Patent Application
20180029323
This application is based upon and claims priority to, under relevant sections of 35 U.S.C. §119, German Patent Application No. 10 2016 113 724.3, filed Jul. 26, 2016, the entire contents of which are hereby incorporated by reference.
The invention relates to a punch for a rotary press comprising a shaft with a punch tip at one end of the shaft and a punch head at the other end of the shaft, wherein the punch head has a mirror surface and a cylindrical surface, as well as an intermediate region between the mirror surface and cylindrical surface.
Rotary presses have a plurality of upper and lower punches which can be assigned in pairs to a cavity of a die plate of the rotor of the rotary press. While the rotor is rotating, the cavities are filled with the filling material to be pressed. In a pressing apparatus, the upper and lower punches are pressed against each other in the cavities to press the filling material into pellets or tablets. The punch tips enter into the cavities, whereas the punch heads located at the other end of the shaft generally interact with pressure rollers of the pressing apparatus. In addition, while the rotor of the rotary press is rotating, the axial movement of the punches can be controlled by control cams that interact with the punch heads.
The mechanical contact of the top side of the punch head with the pressure rollers is along a so-called contact region. The contact region can be divided into two sub-regions. On the one hand, this is the intermediate region between the cylinder surface and the mirror surface of the punch. The first mechanical contact between the pressure roller and the punch head occurs in this region upon entry into the pressing apparatus. During the continued entry of the punch into the pressing apparatus, the pressure rises to the maximum value. The second sub-region is formed by the mirror surface of the punch head, i.e., a flat surface in the middle of the top side of the punch head. While the pressure roller is interacting with the mirror surface, the pressure remains at its maximum value. The diameter of the mirror surface also determines the so-called pressure hold time. The pressure then decreases upon leaving the pressing apparatus and the associated renewed contact with the intermediate region until the punch leaves the pressing apparatus and hence contact with the pressure roller.
Punch heads and in particular their mirror surfaces are the subject matter of the standard DIN ISO 18084:2012-08. Accordingly, the mirror surface is designed flat and circular. Punch heads with such a mirror surface represent the most frequent application. A corresponding punch is for example known from EP 2 111 972 B1. The outer contour of the flat mirror surface can also deviate from the circular shape known from the standard.
Such punches are distinguished by enormous stability which can easily withstand the loads arising from very high pressure while the rotary press is operating. If a punch failure occurs, it has however been revealed that this frequently proceeds from the middle of the mirror surface. In addition, traces of wear occur with the known punches in the region of the middle of the running surface of the pressure roller, which can necessitate an earlier exchange of the pressure roller. In addition, a defective punch transfers its material into the running surfaces of the pressure rollers that interact with this punch. This in turn presses into the other punches which can cause the entire punch set to be damaged in a chain reaction.
In addition to the aforementioned punches with a closed mirror surface, special punches are also known with through-holes in the region of the mirror surface. These holes generally serve additional functions such as the actuation of a clamping mechanism for punch inserts. Such a punch is known from DE 10 2008 053 453 B4. An associated problem is that, by introducing the holes, mechanical stress overloads are generated at the edge of the hole. Due to these stress overloads, the maximum durability and hence the life of the punch decreases. The life of the pressure roller also decreases due to the stress overload at the edge of the hole. Depending on the depth of the hole, the regions of the punch head and punch shaft are weakened by the hole. The cleanability of the punch is also impaired by the through-hole.
Based on the presented prior art, the object of the invention is therefore to provide a punch of the aforementioned type with a longer life that leads to reduced wear of the pressure rollers of a rotary press during operation.
For a punch of the aforementioned type, the invention achieves the object in that the mirror surface has a central recess which is surrounded by an annular mirror surface section.
The punch comprises a shaft, at one end of which the punch tip is arranged that enters the respective cavity in the die plate while the rotary press is operating. In an embodiment, the punch head is located at the other end of the shaft and has an upper mirror surface and a cylindrical surface that are connected to each other by a rounded intermediate region. A conical region can be provided between the cylindrical surface and the punch shaft. The punch shaft can have a punch neck following the punch head and can have a smaller diameter than the other shaft region. At least the punch head, in particular the entire punch, can be designed as a single part.
In an embodiment, the mirror surface has a central recess, which can be bordered by an in particular flat annular mirror surface section. In the region of the mirror surface section, the pressure is substantially constant from the interaction with the pressure rollers of the rotary press. The central recess possesses a closed base like a bay and is hence not a through-hole in which a clamping bolt, or other similar fastener is arranged. The recess can for example be curved concavely. The punch head including its annular mirror surface section as well as its central recess can be rotationally symmetrical. The central recess can be correspondingly circular and surrounded by a preferably annular mirror surface section. The mirror surface section can also possess a ring shape which deviates from the ring shape.
The recess introduced into the mirror surface region according to the invention improves the mechanical properties of the punch head during operation. The recess is designed to reduce weak points in the mirror surface. In this regard, the recess has a geometry which improves the contact conditions between the mirror surface and a pressure element of a pressing apparatus, in particular a pressure roller, as well as the durability of the overall punch structure. The recess improves the maximum durability of the mirror surface and hence the overall life of the punch. In addition, pressure roller wear is reduced.
The invention is based on the insight that pressure rollers roll on the middle of the punch head, or respectively the mirror surface and therefore the middle is particularly stressed while the rotary press is operating. In particular when the punches are unguided, i.e., arranged to rotate freely in the respective punch guides, this causes the middle of the mirror surface to experience a particularly high number of pressings (deformation cycles), whereas the intermediate region and the edge of the mirror surface are loaded less strongly due to the statistically distributed rotary position of the punches in the punch guides. This causes the aforementioned punch failure starting from the middle of the mirror surface.
On the other hand, the invention is based on the insight that the real contact surface between the punch and pressure roller changes significantly during the pressing process due to the contiguous, flat mirror surface of known punches. When the pressure roller is on the middle of the punch, there is a contact line that runs across the entire width of the mirror surface. When the pressure roller is contrastingly at the beginning or end of the mirror surface, the contact line shortens until it becomes a contact point in the intermediate region. It is a further insight of the inventor that this significant alteration in contact conditions is problematic for the mechanical load on the punch and pressure roller and leads to a strong change in the contact stiffness, in particular since the Hertz surface pressure is inversely proportional to the root of the contact line length.
The mirror surface is decreased by the recess according to the invention. The flat region then forms a ring surface in comparison to which the middle of the punch head topside is recessed so that it no longer comes in contact with the pressure roller during the pressing process. This eliminates the middle of the mirror surface, which is subject to a strong mechanical load in the prior art, and leads to a longer life for the piece. In addition, the explained significant change of the contact line length between the pressure roller and mirror surface that occurs in the prior art during a pressing process is reduced by the recess according to the invention. Overall, the path of contact is even since the length of the contact line decreases in the region of the punch axis by the diameter of the recess. This causes a decrease in the dynamics during operation, and the generated noise is also reduced.
Moreover according to the invention, the running surface of the pressure roller is stressed more evenly since the middle of the running surface which is subject to a particular load in the prior art is relieved by the recess in the mirror surface, and regions adjacent to the middle of the running surface are subject to an additional load. The wear of the pressure roller running surface is also accordingly more homogeneous and reduced overall.
Numerous important advantages are thus achieved by the invention. To begin with, the mechanical durability, or respectively the life of the punch tools is increased in that an advantageous effect is produced on the mechanical stress in the contact region of the punch by the geometric design of the recess. The punch head is subject to a more mechanically even load. The number of deformation cycles and the mechanical stress of the contact region are more homogeneously distributed. Given the reduced change in length of the contact line during the pressing process, more even contact conditions are established. In addition, the mechanical stress on the rotary press is reduced overall. Given the more even and reduced stress on the punch head, the stress on all of the participating contact components of the rotary press is also more even and reduced overall. That is, parts such as pressure rollers, pressure rails, control cams, control ramps, etc., also have a longer life. Accordingly, the life and service intervals of the rotary press are increased. Given the reduced dynamics, the generated noise of the rotary press is also reduced overall.
The recess can have an edge region and a base region, which is surrounded by the edge region. The edge region can be designed frustoconical or conical. The base region can in principle be very small and, in an extreme case, can be substantially punctiform when the edge region possesses a (fully) conical shape.
A tangentially continuous transitional region can be provided between the edge region and mirror surface section. An even and hence less stressing transition of the pressure rollers between the annular mirror surface section and the recess is thereby achieved. The mechanical durability is thereby further increased. Only selecting a suitable geometry for the recess permits the introduction of said recess without endangering the function, in particular the mechanical durability of the punch. In this context, it is possible for the tangential continuity to only exist at the direct transition from the transitional region to the mirror surface section. It is, however, also possible for the entire transitional region to be tangentially continuous, in particular also at the transition to the base region. Given tangential continuity, the radius of the rounded transitional region remains constant over the entire extent of the rounded transitional region. This brings about a further homogenization of the transition of the pressure rollers between the annular mirror surface section and the recess and hence further improves mechanical durability of the punch.
According to another embodiment, the transitional region to the mirror surface section can be continuously curved. It is again possible for the continuous curvature to only exist at the direct transition from the transitional region to the mirror surface section. It is however, also possible for the entire transitional region to be continuously curved. Given a continuous curve, the radius of the rounded transitional region increases constantly, starting from the base region, toward the annular mirror surface section and progresses into infinity at the transition to the annular mirror surface section. Accordingly, a maximum homogenization is achieved of the transition of the pressure rollers between the annular mirror surface section and the recess, and hence improved mechanical durability of the punch.
It is also possible for the recess at the transition to the annular mirror surface section to possess a tangential angle relative to the annular mirror surface section of less than 20°, and preferably less than 10°. The aforementioned tangential angle results between a tangent located directly at the transition between the recess and mirror surface section and the plane defined by the in particular flat mirror surface section, the horizontal plane when the rotary press is operating. In the aforementioned embodiment, the tangential angle is relatively small, i.e., less than 20° and preferably less than 10° (and greater than zero). The recess therefore only drops slightly relative to the mirror surface section. The recess according to the invention only must ensure that no contact with the pressure roller arises under maximum pressure in the region of the recess during a pressing process, and the mechanical weakening of the punch structure which occurs in the prior art accordingly fails to materialize. A load-optimized edge results from the small difference in the tangential angle at the transition between the flat mirror surface and recess of less than 20°. In this context, “load optimized” means that force can flow in the direction of the punch axis almost unhindered, and the edge is obtuse enough for there to be effective mechanical support when the edge is subject to load. In contrast to a vertical hole with a tangential angle of 90°, only a slight increase in stress occurs under a load (pressure) due to the effective edge support.
A (second) rounded transitional region can also be provided between the edge region and base region. The base region of the recess can also be (concavely) curved. Given a rounding of the base of the recess, for example with a rounding diameter greater than 1 mm, and given the rounded transitional region between the edge region and base region, cleaning the recess is simplified since any edges are avoided. A notch effect is also excluded.
The depth of the recess relative to the annular mirror surface section is less than 4 mm, preferably less than 2 mm, more preferably less than 1 mm. In this manner, the mechanical weakening of the punch head is minimized by the recess, and cleanability is further improved. As explained, a minimum requirement for the depth of the recess is that the base of the recess during operation does not contact the pressure rollers of a rotary press equipped with the punches.
The ratio between the depth of the recess to the diameter of the recess can be less than 2 according to another embodiment. Moreover, this largely prevents mechanical weakening of the punch structure, and the cleaning of the recess is further simplified.
The ratio between the diameter of the recess to the diameter of the annular mirror surface section can be less than 0.8 according to another embodiment which improves cleanability.
According to another embodiment, the outer contour of the recess can lie within an envelope circle with a diameter which is not greater than one-half the diameter of the region of the shaft adjacent to the punch head. The envelope circle is the smallest circle which encloses the outer contour of the recess (in particular in the plan view of the punch head). The outer contour of the recess is formed by the transition to the mirror surface section. The region of the shaft adjacent to the punch head can be a punch neck. Maintaining the aforementioned relationship ensures that the pressure can be released symmetrically between the punch axis and shaft outer diameter as explained in greater detail below. The flow of force through the transitional region between the punch head and punch shaft which functions like a notch is thereby minimized. The durability of the punch head is consequently increased.
According to another related embodiment, the (overall) contour of the recess can lie within an envelope cone, or envelope conical frustum, with a taper angle (opening angle) of at least 140° and a maximum diameter (diameter of the edge of the cone opening) which is not greater than one-half the diameter of the region of the shaft adjacent to the punch head. Again, this region of the shaft adjacent to the punch head can be formed by a punch neck. If the entire recess is enclosed by such a cone, or respectively conical frustum, the flow of force can be further optimized. The volume area of the recess thus defined ensures that the pressure can expand freely from the force introduction point at an angle of 70° in the direction of the punch axis. This leads to reduced mechanical stress and accordingly also to increased durability of the punch head.
According to another embodiment, the height of all wall sections of the recess perpendicular to the mirror surface section can be less than 1 mm. The recess can have no, one, or a plurality of wall sections that can be connected by conical frustum sections that run perpendicular to the mirror surface section. Such wall sections can form perpendicular circular cylinders. In the aforementioned embodiment, the overall height of any such wall sections is less than 1 mm. If the recess has a plurality of such wall sections, the overall height results from the sum of individual heights. If the recess only has one such wall section, the overall height corresponds to the height of this one wall section. If the recess does not have any such wall sections, the height is zero. In principle, perpendicular cylindrical component parts of the recess worsen the flow of force in the punch head. The forces that flow from the punch head toward the pressing surface are deflected by the perpendicular cylindrical component parts, and the flow of force is accordingly restricted as will be explained below. Given perpendicular wall sections that are as small as possible, force can flow nearly unhindered from the head to the pressing axis. At best, the recess does not have any perpendicular wall sections.
The invention also relates to a rotary press comprising a rotor that can be rotated by means of a rotary drive. The rotor has an upper punch guide for upper punches of the rotary press, a lower punch guide for lower punches of the rotary press and a die plate arranged between the punch guides. The punches can interact with cavities in the die plate. A filling apparatus is provided by means of which the filling material to be pressed is added to the cavities in the die plate. At least one upper pressing apparatus and at least one lower pressing apparatus that interact with the upper punches and the lower punches during operation such that they press the filling material into the cavities in the die plate. The rotary press further comprises an ejection apparatus in which the pellets generated in the cavities are ejected from the rotary press, wherein the upper and lower punches are formed in the manner according to the invention.
The at least one pressing apparatus of the rotary press can in particular have upper and lower pressure rollers which interact with the punch heads of the upper and lower punches in the aforementioned manner. In addition, the punches can be arranged in a freely rotatable manner in the punch guides. In an embodiment, the punches can have a circular cylindrical shaft without keys, or similar form-fit elements. The rotor of such a rotary press possesses, in a known manner, a rotary drive that rotatably drives the rotor, in particular the die plate with the upper and lower punches, for example by means of a drive shaft. The die plate can comprise a single piece or be constructed from individual die segments. The cavities of the die plate can be formed by holes introduced directly in the die plate, or by releasable dies inserted in seats in the die plate. In the filling apparatus, the cavities of the die plate are filled in a known manner with, for example, a powdered filling material. Then the filling material is pressed in a manner which is also known by the upper and lower punch of the rotary press in the cavities into a pellet, especially a tablet. After the pellets are expelled from the cavities, for example by the lower punch of the rotary press, the pellets are ejected from the rotary press in an ejector station. The ejector station can comprise a scraper that is arranged directly above the die plate and scrapes off the ejected pellets from the die plate rotating below the scraper toward the discharge channel
Exemplary embodiments of the invention are explained in greater detail below with reference to figures. The drawing shows schematically in:
The same reference numbers refer to the same objects in the figures unless indicated otherwise.
The rotary press shown in
As shown in
A control apparatus for operating the rotary press is shown with reference number 48. The control apparatus 48 is connected by lines (not shown) to, inter alia, the rotary drive of the rotor.
Referring to
Height lines are depicted on the top side of the punch head 50 in
Referring to
The upper punch 14′ shown in
As can be seen in
By providing the recesses 70, 70′ in the punch heads 50, a more even load on the punch heads 50 and the upper and lower pressing rollers 32, 34, 36, 38 interacting with them is achieved so that the life of the punches 14, 14′, 16 is increased without impairing the durability of the punches 14, 14′, 16. The wear of the pressing rollers 32, 34, 36, 38 and the rotary press overall is reduced, and the generated noise is reduced.
Punch head Punch shaft Punch neck Punch tip Upper punch guide Lower punch guide Cylindrical surface Conical intermediate region Annular mirror surface section Intermediate region Recess 70′ Recess Base region 72′ Base region Edge region 74′ Edge region Force lines Tangent Perpendicular cylindrical wall section
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2016 113 724.3 | Jul 2016 | DE | national |
