Ceramic center pin for compaction tooling and method for making same

Abstract

The present invention is a method and apparatus for the production of compacted powder elements. More specifically, the present invention is directed to the improvement of tooling for powder compaction equipment, and the processes for making such tooling. The improvement comprises the use of a ceramic tip or similar component in high wear areas of the tooling, particularly center pins. Moreover, the use of such ceramic components enables reworking and replacement of the worn tool component.

Description

[0003] This invention relates generally to compaction tooling components, and more particularly to a compaction tool, such as a center pin, incorporating a tip or wear surface comprising a ceramic component and the method for manufacturing and assembling such a center pin.

BACKGROUND ART AND DISCLOSURE OF THE INVENTION

[0004] The present invention is directed to improvements in the tooling used in compaction equipment and tableting machines, and particularly the tooling used in the equipment utilized in making components of dry-cell batteries, e.g., various sizes of 1.5 volt (AAA, AA, C, D) and 9 volt batteries used in consumer electronic devices. It will be further appreciated that various aspects of the invention described herein may be suitable for use with well-known compaction tooling and tableting equipment, and particularly to center pins and punches employed in the manufacture of oral pharmaceuticals, etc.

[0005] Heretofore, a number of patents have disclosed processes and apparatus for the forming of parts by the compression of unstructured powders, sometimes followed by heat-treating of the compressed part. The relevant portions of these patents may be briefly summarized as follows:

[0006] U.S. Pat. No. 5,036,581 of Ribordy et al, issued Aug. 6, 1991, discloses an apparatus and method for fabricating a consolidated assembly of cathode material in a dry cell battery casing.

[0007] U.S. Pat. No. 5,122,319 of Watanabe et al, issued Jun. 16, 1992, discloses a method of forming a thin-walled elongated cylindrical compact for a magnet.

[0008] U.S. Pat. No. 4,690,791 of Edmiston, issued Sep. 1, 1987, discloses a process for forming ceramic parts in which a die cavity is filled with a powder material, the powder is consolidated with acoustic energy, and the powder is further compressed with a mechanical punch and die assembly.

[0009] U.S. Pat. No. 5,930,581 of Born et al, issued Jul. 27, 1999, discloses a process for preparing complex-shaped articles, comprising forming a first ceramic-metal part, forming a second part of another shape and material, and joining the two parts together.

[0010] Referring to FIG. 1, there is illustrated a prior art compaction tool as might be employed for the production of a cylindrically shaped battery component. In use of such a tool in battery manufacturing, the die 20 receives a lower punch 22 that is inserted into the die. The lower punch includes a through-hole in the center thereof that allows a center pin 24 to be inserted therein. The punch and center pin then, in conjunction with the die, form a cavity into which a powder mix employed in battery manufacture can be deposited. Such a powder mix may include wetting agents, lubricating agents, and other proprietary solvents added just before filing the die cavity. Once filled, the cavity is then closed by an upper punch 26 that is inserted into the upper end of the die and the punches are directed toward one another so as to compact the powder material 28 therein. In typical systems, the compaction force is applied by mechanical and/or hydraulic systems so as to compress the powder material and produce a compacted part (e.g., a tablet or a cylindrical component), examples of which are described in the patents incorporated by reference above.

[0011] During the compaction process, however, the application of significant compressive forces results in a high friction level applied to the interior of the die surface in region 30 and to the exterior of the center pin tip in region 31. This friction force causes a high level of wear on the compaction tooling, resulting in the frequent need to change out and rework such tooling. Although it is known to employ ceramics in the interior region of the die, to reduce the wear from friction, ceramics have not been successfully employed on the center pin tip because of the difficulty in reliably affixing the ceramic to the center pin. Although a ceramic coating may be provided on a center pin tip by known methods, e.g. arc plasma spray coating, such coatings have not been found to be satisfactory.

[0012] Thus, it is often the case that the dies considerably outlast the center pins and that frequent replacement and rework of center pins continues to be a problem that plagues the powder compaction industry. One prior art method and apparatus for the manufacturing of cylindrical dry cell batteries, which entails the compression of powdered material is described in U.S. Pat. No. 5,036,581 of Ribordy et al, previously incorporated by reference.

[0013] The present invention is, therefore, directed to both an apparatus that successfully employs a ceramic component on the wear surfaces of a compaction tooling center pin or core rod, as well as the methods of making and repairing the same. In particular, the invention relies on various alternative embodiments for connecting a ceramic component to the end of a metal center pin base; the selection of the particular embodiment may be dependent upon the use characteristics for the apparatus.

[0014] In accordance with an aspect of the present invention, there is provided an apparatus for forming a powder material into a solid form through the application of pressure, comprising: a die; a lower compression punch insertable into a lower end of said die, said lower compression punch having a ceramic-tipped center pin passing therethrough where the ceramic reduces the wear of said outer surface of said center pin; means for filling at least a portion of the cavity defined by said die, said lower compression punch, and said center pin with the powder material; and an upper compression punch, insertable into an upper end of said die to compact the powder material.

[0015] In accordance with another aspect of the present invention, there is provided a method of manufacturing a compression center pin for use in a punch and die powder compaction apparatus, comprising the steps of: forming a center pin base of a rigid material (e.g., tool steel or pre-hardened steel); forming a center pin tip of a ceramic material (e.g., zirconia); and affixing the center pin tip to the center pin base.

[0016] In accordance with yet another aspect of the present invention, there is provided a method of repairing a compression center pin for use in a punch and die powder compaction apparatus, comprising the steps of: removing a center pin tip from a center pin base; reworking or replacing the center pin tip with a ceramic material (e.g., zirconia); and affixing the center pin tip to the center pin base.

[0017] One aspect of the invention is based on the discovery of techniques for connecting or semi-permanently affixing a ceramic tip for a center pin to the center pin base in a manner that will survive the high pressure and friction of the compaction apparatus. The techniques described herein not only allow for the successful attachment of ceramic tips, but also allow for the reworking and replacement thereof, so that only damaged or worn components are replaced, and not the entire center pin. It will be appreciated that solid ceramic center pins may be produced, however, they are believed to be cost prohibitive and difficult to repair and rework.

[0018] The techniques described herein are advantageous because they can be adapted to any of a number of compaction tooling applications. In addition, they can be used in other similar compaction embodiments to allow for the use of ceramic materials in high-friction environments where tool steels and other surface hardening processes fail to provide sufficient improvement in tool life. The techniques of the invention are advantageous because they provide a range of alternatives, each of which is useful in appropriate situations. As a result of the invention, the life of compaction center pins and other tooling may be significantly increased and the cost of reworking the same may be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG. 1 is a cross-sectional view of a prior art compaction tooling die, punch and center pin set for compaction of a powder material for use in a dry cell battery;

[0020] FIG. 2 is a cross-sectional view of the various components of FIG. 1, including an aspect of the present invention;

[0021] FIGS. 3A, 3B, 3C, 3D and 3E are cross-sectional views of the components and assemblies of embodiments of the present invention;

[0022] FIGS. 4A, 4B, and 4C are side elevation views of alternative center pin designs, for the purpose of illustrating, without limitation, three alternative configurations of attaching the center pin base to the associated tableting or compaction equipment;

[0023] FIGS. 5A and 5B are cross-sectional views of two alternative embodiments of the present invention;

[0024] FIGS. 6A and 6B are cross-sectional views of the components and assemblies of an alternative center pin made in accordance with the present invention;

[0025] FIGS. 7A, 7B and 7C are cross-sectional views of alternative embodiments of the present invention;

[0026] FIGS. 8A, 8B and 8B are view of an alternative means for connecting a ceramic tip to a center pin in accordance with yet another embodiment of the present invention;

[0027] FIG. 9 is a detailed cross sectional view of an embodiment of the present invention wherein a ceramic tip is joined to a base using adhesive, and wherein a shimming wire is helically disposed on the male part thereof to effect the alignment of such part with the female part; and

[0028] FIG. 10 is a cross sectional view of an additional embodiment of the present invention, in which a threaded fastener is used to join the parts thereof.

[0029] The present invention will be described in connection with a preferred embodiment, however, it will be understood that there is no intent to limit the invention to the embodiments described. On the contrary, the intent is to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

BEST MODE FOR CARRYING OUT THE INVENTION

[0030] For a general understanding of the present invention, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements.

[0031] Reference may also be had to Table 1, “Glossary Of Ceramic Terms”, and Table 2, “General Descriptions of Structural Ceramic Materials”, both Innex Industries, Inc. internal publications. Tables 1 and 2 are incorporated herein for their teachings of terms and properties related to ceramic materials used in the present invention.

TABLE 1
GLOSSARY OF CERAMIC TERMS: ZIRCONIA WEAR PARTS
TERM                  DEFINITION
Hardness              Hardness is the resistance of a material to com-
                      pression, deformation, denting, scratching, and
                      indentation. Hardness is a useful relative measure
                      rather than a material property, and is usually
                      measured by indentation.
                      Hardness important for wear resistance, but
                      higher hardness leads to lower toughness
                      Hardness greatly affected by ceramic processing
Vickers Hardness, Hv  The Vickers Hardness test is used for ceramics. It
Vickers Hardness      is similar to the Brinell Hardness test, using an
Number, VHN           indentor in the form of a square-based diamond
(metric units: GPa,   pyramid. The result is expressed as the load
Kg/mm2)               divided by the area of the impression.
Wear-resistance       Wear-resistance is generally defined as the pro-
                      gressive removal of material from the surface
                      under operational conditions.
                      High hardness, toughness, strength are best for
                      wear-resistance, but harder materials can lack
                      toughness
                      Correct material must be selected for the
                      application
Density               Mass per unit volume of a substance
(metric units: g/cm3,
Kg/m3)
Strength              The stress (force per area) required to rupture,
Flexural strength     crack, fracture, break the material
Modulus of Rupture,   High strength needed for impact and thermal
MOR 3 or 4-point-     shock
bend strength (metric Flaws cause fracture in ceramics and must be
units: MPa, GPa)      controlled by careful processing
Toughness             Toughness is described as the load per unit area
Fracture Toughness    required to initiate a crack when load is applied
Critical Stress In-   to a surface. Ceramics and glass are stronger than
tensity Factor K1c    metals, but less tough and fail by fracture
(metric units:        (cracking).
MPa-m1/2)             High toughness stops cracking
                      Toughness improves strength, impact resistance
                      Low toughness can lead to wear and fracture
Zirconia              Zirconia in the partially stabilized phase is a
Zirconium oxide       tough, white ceramic with fairly good hardness.
Zirconium dioxide     Alumina can be added to zirconia to increase the
ZrO2                  hardness. Zirconia's excellent wear resistant
Partially stabilized  properties depend on a phase change (martensitic
zirconia, PSZ         transformation) that limits the high temperature
Tetragonal zirconia   use. Fully stabilized zirconia is used in fuel
polycrystal, TZP      cells, oxygen sensors, and jewelry.
Alumina               Aluminum oxide is a very hard white ceramic that
Aluminum oxide        is stable at elevated temperatures but has fairly
Corundum              low toughness. Alumina is excellent in sliding
Al2O3                 wear, if there is no impact. Zirconia can be added
                      to alumina to increase the toughness.
Stabilizers           Stabilizers are added to zirconia to produce the
Additives             toughening effect. The stabilizers are oxide addi-
Stabilizing,          tives that change the zirconia to the toughened
stabilization         (partially stabilized) phase. These include yttria
Partially stabilized  (Y2O3), magnesia (MgO), calcia (CaO), and ceria
                      (CeO2). The additives also affect the hardness
                      of the zirconia.

[0032]

TABLE 2
GENERAL DESCRIPTIONS OF STRUCTURAL CERAMIC
MATERIALS
		COMMON	RELATIVE
MATERIAL	PROCESSING	APPLICATIONS	COST
Oxides
Alumina	Pressureless	Wide range of applications	1
Al2O3	sintering	including: Electronic sub-
	(1550-1700 C.)	strates, spark plug insula-
	Hot Isostatic	tors, transparent envelopes
	Pressing	for lighting, structural re-
	(HIPing)	fractories, wear resistant
		components, ceramic-to-
		metal seals, cutting tools,
		abrasives. Thermal insula-
		tion, catalyst carriers,
		biomedical implants
Zirconia	Pressureless	Wear resistant components,	3
(ZrO2)	sintering	cutting tools, engine com-
	(1500 C.)	ponents, thermal coatings,
		thermal insulation, bio-
		medical implants, fuel cell
Zirconia	Pressureless	Wear resistant components	3
Toughened	sintering
Alumina	(1500-1600 C.)
(ZTA)
Alumina	Pressureless	Wear resistant components	3
Toughened	sintering
Zirconia	(1500-1600 C.)
(ATZ)
Nonoxides
Silicon	Pressureless	Refractories, abrasives,	5
Carbide	sintering	mechanical seals, pump
(SiC)	Hot Pressing,	bearings
	HIPing
Silicon	Pressureless	Molten-metal-contacting	6
Nitride	sintering	parts, wear surfaces,
(Si3N4)	Hot Pressing,	Special electrical insulators,
	HIPing	metal forming dies,
	Reaction	Gas turbine components
	bonding.
Boron	Hot Pressing	Fine polishing, abrasive	10
Carbide	(2100-	resistant parts
(B4C)	2200 C.), Pres-
	sureless
	Sintering,
	HIPing
Titanium	Pressureless	Light weight ceramic	9
diboride	sintering	armor, nozzles, seals, wear
(TiB2)	Hot Pressing,	parts, cutting tools
	HIPing
Tungsten	Pressureless	Abrasives, cutting tools	3
Carbide	sintering
(WC)	Hot Pressing,
	HIPing
Relative cost is on a scale of 1 (low) to 10 (high) for dense material suitable for structural applications.
Note that gaps in the scale are indicative of large differences in cost.

[0033] Having described the basic operation of the compaction apparatus with respect to FIG. 1, attention is now turned to the particular components of the present invention as illustrated in FIG. 2. FIG. 2 is a cross-sectional view of the components similar to FIG. 1, wherein the center pin assembly 34, in accordance with the present invention, is comprised of a center pin base 40 and a center pin tip 42. In the embodiment, center pin tip 42 is preferably comprised of a structural ceramic material such as wear resistant ceramic oxides.

[0034] One such group of suitable wear resistant ceramic oxides is zirconia, which includes the species zirconium oxide, zirconium dioxide, tetragonal zirconia polycrystal (TZP), and partially stabilized zirconia (PSZ). Such partially stabilized zirconia may comprise stabilizers, e.g. yttria (Y2O3), magnesia (MgO), calcia (CaO), and ceria (CeO2). A second group of suitable wear resistant ceramic oxides is alumina, also known as aluminum oxide (Al2O3) and corundum. A third group of suitable wear resistant ceramic oxides comprises mixtures of zirconia and alumina, including zirconia toughened alumina (ZTA), comprising between about 5 weight percent Zr2O3 and about 40 weight percent Zr2O3. Further examples of suitable wear resistant ceramic oxides are found in Table 3, along with their relevant physical properties.

TABLE 3
PROPERTIES OF WEAR RESISTANT CERAMIC OXIDES.
	DENSITY	STRENGTH	HARDNESS	TOUGHNESS
MATERIAL	(g/cm3)	(MPa)	(GPa)	(MPa-m1/2)
Zirconia	5.9-6.2	400-1400	8-14	5-15
*Y-TZP	6.0	800-1400	13-14	5-8
**Y-PSZ	6.0	800-1400	12-13	5-8
+Ce-TZP	6.1-6.2	1000-1300	11-13	10-15
xMg-PSZ	5.9-6.0	400-1100	9-13	6-11
#Ca-PSZ	5.9-6.0	400-800	9-11	5-9
++Ce-PSZ	6.1-6.2	400-800	7-9	6-15
ZTA	4.1-5.0	300-1600	12-19	3-8
zirconia
toughened
alumina
5% ZrO2	4.1-4.2	300-500	15-19	3-5
20% ZrO2	4.4-4.5	500-1000	14-17	3-6
40% ZrO2	4.8-5.0	500-1600	12-16	4-8
AZ	5.4-5.6	800-2000	10-15	5-10
alumina
strengthened
zirconia
80% ZrO2	5.4-5.6	800-2000	10-15	5-10
Alumina	3.8-4.0	250-600	15-21	3-4
99% alumina	3.80	250-350	15-17	3-4
99.5%	3.8	300-400	17-19	3-4
alumina
99.9%	3.9-4.0	350-500	17-20	3-4
alumina
99.95%	3.9-4.0	350-600	18-21	3-4
alumina
Note:
The “stabilizing” additive is a minor addition to the zirconia, but has a significant effect on the hardness and toughness. In general, the higher toughness zirconias have lower hardness.
*Y-TZP (also called TZP) = Yttria stabilized Tetragonal Zirconia Polycrystal (special case of hard Y-PSZ)
**Y-PSZ = Yttria Partially Stabilized Zirconia
+Ce-TZP = Ceria stabilized Tetragonal Zirconia Polycrystal (new material-special case of tough Ce-PSZ)
xMg-PSZ = Magnesia Partially Stabilized Zirconia
#Ca-PSZ = Calcia Partially Stabilized Zirconia (not usually used in wear parts)
++Ce-PSZ = Ceria Partially Stabilized Zirconia

[0035] In one embodiment, center pin tip 42 was fabricated by machining a ceramic tube of zirconia supplied, for example, by the CoorsTeck Corporation. Such a tube was supplied in near net shape form, oversized by 0.030 on the outside diameter and undersized by 0.030 inch on the inside diameter. The tube was finished to a 0.250 inch inside diameter and a 1.250 inch outside diameter, using a cylindrical grinding machine tool.

[0036] In addition to ceramics, other materials are also suitable for the fabrication of a center pin tip, and to be considered within the scope of the present invention. For example, one may use a tip comprised of e.g., silicon carbide, tungsten carbide, titanium nitride, or carborundum. In one further embodiment, a tip comprising a pre-hardened steel sleeve having a diamond impregnated surface may be used.

[0037] Referring to FIG. 3A, the center pin assembly 34 includes at least three components. A first component is a center pin base 40, which is a generally cylindrical component having an aperture 38 in the lower end 39 thereof for controlling the position of the center pin with a shaft of the compaction apparatus (not shown) inserted into the aperture 38. It will be noted that the present invention contemplates use in any number of compaction tooling machines and that aperture 38 may be replaced by any center pin attachment design, for example, those depicted in FIGS. 4A, 4B, and 4C. In a first embodiment depicted in FIG. 4A, aperture 38 is replaced by center beam 38A. In a second embodiment depicted in FIG. 4B, aperture 38 is replaced by slot 38B. In a third embodiment depicted in FIG. 4C, aperture 38 is replaced by offset beam 38C.

[0038] It will be apparent that corresponding mating tools are provided in the drive mechanism (not shown) to properly engage each of these three embodiments and apply an upward axial force thereupon. It will be further apparent that many other suitable configurations of center pin assembly 34 may be used, with the operative requirement being that center pin assembly 34 comprises a surface that is engageable with a mating tool to apply a force along the axis of center pin assembly 34, as indicated by arrow 36 of FIGS. 3A-3E.

[0039] At the upper end 41 of the center pin base 40, in the embodiment of FIGS. 3A-3E, is a cylindrical hole 68 that extends into the center pin base 40 for approximately 1.50 inches. Hole 68 may have a depth in the range of 0.500 inches to 2.000 inches. The center pin base is preferably made from tool steel or pre-hardened steel, although various metals and possibly other materials may be employed. The compositions and properties of suitable tools steels and pre-hardened steels are provided on pp. 2069-2095 of Machinery's Handbook, 22nd Ed., the disclosure of which is incorporated herein by reference.

[0040] Referring again to FIGS. 3A-3E, a second component of center pin assembly 34 is a ceramic tip 42 that forms the wear surface of the center pin assembly 34. Ceramic tip 42 is attached to center pin base 40 using a third component, mandrel arbor 44, preferably made from tool steel or pre-hardened steel. As illustrated, mandrel arbor 44 is generally cylindrical, but includes either a tapered head at an upper end 37 thereof mated with tapered hole in ceramic tip 42 (e.g., FIG. 3A), a square head mated with counterbored hole in ceramic tip 42, so as to provide a positive engagement between mandrel arbor 44 and the ceramic tip 42 (e.g., FIGS. 3B-3D), or a box head at upper end 37 having a shoulder in positive contact with a flat upper surface 75 of the ceramic tip 42 (e.g., FIG. 3E).

[0041] In one embodiment depicted in FIG. 3A, ceramic tip 42 comprises a tapered hole 47, and mandrel arbor 44 comprises a matching tapered head 45, which is congruent with tapered hole 47 of ceramic tip 42, when center pin assembly 34 is fully assembled. In a more embodiment depicted in FIGS. 3B-3D, ceramic tip 42 comprises a counterbored hole 53 having a shoulder, and mandrel arbor 44 comprises a matching square head 57, which is congruent with counterbored hole 53 of ceramic tip 42, when center pin assembly 34 is fully assembled.

[0042] To affix ceramic tip 42 to base 40, the components 40 and 42 may be fastened together by a number of joining methods known in the art, such as the methods disclosed in “Mechanical and Industrial Ceramics” published in 2002 by the Kyocera Industrial Ceramics Corporation of Vancouver, Wash. As recited at page 19 of such publication, “Joining Ceramics to Other Materials” bonding methods include screwing, shrink fitting, resin molding, metal casting, organic adhesives, inorganic adhesives, inorganic material glazing, metallizing, and direct brazing. Soldering may also be a suitable joining method.

[0043] In the embodiment depicted in FIG. 3A, one end 51 of mandrel arbor 44 is provided with an outside diameter sufficient to provide joining by gluing or by an interference fit with the inside diameter of the hollow or hole 68 in the center pin base 40. Such an interference fit is preferably achieved by performing a shrinkage fit, wherein base 40 is heated, and expands sufficiently to slide over mandrel arbor 44. A description of allowances and tolerances for fits between two parts may be found in Machinery's Handbook, 22nd Ed. pp. 1517-1566, the disclosure of which is incorporated herein by reference. In particular, the assembly of parts by a shrinkage fit is described on pp. 1520-1524.

[0044] To assemble the center pin assembly 34 by use of a shrinkage fit, two operations are required. In the first operation, mandrel arbor 44 is fitted within ceramic tip 42. Mandrel arbor 44 may be a slip fit within ceramic tip 42. In one embodiment, mandrel arbor 44 is an interference fit within ceramic tip 42. In such an embodiment, either mandrel arbor 44 is cooled, or ceramic tip 42 is heated, or both, and mandrel arbor 44 is inserted through and engaged with ceramic tip 42, as shown in FIG. 3A. Assembled ceramic tip 42 and mandrel arbor 44 are allowed to thermally equilibrate with each other and reach approximately room temperature, whereupon such parts are firmly joined with an interference fit.

[0045] In another embodiment of an interference fit between mandrel arbor 44 and ceramic tip 42, both mandrel arbor 44 and ceramic tip 42 are maintained at room temperature, and mandrel arbor 44 is “press fit” through ceramic tip 42 using a pressing machine. In another embodiment, mandrel arbor 44 and ceramic tip 42 are joined together using an adhesive. Suitable adhesives are described elsewhere in this specification. Alternatively, mandrel arbor 44 and ceramic tip 42 are joined together by brazing.

[0046] Subsequent to the formation of an arbor and tip subassembly, the subassembly is joined to base 40. In one embodiment, base 40 is heated preferably by induction heating means, to expand the diameter of hole 68 therein. The lower end 51 of mandrel arbor 44 extending beyond tip 42 is then press fit into the heat-expanded hole 68. Once assembled, the assembly 34 may be air cooled or quenched in a synthetic oil or similar liquid to cool the base and to prevent damage to the ceramic from uneven heating.

[0047] In one embodiment, mandrel arbor 44 was fabricated of Histar 40 pre-hardened steel with a diameter of 0.252 inch at its end 51. Base 40 was fabricated of Histar 40 pre-hardened steel with an outside diameter of 0.50 inch, and a hole 68 therein of 1.50 inches in length and 0.250 inch in diameter. Base 40 was heated to a temperature of between 600° and 1000° Fahrenheit using induction heater Model No. 301-0114H of the Ameritherm Corporation, Inc. of Scottsville, N.Y. End 51 of mandrel arbor 44 was then immediately slidably inserted into heat-expanded hole 68 of base 40 to a depth wherein the ends of ceramic tip 42 and base 40 were in contact with each other. The resulting assembled center pin assembly 34 was then air cooled to approximately 100° Fahrenheit.

[0048] In an alternative embodiment, instead of or in addition to an interference fit, mandrel arbor 44 may be attached to the base 40. In a manner similar to that described above, and referring to FIG. 3B, mandrel arbor 44 is inserted through the tip 42, and into hole 68 in base 40. Once assembled, a retainer pin 48 is inserted through coaxially aligned hole 46 in base 40 and hole 49 in mandrel arbor 44 as illustrated in FIG. 3B. In one embodiment, it is contemplated that the holes 46 in base 40 and hole 49 in mandrel arbor 44 are not drilled until the components are assembled and mandrel arbor 44 and tip 42 are held in a compressive relationship, thereby assuring a “tight” attachment of the tip 42 to the base 40. In one embodiment, retainer pin 48 comprises pre-hardened steel of the same composition as mandrel arbor 44 of FIG. 3B.

[0049] FIGS. 3C and 3D depicts alternate embodiments of means for securing mandrel arbor 44 to base 40. Referring to FIG. 3C, in one embodiment, center pin assembly 34 further comprises a setscrew 58, which is threadably engaged with tapped hole 59. Tapped hole 59 and the threads therein are formed through both center pin base 40 and mandrel arbor 44. Thus, it is preferable that in the process of assembly of center pin base 40 and mandrel arbor 44, mandrel arbor 44 is pressed into center pin base 40, and tapped hole 59 is formed by drilling and tapping while mandrel arbor 44 and center pin base 40 are forcibly held together, followed by the screwing of setscrew 58 into hole 59, until setscrew 58 has been forced into the bottom of hole 59.

[0050] In one embodiment, setscrew 58 is bonded into tapped hole 59 by a thread locking sealant such as e.g. a cyanoacrylate adhesive. In another embodiment, setscrew 58 is a self locking setscrew, provided with a plastic (e.g. nylon) insert along its threaded length, which is deformed when setscrew 58 is engaged with tapped hole 59. Such self-locking setscrews are well known in the art. In another embodiment, setscrew 58 is a self locking setscrew, having a coating of microencapsulated beads of reactive resin and hardener, such that when setscrew 58 is threadably engaged with tapped hole 59, the shearing action of threads of setscrew 58 with threads of tapped hole 59 rupture and mix the contents of the microencapsulated beads, thereby making an adhesive composition (e.g. an epoxy), which locks setscrew 58 into tapped hole 59. Such reactive adhesive coatings for the securing of threaded fasteners are well known in the art.

[0051] Referring to FIG. 3D, and in further embodiments, a plug 61 of material is engaged with hole 63 to effect the fastening of mandrel arbor 44 to base 40. As was described for the uses of a setscrew fastener, it is preferable that mandrel arbor 44 is pressed into center pin base 40, and hole 63 is formed by drilling through base 40 into mandrel arbor 44 while mandrel arbor 44 and center pin base 40 are forcibly held together, followed by the engagement of plug 61 of material with hole 63. The manner in which plug 61 of material is engaged with hole 63 depends upon the material composition of plug 61.

[0052] In one embodiment, plug 61 is a dowel pin, preferably made of a pre-hardened steel of the same composition as mandrel arbor 44 of FIG. 3B. In such circumstances, plug 61 is dimensioned to have an interference fit in hole 63, and plug 61 is forcibly pressed into hole 63. In a similar embodiment, hole 63 is formed in a rectangular shape, and plug 61 is formed from a matching piece of rectangular key stock, and pressed into hole 63.

[0053] In other embodiments, plug 61 is engaged with hole 63 by a phase change and/or an alloying operation. Plug 61 may be of the same composition as mandrel arbor 44 and base 40, so that plug 61 may be welded into hole 63. Alternatively, plug 61 may be brazed into hole 63. Plug 61 may comprise a plug of solder, such that plug 61 is heated and melted, and flows into hole 63, whereupon plug 61 cools and solidifies therein.

[0054] Alternatively or additionally, adhesives may be used to join mandrel arbor 44 and base 40. Such adhesives may be applied to the wall surface of hole 68 of base 40, or the end 51 of mandrel arbor 44 and/or the tapered surface 45 of mandrel arbor 44 (see FIG. 3A), or the stepped surface 57 of mandrel arbor 44 (see FIGS. 3B-3D), followed by inserting of mandrel arbor 44 into base 40.

[0055] Suitable adhesives for such assembly may be e.g. cyanoacrylates, epoxies, and the like, and such adhesives may also include metal and/or ceramic fillers to match properties such as thermal expansion coefficient with those of mandrel arbor 44 and base 40. One suitable product line of adhesives is manufactured by the Cotronics Corporation of Brooklyn, N.Y. In one embodiment, Cotronics Duralco 4535 Vibration Proof Structural Adhesive was used to join mandrel arbor 44 to base 40. Other suitable adhesives manufactured by Cotronics are Resbond S5H13 epoxy, Duralco 4540 Liquid Aluminum Epoxy, and Duralco 4703 Adhesive and Tooling Compound. Such adhesives are described in Cotronics Corporation sales bulletin Volume 01 Number 41, “High Temperature Materials and Adhesives for Use to 3000°F.”. Other suitable adhesives used in ceramic-ceramic and ceramic-metal bonding may be used such as e.g., dental adhesives.

[0056] Referring to FIG. 3E, and in further embodiments, a plug or pin 61 of material is engaged within hole 63 to effect the fastening of mandrel arbor 44 to base 40. As was described for the uses of a setscrew fastener, it is preferable that mandrel arbor 44 is pressed into center pin base 40, and hole 63 is formed by drilling through base 40 into mandrel arbor 44 while mandrel arbor 44 and center pin base 40 are forcibly held together, followed by the engagement of plug 61 of material with hole 63. The manner in which the plug of material 61 is engaged with hole 63 depends upon the material composition of plug 61.

[0057] In one embodiment, plug 61 is a dowel pin, preferably made of a pre-hardened steel of the same composition as mandrel arbor 44 of FIG. 3B. In such circumstances, plug 61 is dimensioned to have an interference fit in hole 63, and plug 61 is forcibly pressed into hole 63. In a similar embodiment, hole 63 is formed in a rectangular or other shape, and plug 61 is formed from a matching piece of key stock, and pressed into hole 63.

[0058] In other embodiments, plug 61 is engaged with hole 63 by a phase change and/or an alloying operation. Plug 61 may be of the same composition as mandrel arbor 44 and base 40, so that plug 61 may be welded into hole 63. Alternatively, plug 61 may be soldered or brazed into hole 63. Plug 61 may comprise a plug of solder, such that plug 61 is heated and melted, and flows into hole 63, whereupon plug 61 cools and solidifies therein.

[0059] In the optional embodiment, also depicted in FIG. 3E, a second pin 61′ may be inserted in a through-hole 63′ to cause the sleeve 42 to be affixed to the mandrel 44. It will be further appreciated that yet another alternative to this embodiment may employ a mandrel 44 that is simply a shaft without a head 37, and where sleeve 42 is a cup-shaped member such as depicted in FIG. 8A. Assembly of such an embodiment would require fastening the cylindrical mandrel to the base 40 and then to the sleeve.

[0060] It will be appreciated that the reworking of the ceramic tip, in the event of wear or damage, can be easily accomplished by pressing retainer pin 48 out of the assembly 34, replacing the worn ceramic tip 42 and reinstalling the mandrel arbor 44 and retainer pin 48. A similar reworking method may be employed for the first embodiment, where the interference fit between the base and the mandrel arbor 44 is released by heating the base, thereby allowing mandrel arbor 44 to be pulled from the base. Such a process is believed to be superior to the complete replacement or known stripping, re-plating, and regrinding operations presently used to rework worn metal center pins. Such a process is clearly superior from an environmental, health, and safety standpoint, as the practice of chrome plating requires the use of hexavalent chromium reagent.

[0061] Referring next to FIGS. 5A and 5B, there are illustrated two alternative embodiments of the center pin 34. In the embodiment of FIG. 5A, the center pin 34 consists of only two components: base 50 and ceramic tip 56. Base 50 has a shoulder 52 and a shaft 54 extending outwardly beyond shoulder 52. Ceramic tip 56 is formed as a hollow sleeve or tube, with an outside diameter, and an inside diameter. The shaft 54 of base 50 is made to slidably fit within the inner diameter of ceramic tip 56. In this embodiment, the ceramic tip 56 may be affixed to shaft 54 by brazing the ceramic to the steel of the base 50 with a brazing compound. Brazing compound flows by capillary forces into the interstice 55 between the surfaces of shaft 54 and ceramic tip 56. For such purposes, it is believed that Ticusil (Ag 49.7%, Cu 47.2%, Ti 3.1%) or Cusil (Ag 55.4%, Cu 36.5%, Ti 8.1%) brazing compounds sold by Wesgo Metals of San Carlos, CA may prove suitable for such brazing of the ceramic tip 56 to the steel shaft 54 of base 50. A description of the art of brazing and the composition and properties of various brazing compounds is provided on pp. 2197-2204 of Machinery's Handbook, 22nd Ed., the disclosure of which is incorporated herein by reference.

[0062] In the alternative embodiment of FIG. 5B, the base 60 is formed as described with respect to base 40 of FIG. 3A. However, instead of employing an arbor to attach the ceramic tip, the ceramic tip 62 itself includes a shoulder 64 and a shaft 66 extending therefrom. The shaft 66 may be inserted into hole 68 of the center pin base 60 and brazed with brazing compound so as to retain the ceramic tip 62 therein. Brazing compound flows by capillary forces into the interstice 65 between the surfaces of shaft 66 and hole 68. Alternatively, instead of brazing, it may be possible to produce the shaft 66 and base 50 so as to provide an interference fit between these parts as described above.

[0063] In a further alternative embodiment, the shaft 66 may be produced with a slight negative taper—where the extreme end of the shaft 66 is larger in diameter than the end nearest shoulder 64, and the diameter of the entire shaft being of a diameter so as to be interference fit with the inside diameter of hollow 68. Then, in order to assemble the tip 62 to the base 60, the base is heated, preferably by induction heating, to expand the diameter of the hollow 68 sufficiently to allow the tapered shaft of the tip 62 to slide into the hollow. Once cooled to ambient temperature, the interference fit, or alternatively the taper of the shaft, would serve to hold the ceramic tip in semi-permanent attachment to the base. In this embodiment, it will be appreciated that reworking of a worn tip may be accomplished simply by heating the base 60 to remove the worn tip and inserting a new tip therein, thereby significantly reducing the steps and labor of rework.

[0064] Alternatively, an adhesive may be used to join ceramic tip 56 and base 50 of FIG. 5A, or ceramic tip 62 to base 60 of FIG. 5B. Such adhesives may be applied to the respective tip or base in the same manner as described for the embodiments of FIGS. 3A-3D, followed by the engagement of the tip with the base.

[0065] Attention is now turned to FIGS. 6A and 6B, where a smaller diameter center pin is depicted. The reduced diameter leads to additional considerations in the methods by which the center pin assembly 34 might be produced in order to provide the ceramic tips of the present invention. More specifically, center pin base 70, has a cylindrical hole 68 that extends into the center pin base for approximately 2.25 inches, but perhaps as far as aperture 38. Ceramic tip 72 forms the center pin tip so as to provide a wear resistant surface for the center pin assembly 34. Tip 72 is attached to the base using the mandrel arbor 74 as in the previously described embodiment shown in FIG. 3A, and an interference fit is used to retain the mandrel arbor 74 therein. Alternatively, in the embodiment depicted in FIG. 6B, a retainer pin 78 is inserted into hole 76 in the base 70 and hole 79 in mandrel arbor 74 to assemble the center pin assembly 34 as depicted in FIG. 6B. It is further contemplated, due to the reduced diameter of the top of center pin base 70, that the mandrel arbor 74 may be extended (and the cylindrical hollow 68 in the base 70 as well) so that the mandrel arbor 74 extends further into the base 70. Retainer pin hole 76 is correspondingly lower on the base 70, located in a region where the diameter of the base is somewhat larger than the minimum diameter at the tip, possibly near hole 38, where the diameter is at a maximum.

[0066] Alternatively or additionally, an adhesive may be used to join mandrel arbor 74 and base 70 of FIGS. 6A and 6B. Such adhesives may be applied to mandrel arbor 74 or base 70 in the same manner as described previously for the center pin assembly 34 of FIGS. 3A-3D, followed by the engagement of mandrel arbor 74 with base 70.

[0067] Referring to FIGS. 7A and 7B, there are illustrated two additional embodiments of the reduced diameter center pin assembly 34. In the embodiment shown in FIG. 7A, the center pin assembly 34 consists of only two components, a base 80 having a shoulder 82 and a shaft 84 extending outwardly beyond shoulder 82. The shaft 84 is made to slidably fit within the hole 88 of ceramic tip 86. In this embodiment, the ceramic tip 86 may be affixed to shaft 84 by brazing the ceramic to the steel of the base 80 (as shown in FIG. 5A). For such purposes, it is believed that Ticusil or Cusil (as previously described) may prove suitable for such brazing or soldering so as to bond the ceramic to the steel shaft. It is known that such brazing materials may be used in a sheet or paste form.

[0068] In the alternative embodiment shown in FIG. 7B, the base 90 is formed with a cylindrical hollow 98, and ceramic tip 92 includes a shoulder 94 and a shaft 96 extending therefrom. The shaft may be inserted into the hollow cylindrical region 98 and brazed so as to retain the ceramic tip therein (as shown in FIG. 5B). In a further alternative embodiment, the shaft 96 may be produced with a slight negative taper. Then, in order to assemble the tip 92 to the base 90, the base 90 is heated, preferably by induction heating means, to expand the inner diameter of hollow 98 sufficiently to allow the tapered shaft 96 of the tip 92 to slide into the hollow 98. Once cooled to ambient temperature, the taper of the shaft 96 would serve to hold the ceramic tip 92 in semi-permanent attachment to the base 90.

[0069] Alternatively or additionally, adhesives may be used to join shaft 84 and ceramic sleeve 86 of FIGS. 7A and 7B, in the same manner as recited previously for the center pin assembly 34 of FIGS. 3A-3D.

[0070] Alternatively or additionally, an adhesive may be used to join shaft 84 and ceramic sleeve 86 of FIGS. 7A and 7B. Such adhesives may be applied to the shaft 84 or ceramic sleeve 86 in the same manner as described previously for the center pin assembly 34 of FIGS. 3A-3D, followed by the engagement of shaft 84 with ceramic sleeve 86.

[0071] FIG. 7C depicts a further alternative embodiment of the means for securing a sleeve (open end shown) or ceramic cap (closed end not shown) 42 to shaft 84 extending from base 40. Referring to FIG. 7C, and in further embodiments, a plug or pin 77 of material is engaged with a throughhole 78 to effect the fastening of the sleeve 42 to the shaft 84. As was described for the previous pin fastening techniques, it is believed preferable that the sleeve is formed with a through-hole 78 therethrough, whereas hole 78 through the shaft 84 is formed by drilling when the sleeve and the shaft are forcibly held together, followed by the engagement of plug 77 of material with hole 78. The manner in which plug 77 of material is engaged with hole 78 depends upon the material composition of plug 77.

[0072] In what may be a preferred embodiment, sleeve 42 may first be affixed to shaft 84 using one of the various adhesives described herein. Adhesives that may find particular use are a two-part adhesive sold under the trade name Permatex® Cold Weld Bonding Compound or JB Cold Weld. The adhesives are two-part adhesive and filler systems that eliminate the need for welding or brazing, yet withstanding temperatures up to 300° F. and exhibiti over 3,000 PSI shear strength on steel.

[0073] In one embodiment, plug 77 is a dowel pin, preferably made of a pre-hardened steel of the same composition as the shaft. In such circumstances, plug 77 is dimensioned to have an interference fit in hole 78, and plug 77 is forcibly pressed into hole 78. In a similar embodiment, hole 78 is formed in a rectangular or other shape, and plug 77 is formed from a matching piece of key stock, and pressed into hole 78.

[0074] In other embodiments, plug 77 is engaged with hole 78 by a phase change and/or an alloying operation. Plug 77 may be of the same composition as base 40, so that plug 77 may be welded into hole 78. Alternatively, plug 78 may be soldered or brazed into hole 78. Plug 77 may comprise a plug of solder, such that plug 77 is heated and melted, and flows into hole 78, whereupon plug 77 cools and solidifies therein. Once assembled, the ends of the plug may be finish ground so as to provide a smooth profile with the outer surface of sleeve 42.

[0075] As indicated in FIG. 7C, the plug 77 and hole 78 are preferably located near the bottom of sleeve 42 in a region that is not subject to severe compaction forces that are present during the compaction cycle. By locating the plug and hole at the bottom, the fastening means will provide adequate fastening of the sleeve 42 to the shaft 84.

[0076] Referring to FIG. 7C, and in further embodiments, a plug or pin 61 of material is engaged with hole 63 to effect the fastening of mandrel arbor 44 to base 40. As was described for the uses of a setscrew fastener, it is preferable that mandrel arbor 44 is pressed into center pin base 40, and hole 63 is formed by drilling through base 40 into mandrel arbor 44 while mandrel arbor 44 and center pin base 40 are forcibly held together, followed by the engagement of plug 61 of material with hole 63. The manner in which the plug of material 61 is engaged with hole 63 depends upon the material composition of plug 61.

[0077] In one embodiment, plug 61 is a dowel pin, preferably made of a pre-hardened steel of the same composition as mandrel arbor 44 of FIG. 3B. In such circumstances, plug 61 is dimensioned to have an interference fit in hole 63, and plug 61 is forcibly pressed into hole 63. In a similar embodiment, hole 63 is formed in a rectangular or other shape, and plug 61 is formed from a matching piece of key stock, and pressed into hole 63.

[0078] In other embodiments, plug 61 is engaged with hole 63 by a phase change and/or an alloying operation. Plug 61 may be of the same composition as mandrel arbor 44 and base 40, so that plug 61 may be welded into hole 63. Alternatively, plug 61 may be soldered or brazed into hole 63. Plug 61 may comprise a plug of solder, such that plug 61 is heated and melted, and flows into hole 63, whereupon plug 61 cools and solidifies therein.

[0079] Turning next to the various embodiments depicted in FIGS. 8A-8C, there are depicted a series of further alternative embodiments for the attachment of the ceramic tip or sleeve 42 to the base 40. These embodiments, as some of those described above, are intended to add a second level or backup means for fastening the ceramic sleeve or tip 42 to the base. Such a feature is believed to greatly improve the reliability of the center pin in use and to prevent damage to related equipment and machinery (e.g., dies).

[0080] More specifically, each of the attachment mechanisms illustrated in FIGS. 8A-8C include the use of a threaded member to assure the complete coupling of the assembly. It will be appreciated that it may also be possible to continue to utilize an adhesive or similar means to resist the loosening of the threaded members once they are assembled.

[0081] Referring to FIG. 8A, depicted therein is a first embodiment using a threaded attachment means for coupling the inverted, cup-shaped ceramic tip 142 to the base 40. In particular, cup-shaped tip 142 is preferably constructed from a green ceramic that is formed to a desired shape, fired and then finish machined as described above. In one method, the forming process may include near net-shape molding of the ceramic in a mold. In this way it may be possible to provided the threads on the inside diameter in region. It may also be appreciated that the threads on the inside diameter of tip 142 and on the outside diameter of shaft 84 may cover all or only a portion of the contact region between the respective inside and outside diameters, where a non-threaded region of the shaft outside diameter and the tip inside diameter may be used to assure proper alignment of the two components. It is also believed to be preferably to assure that the length of shaft 84 is slightly less that the depth of the corresponding hole in the tip so that the tip may be assembled to be in positive engagement with the base at shoulder 82.

[0082] As further depicted in FIG. 8A, the tip may have a chamfered or radiused upper edge so as to allow it to easily fit within the corresponding die (20 of FIG. 1). Once assembled, tip 142 may be locked in place by the insertion of a plug or pin 77 into a through-hole 78 that is drilled through shaft 84. As described above, the pin may be a steel dowel pin, preferably made of a pre-hardened steel. In such circumstances, pin 77 is dimensioned to have an interference fit in hole 78, and pin 77 is forcibly pressed into hole 78. In a similar embodiment, hole 78 is formed in a rectangular or other shape, and pin 77 is formed from a matching piece of key stock, and pressed into hole 78.

[0083] In other embodiments, pin 77 is engaged with hole 78 by a phase change and/or an alloying operation. Pin 77 may comprise a plug of solder, such that plug 77 is heated and melted, and flows into hole 78, whereupon plug 77 cools and solidifies therein. In yet another alternative embodiment, pin 77 may be replaced by a threaded screw as depicted in FIG. 3C.

[0084] Turning next to FIG. 8B, depicted therein is an embodiment similar to that shown in FIG. 3E, with the exception that the mandrel arbor is now threaded on at least a lower end thereof in region 150. More specifically, screw threads 152 on the outside diameter of the mandrel arbor 44 are engaged with mating threads on the inside diameter of hole 68 in the center pin base 40. Furthermore, the top of mandrel arbor 44 is not only chamfered or radiused, but preferably includes a hexagonal hole 158 for the receipt of a hex wrench for tightening the mandrel arbor to the base and clamping the ceramic sleeve 42 therebetween. Here again, as described above, the outside diameter of the non-threaded region of mandrel arbor 44 may be in toleranced contact with the inside diameter of the ceramic sleeve in order to assure the accurate positioning of the ceramic sleeve with the base (longitudinally aligned). It will also be appreciated that a series of concentric ridges or a rim in the region of shoulder 41 may also serve to provide for the alignment of the sleeve with the base.

[0085] FIG. 8C illustrates a further alternative embodiment of the present invention wherein the base includes a hollow shaft 84 extending from the base. The outer diameter or surface of the shaft is in direct contact with the inner diameter of the ceramic sleeve 42 as described in the embodiments of FIGS. 5A and 7A. However, in addition to gluing or otherwise affixing the ceramic sleeve to the shaft, a mandrel arbor 44 is again employed. In this embodiment, the mandrel arbor preferably includes a lower region that is at least partially threaded so that a hex wrench may be used in hex hole 158 to tighten or secure the mandrel arbor to the base. In this manner, mandrel arbor 44 is not relied upon to position the ceramic sleeve relative to the longitudinal axis of the base, but to provide a compressive force to assure the contact of the ceramic sleeve and the base at shoulder 41. As has been well described above, this embodiment may also include a pin, plug 61 or even a set screw (not shown) to assure that the threaded mandrel arbor does not back our or loosen from the base.

[0086] It will, of course, be further appreciated that the height of shaft 84 (the distance it extends from the base beyond shoulder 41, is a matter of design preference. Although shown as extending entirely through the ceramic sleeve 42, it is also possible that the shaft extends only partially into the sleeve, or even that it is only a small protrusion from the shoulder in the nature of a rim as described above.

[0087] In all of the preceding embodiments of FIGS. 3A-8C, in which adhesive is or may be used as to join a base and a tip together, there is formed an interstice (such as e.g. interstice 55 of FIG. 5A) between such parts, in which the adhesive (such as e.g. a liquid glue) flows and contacts the surface of such parts. Such an interstice is typically between 0.001 and 0.002 inches wide. In one embodiment, a fixture is used, which coaxially aligns such parts when the male part is inserted into the female part, and maintains such alignment until the adhesive is cured.

[0088] In another embodiment, a shimming wire is used to provide coaxial alignment of the parts of a center pin assembly. FIG. 9 is a detailed cross sectional view of an embodiment of the present invention wherein a ceramic tip is joined to a base using adhesive, and wherein a shimming wire is helically disposed on the male part thereof to effect the alignment of such part with the female part. Referring to FIG. 9, the upper end of the center pin assembly 34 of FIG. 5A is depicted, with ceramic tip 56 shown in cross-section. The front portion of ceramic tip 56 is thus removed, thereby exposing shaft 54 of base 50.

[0089] A shimming wire 67 is helically disposed around shaft 54, beginning near shoulder 52 of base 50, and ending near the top 43 of ceramic tip 56. Shimming wire 67 is of a uniform diameter along its length, equal to the width of interstice 55 between shaft 54 and ceramic tip 56. Thus, shimming wire 67 serves the purpose of maintaining shaft 54 and ceramic tip 56 in coaxial alignment when shaft 54 and ceramic tip 56 are assembled.

[0090] When shaft 54 and ceramic tip 56 are joined together with an adhesive, such adhesive occupies interstice 55, and shimming wire 67 maintains the coaxial alignment of shaft 54 and ceramic tip 56 while such adhesive cures. Suitable adhesives may be the same as those described for the embodiments of FIGS. 3A-3D.

[0091] Shimming wire 67 is preferably disposed around shaft 54 for at least three full 360 degree turns, along at least half of the length of shaft 54. In one embodiment, interstice 55 has an average width of 0.005 inches; shimming wire has a diameter of 0.005 inches.

[0092] In the preceding embodiment, shaft 54 is considered to be the male part of center pin assembly, and ceramic tip 56 is considered to be the female part. It is to be understood that the preceding description is also applicable to the center pin assemblies of, for example, FIGS. 3A, 5B, 6A, 6B, 7A, 7B, and 8C, wherein the shimming wire is helically disposed around the equivalent male (shaft) part. It is also to be understood that a narrow ribbon of shim stock having a rectangular cross section and a uniform thickness could be substituted for the shimming wire of the preceding embodiments, wherein such shim stock ribbon is helically disposed about the male part of the center pin assembly, thereby achieving substantially the same result.

[0093] In a further alternative embodiment, mandrel arbor 44 (FIG. 3A) or shaft 66 (FIG. 5B), or various other mating surfaces as described herein, may include a threaded portion to engage with a threaded mating portion of the base. For example, referring to FIG. 3A, a lower portion 51 of mandrel arbor 44 may include threads that are screwed into threaded interior region within the base 40. It is further contemplated that the exposed (top) end of mandrel arbor 44 may then have a slot, hex key or similar mechanism (not shown) to tighten mandrel arbor 44 within the base. Moreover, the use of a retaining pin or similar mechanism may be employed to lock the threaded shaft within the base.

[0094] In another embodiment, the center pin assembly of the present invention, which comprises a ceramic tip and a base, is joined together with a threaded fastener. FIG. 10 is a cross sectional view of such an embodiment, in which a threaded fastener is used to join the ceramic tip to the base. Referring to FIG. 10, base 50 of ceramic pin assembly 34 is similar to base 50 of FIG. 5A, but further comprises a threaded hole 69 tapped in the end thereof. Ceramic tip 56 is similar to ceramic tip 42 of FIG. 3B, comprising a counterbore 53 disposed in the end 43 thereof. A threaded fastener 71 having a square shoulder 73 (such as, e.g. a socket head cap screw) is engaged with threaded hole 69 such that square shoulder 73 bears upon the base of counterbore 53 of ceramic tip 42, thereby securing ceramic tip 42 to base 50.

[0095] In one embodiment, threaded fastener 71 is bonded into tapped hole 69 by a thread locking sealant such as e.g. a cyanoacrylate adhesive. In another embodiment, threaded fastener 71 is a self locking setscrew, provided with a plastic (e.g. nylon) insert along its threaded length, which is deformed when threaded fastener 71 is engaged with tapped hole 69. Such self-locking screws are well known in the art. In another embodiment, threaded fastener 71 is a self locking screw, having a coating of microencapsulated beads of reactive resin and hardener, such that when threaded fastener 71 is threadably engaged with tapped hole 69, the shearing action of threads of threaded fastener 71 with threads of tapped hole 69 rupture and mix the contents of the microencapsulated beads, thereby making an adhesive composition (e.g. an epoxy), which locks threaded fastener 71 into tapped hole 69. Such reactive adhesive coatings for the securing of threaded fasteners are well known in the art.

[0096] In the embodiment of FIG. 10, the inner diameter of ceramic tip 42 and the diameter of shaft 54 are preferably chosen such that the width of interstice 55 is substantially zero, and ceramic tip 42 requires only a hand press fit to be assembled onto shaft 54. Thus, by providing a center pin assembly comprising a threaded fastener and ceramic tip that are easily removed by hand, the ceramic tip may be changed while the entire center pin assembly 34 remains installed in the compaction tool. Such a feature is advantageous, because it enables a simple and rapid changeover of ceramic tips, thereby minimizing the cost of downtime of the compaction process of battery manufacturing.

[0097] Although described relative to the tooling employed for the compaction of battery components, the present invention is intended to include, within its scope, the use of similar techniques to extend the life of other compaction tools and punches, including, but not limited to tablet compaction, powder metal compaction etc. For example, the techniques described with respect to FIGS. 5A and 5B, FIGS. 7A through 7E, and FIGS. 8A through 8C may be employed to produce ceramic tips for various compaction punches (upper and lower, etc.) wherein the tips may be manufactured from longer-wearing ceramic components and fitted to the metal punch base.

[0098] In recapitulation, the present invention is a method and apparatus for the production of compacted powder elements. More specifically, the present invention is directed to the improvement of tooling for powder compaction equipment, and the processes for making such tooling. The improvement comprises the use of a ceramic tip or similar component in high wear areas of the tooling. Moreover, the use of such ceramic components enables reworking and replacement of the worn tool components.

[0099] It is, therefore, apparent that there has been provided, in accordance with the present invention, a method and apparatus for improving the performance of compaction tooling. While this invention has been described in conjunction with preferred embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

Claims

1. An apparatus for forming a powder material into a solid form through the application of pressure, comprising: a die; a lower compression punch insertable into a lower end of said die, said compression punch having a center pin with a ceramic-tip passing therethrough where the ceramic reduces the wear of said outer surface of said center pin, wherein said center pin further comprises a mandrel arbor positively engaged and passing through said ceramic tip of said center pin; powder material for filling at least a portion of the cavity defined by said die, said lower compression punch and said center pin; and an upper compression punch, insertable into an upper end of said die to compact the powder material.

2. The apparatus of claim 1, wherein said mandrel is positively engaged along a planar surface between at least a portion of an end of said center pin and a shoulder of said mandrel.

3. The apparatus of claim 2, wherein said mandrel is fastened to said base by a retainer pin inserted in coaxially aligned holes in said base and said mandrel arbor.

4. The apparatus as recited in claim 1, wherein said tip is affixed to said shaft of said base by a retainer pin inserted in coaxially aligned holes in said base and said tip.

5. The apparatus as recited in claim 1, wherein said tip is affixed to said shaft of said base by a plug inserted in coaxially aligned holes in said base and said tip.

6. The apparatus as recited in claim 5, wherein said plug positively engages an inside diameter of the coaxially aligned holes in an interference fit.

7. The apparatus as recited in claim 5, wherein said plug is retained within an inside diameter of the coaxially aligned holes using an adhesive.

8. The apparatus as recited in claim 5, wherein said plug is retained within an inside diameter of the coaxially aligned holes using a phase change alloy.

9. The apparatus of claim 1, wherein said mandrel is positively engaged along a planar surface between at least a portion of an end of said center pin and a shoulder of said mandrel and is threadably engaged with the lower compression punch.

10. A method of manufacturing a compression center pin for use in a punch and die powder compaction apparatus, comprising the steps of: forming a center pin base of a rigid material); forming a center pin tip of a ceramic material; and affixing the center pin tip to the center pin base, wherein the step of affixing the center pin tip to the center pin base includes inserting a plug into coaxially aligned holes in the center pin base and the center pin tip.

11. The method of claim 10, wherein said plug is positively engages an inside diameter of the coaxially aligned holes in an interference fit.

12. The method of claim 10, wherein said plug is retained within an inside diameter of the coaxially aligned holes using an adhesive.

13. The method of claim 10, wherein said plug is retained within an inside diameter of the coaxially aligned holes using a phase change alloy.

14. A compression punch insertable into die for forming a powder material into a solid form through the application of pressure, said compression punch comprising: a base of a rigid material; and a ceramic tip, attached to said base, where the ceramic tip reduces the wear of at least a portion of an outer surface of the compression punch.

15. The apparatus as recited in claim 14, wherein said ceramic tip is affixed to a shaft extending from said base by a retainer pin inserted in coaxially aligned holes in said shaft and said ceramic tip.

16. The apparatus as recited in claim 15, wherein said ceramic tip is affixed to a shaft extending from said base by a plug inserted in coaxially aligned holes in said shaft and said ceramic tip.

17. The apparatus as recited in claim 16, wherein said plug positively engages an inside diameter of the coaxially aligned holes in an interference fit.

18. The apparatus as recited in claim 16, wherein said plug is retained within an inside diameter of the coaxially aligned holes using an adhesive.

19. The apparatus as recited in claim 16, wherein said plug is retained within an inside diameter of the coaxially aligned holes using a phase change alloy.

20. A center pin of a lower compression punch insertable into a die for forming a powder material into a solid form through the application of pressure, the center pin comprising: a center pin base, said base having a shoulder; and a ceramic tip affixed to said base at the shoulder.

21. The center pin of claim 20, wherein said ceramic tip is affixed to a shaft extending from said base.

22. The center pin of claim 21 wherein the ceramic tip is affixed to the shaft via threaded mating surfaces.

23. The center pin of claim 22, further including means for preventing the threads from loosening.

24. The center pin of claim 23, wherein said means for preventing the threads from loosening includes an adhesive.

25. The center pin of claim 24, wherein said means for preventing the threads from loosening includes a through hole with a plug inserted therein.

26. The center pin of claim 20, wherein said ceramic tip is a cup-shaped tip having a threaded recess therein; and wherein said shoulder has a threaded region thereon for providing a mating surface to the threaded recess in the tip.

27. The center pin of claim 20, wherein said ceramic tip is affixed to said base using a mandrel arbor passing therethrough.

28. The center pin of claim 27 wherein said mandrel arbor is affixed to the base via threaded mating surfaces.