 is filled with the second raw material powder in an appropriate amount is moved along the upper surface of the molding die 110, and the second raw material powder is put into the molding space 118. (See FIG. 9C). The first raw material powder is subjected to the first and second layers 122,
Since it is provisionally molded into the shape of 124, the second raw material powder is charged during that time. After the input of the second raw material powder is completed, the feeder 130 returns to the original position.

Step 4: Next, after replacing the upper punch 228 with the upper punch 116 whose pressing surface is horizontal, the forming die 11
The exchanged upper punch 116 is lowered into the molding space 118 of No. 0 (see FIG. 9D). At this time, since the second raw material powder is filled between the temporarily formed first raw material powder, two types of raw material powders are pressed by the lower punch 114 and the lower punch 114 raised. Thus, the three-layer brush 120 shown in FIG. 15 is formed.

Thereafter, the lower punch 114 is further raised to take out the brush that has been pressed and engaged, and the taken-out brush is fired in a predetermined firing step, whereby the three-layer brush 120 is finally completed.

Seventh Embodiment Next, a seventh embodiment will be described.

The manufacturing apparatus of this embodiment has a three-layer brush 120.
The basic structure is the same as that of the fourth embodiment shown in FIG. 6, and the three-layer brush 120 is manufactured by changing the upper and lower punches.
Except for the upper and lower punches, the structure in FIG. 6 is used as it is, and a detailed description thereof will be omitted.

FIG. 10 is an explanatory view of the manufacturing process of the brush of this embodiment. As shown in the drawing, the lower punch 230 used in the present embodiment has a concave portion whose pressing surface has a V-shaped cross section.

Hereinafter, a process for manufacturing the three-layer brush 120 using the above-described manufacturing apparatus will be described in detail with reference to FIG.

Step 1: First, the feeder 120 in which the filling space 122 is filled with an appropriate amount of the first raw material powder is moved along the upper surface of the molding die 110, and the filled first raw material powder is molded. Put into space 118 (FIG. 10A)
reference). After the input of the first raw material powder is completed, the feeder 120 returns to the original position.

Step 2: Next, the upper punch 116 is lowered into the molding space 118 of the molding die 110 (FIG. 10).
(B)). Since the pressing surface of the lower punch 230 forms a V-shaped concave portion and the pressing surface of the upper punch 116 is horizontal, a brush having a right-angled isosceles triangular cross section is formed by this temporary molding (third in FIG. 15). (Corresponding to layer 126).

Step 3: Next, after temporarily removing the brush which has been subjected to the temporary forming in step 2, the lower punch 230 is replaced with the lower punch 114 having a horizontal pressing surface. Then, the temporarily formed brush is placed upside down on the pressing surface of the lower punch 114 (see FIG. 10C).

Step 4: Next, the feeder 130 in which the filling space 132 is filled with the second raw material powder in an appropriate amount is moved along the upper surface of the molding die 110, and the filled second raw material powder is molded. It is put into the space 118 (see FIG. 10D). After the charging of the second raw material powder is completed, feeder 1
30 returns to the original position.

Step 5: Next, the upper punch 116 is lowered into the molding space 118 of the molding die 110 (FIG. 10).
(E)). At this time, since the second raw material powder is filled on the temporarily formed first raw material powder, the lowered upper punch 116 and the raised lower punch 114 cause
As shown in FIG.
Is formed.

Thereafter, the brush which has been pressed and engaged is taken out, and the taken-out brush is fired in a predetermined firing step, whereby the three-layer brush 120 is finally completed.

As described above, in the seventh and eighth embodiments, the three-layer brush 120 having the inclined boundary surface is formed by performing the temporary forming by the upper punch 228 or the lower punch 230 whose pressing surface is inclined in a V shape. Has been manufactured. Therefore,
The three-layer brush 120 can be easily manufactured only by adding the temporary forming process, and the post-process such as cutting is not required.

Eighth Embodiment Next, an eighth embodiment will be described.

The manufacturing apparatus of this embodiment has the same basic structure as that of the fourth embodiment shown in FIG. 6, and manufactures the three-layer brush 120 shown in FIG. 15 by replacing the upper punch. Things. In addition, except for the upper punch,
The structure of FIG. 6 is used as it is, and a detailed description thereof will be omitted.

FIG. 11 is an explanatory diagram of a manufacturing process of the three-layer brush of this embodiment. As shown in the drawing, the upper punch 232 of the present embodiment has a pressing surface having a predetermined angle with respect to a horizontal plane, and when the lower punch 114 and the upper punch 232 are combined, the first punch of FIG. A layer 122 is formed. The pressing surface of the upper punch 234 has a predetermined inclination angle, and the inclination direction is the upper punch 232.
Is opposite to the inclination direction.

Hereinafter, a process for manufacturing the three-layer brush 120 using the above-described manufacturing apparatus will be described in detail with reference to FIG.

Step 1: First, the feeder 120 in which the filling space 122 is filled with the first raw material powder in an appropriate amount is moved along the upper surface of the forming die 110, and the filled first raw material powder is formed. Put into space 118 (FIG. 11A)
reference). After the input of the first raw material powder is completed, the feeder 120 returns to the original position.

Step 2: Next, the upper punch 232 is lowered into the molding space 118 of the molding die 110 (FIG. 11).
(B)). The first layer 122 shown in FIG. 15 is formed by the first temporary molding.

Step 3: Next, the feeder 130 in which the filling space 132 is filled with an appropriate amount of the second raw material powder is moved along the upper surface of the molding die 110, and the filled second raw material powder is molded. It is put into the space 118 (see FIG. 11C). After the charging of the second raw material powder is completed, feeder 1
30 returns to the original position.

Step 4: Next, after replacing the upper punch 232 with the upper punch 234, the replaced upper punch 234 is lowered into the molding space 118 of the molding die 110 (see FIG. 11D). By this second temporary molding, FIG.
The first layer 122 and the third layer 126 shown in FIG.

Step 5: Next, the feeder 120 is moved again along the upper surface of the molding die 110, and the feeder 120 is moved.
The first raw material powder filled in the filling space 122 is charged into the molding space 118 (see FIG. 11E). After the last charging of the first raw material powder is completed, the feeder 12
0 returns to the original position.

Step 6: Next, after replacing the upper punch 234 with the upper punch 116 having a horizontal pressing surface, the forming die 11
The replaced upper punch 116 is lowered into the molding space 118 of 0 (see FIG. 11F). By the second temporary molding, the first layer 122 and the third layer 1 already shown in FIG.
26, the second layer 1 is formed in this step.
By pressurizing 24, three layers of raw material powders are pressed and engaged, and a three-layer brush 120 is formed.

As described above, in the present embodiment, the first and second temporary moldings are performed by the upper punches 232 and 234 having the inclined pressing surfaces, thereby manufacturing the three-layer brush 120 having the inclined boundary surface. ing. Therefore, the upper punches 232 and 234 can be used without significantly changing the conventional manufacturing apparatus.
A three-layer brush 12 can be obtained simply by adding a temporary molding process using
0 can be manufactured. Further, since the three-layer brush 120 formed in this manner already has a sloping boundary surface in the forming process, post-processing such as cutting is unnecessary, and no waste is caused in the material.

The present invention is not limited to the above embodiments, and various modifications can be made within the scope of the present invention.

For example, in the first to fifth embodiments described above,
As shown in FIG. 12, the first layer and the second layer
A case has been described in which the two-layer brush 100 is manufactured in which the boundaries of the layers coincide with each other. However, the inclination angle of this boundary surface is arbitrary, and does not need to coincide with the diagonal line.

Also, for the three-layer brush 120 shown in FIG. 15, the inclination of the boundary surface can be arbitrarily determined.

[0122]

According to the manufacturing apparatus and manufacturing method for a multilayer brush of the present invention as described above, according to the present invention, and pressed by punch two or more kinds of raw material powder after filling was poured into sequential layers,
Or perform preformed part, finally and manufactures multi-layer brush is pressed by punch, without significantly changing the conventional process machining after cutting or the like not be required, the waste of material Thus, an inexpensive multilayer brush can be manufactured.

Further, according to the method for manufacturing a multilayer brush of the present invention, by temporarily molding after charging the raw material powder, 2
Since the inclined boundary surface of the layer brush or the three-layer brush is formed, post-processing such as cutting is unnecessary, and there is no need to largely change the conventional process.

Further, according to the method for manufacturing a multilayer brush of the present invention, the pressing surface of the upper and lower punches is V-shaped concave shape, and the boundary surface is formed by one pressing step after the two kinds of raw material powders are sequentially charged. The two-layer brush is formed by pressurizing, so that post-processing such as cutting is unnecessary, and the conventional process can be applied as it is.

[Brief description of the drawings]

FIG. 1 is a diagram showing a cross-sectional structure of a manufacturing apparatus according to a first embodiment.

FIG. 2 is an explanatory view of a manufacturing process when a brush is manufactured using the apparatus of FIG. 1;

FIG. 3 is a diagram showing a vertical dimension and a horizontal dimension of a cross section of the two-layer brush.

FIG. 4 is a diagram illustrating a cross-sectional structure of a manufacturing apparatus according to a second embodiment.

FIG. 5 is a diagram illustrating a cross-sectional structure of a manufacturing apparatus according to a third embodiment.

FIG. 6 is a diagram illustrating a cross-sectional structure of a brush manufacturing apparatus according to a fourth embodiment.

FIG. 7 is an explanatory view of a manufacturing process when a brush is manufactured using the apparatus of FIG. 6;

FIG. 8 is an explanatory diagram of a manufacturing process of a fifth embodiment when manufacturing a two-layer brush.

FIG. 9 is an explanatory diagram of a manufacturing process of a sixth embodiment when manufacturing a three-layer brush.

FIG. 10 is an explanatory diagram of a manufacturing process of a seventh embodiment when manufacturing a three-layer brush.

FIG. 11 is an explanatory diagram of a manufacturing process of an eighth embodiment when manufacturing a three-layer brush.

FIG. 12 is a diagram showing a structure of a two-layer brush proposed by the present applicant.

FIG. 13 is a view showing an assembled state of the two-layer brush shown in FIG. 12;

FIG. 14 is an explanatory diagram of a case where a two-layer brush having a boundary surface inclined with respect to the upper and lower surfaces is cut out from a two-layer brush having a boundary surface parallel to the upper and lower surfaces.

FIG. 15 is a diagram showing a structure of a three-layer brush proposed by the present applicant.

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 forming die 12 upper punch 14 lower punch 18 forming space 20, 30 feeder 22, 32 filling space 24, 34 raw material powder reservoir 26, 36 raw material powder discharge device

────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Yoji Hino 390 Umeda, Kosai-shi, Shizuoka Prefecture Asmo Co., Ltd. (56) References JP-A-6-70511 (JP, A) JP-A-6-225501 (JP) JP-A-62-123939 (JP, A) JP-B-55-44431 (JP, B1) (58) Fields investigated (Int. Cl. ⁷ , DB name) H01R 43/12 H01R 39/26 H02K 13/00

Claims (5)

(57) [Claims] The pressing surface is inclined with respect to the horizontal.TapaNunch
And a molding space arranged at an angle to the horizontal,
NoteA forming die that forms a forming die together with the punch,With  The molding spaceTo 2More than one kind of raw material powderFill in layers sequentially
After that, with the punchPressurizing the multi-layer brush
An apparatus for manufacturing a multi-layer brush, which is formed by molding. 2. A method of manufacturing a multilayer brush having an inclined interlayer boundary surface, after filling successively charged in a layer two or more kinds of raw material powder constituting the multilayer brush molding die molding space is inclined , two or more of the raw material powder filled and pressed by punch, a method for manufacturing a multilayer brush, characterized by integrating the raw material powder by press molding. 3. A method of manufacturing a multi-layer brush having an inclined interlayer boundary surface, the method comprising temporarily forming a first raw material powder having a horizontal surface and an inclined surface.
The first brush that has been formed is removed from the molding cavity formed in the molding die.
After the second raw material powder is placed on the first brush in the molding space , the pressing surface is arranged perpendicular to the pressing direction. A method of manufacturing a multilayer brush, wherein the first and second raw material powders are pressed and integrated so as to have the inclined interlayer boundary surface by pressing with a punch. 4. A method for manufacturing a multi-layer brush having an inclined interlayer boundary surface, comprising: charging a first raw material powder into a molding die having a molding space; The first raw material powder is pressed by the upper punch and the lower punch to temporarily form the first brush, and after the second raw material powder is put on the first brush in the forming space, the first brush is pressed. The second brush is temporarily pressed by a second upper punch and a lower punch whose surface is inclined in a direction different from the first upper punch and the lower punch, and the second brush in the forming space is temporarily pressed. After the third raw material powder is put on the above, any pressing surface is pressed by a third upper punch and a lower punch perpendicular to the pressing direction, so that the inclined interlayer boundary surface is provided. First, second and third Method for manufacturing a multilayer brush, characterized by integrating the raw material powder is pressure-molded. 5. A method for manufacturing a multi-layer brush having an inclined interlayer boundary surface, wherein the pressing surface is in a V-shaped concave lower punch in a molding die having a vertical molding space. First
And after sequentially charging and charging the second raw material powder, the filled first and second raw material powders are pressed by the lower punch and the upper punch whose pressing surface has a V-shaped concave shape,
A method for producing a multi-layer brush, wherein the raw material powder is pressure-formed and integrated.