The present invention relates to a method and apparatus for injection molding a powder suspension to form a molded powder greenware composite. The powder is suitably a ceramic, a metal or a cermet.

Ceramic parts are commonly produced by injecting a ceramic suspension into a mold and then treating the injected suspension to form a molded ceramic greenware composite. The molded ceramic greenware composite is subsequently removed from the mold for further processing to form the finished ceramic part.

Injection molding typically requires that a ceramic suspension be injected into a mold cavity having a cross-section that is larger than a conduit through which the ceramic suspension is delivered. The ceramic suspension is typically cohesive enough to form a stream during mold-filling. The stream will break apart, or jet, and fold upon itself to form knit lines as it fills the mold cavity. The ceramic suspension often does not recombine intimately at these knit lines. The

inadequate recombination can result in structural flaws that limit the performance of the finished ceramic part.

When using certain binder systems, such as aqueous methylcellulose formulations, stresses caused by handling a rubbery gelled ceramic greenware composite can cause irregularities in the molded ceramic greenware composite after gellation of the methylcellulose. In addition, the gelled greenware composites must be dried at a controlled rate before further processing and densification.

Molds often cause seams to form in molded ceramic greenware composites. The seams must be removed during finishing steps. The mold cavity typically must have a highly polished surface in order to produce a ceramic part having an acceptable finish. The ceramic suspension can abrade mold cavity walls, thereby limiting the mold's usable life.

Thus, a need exists for an improved powder injection molding method and apparatus for forming molded powder greenware composites that overcome or minimize the aforementioned problems.

A first aspect of the present invention is a method for injection molding a powder suspension to form a molded powder greenware composite that includes injecting the powder suspension that comprises a binder system, formed of a binder and a carrier, and a powder selected from ceramics, metals or cermets into an elastomeric bladder disposed within a mold cavity defined by a mold, whereby the elastomeric bladder is distended by the powder suspension. The distention of the elastomeric bladder causes the elastomeric bladder

to apply a significant force to the powder suspension to prevent jetting of the powder suspension and formation of knit lines within the injected powder suspension. The injected powder suspension is exposed to conditions sufficient to form the molded powder greenware composite.

A second aspect of the present invention is an apparatus for injection molding a powder suspension to form a molded powder greenware composite. The powder suspension is preferably the same as that of the first aspect. The apparatus comprises a mold defining a mold cavity, an elastomeric bladder disposed within the mold cavity for receiving the powder suspension and a means for injecting the powder suspension into the elastomeric bladder. The injected powder suspension causes the elastomeric bladder to distend. Distention of the elastomeric bladder causes it to apply significant force to the powder suspension. The applied force prevents jetting of the powder suspension and formation of knit lines within the powder suspension. The apparatus preferably further comprises a means for exposing the injected powder suspension to conditions sufficient to form the molded powder greenware composite.

Molded powder greenware composites can thereby be formed from a powder suspension without jetting or formation of knit lines within the powder suspension. Finished molded powder parts are thus formed having a substantially reduced number of structural flaws. Further, the molded powder greenware composites formed can be removed from the mold without adhesion of the molded powder greenware composite to mold walls. In addition, the bladder adds stiffness to the molded powder greenware composite, thereby reducing distortion

of the molded powder greenware composite. Also, because the finish of the molded powder greenware composite is not determined by the mold, mold cavity surfaces need not be highly polished. Eliminating contact between the molded powder greenware composite and the mold can also prolong the useful life of the mold.

Figure 1 is a section view of one embodiment of the invention wherein an elastomeric bladder is disposed in a relaxed state within a mold cavity defined by a mold.

Figure 2 is a section view of the embodiment of Figure 1 wherein the elastomeric bladder has been evacuated.

Figure 3 is a section view of the embodiment of Figures 1 and 2 during injection of a powder suspension such as a ceramic suspension, into the evacuated elastomeric bladder from a source of the powder suspension.

Figure .4 is a section view of the embodiment of Figures 1-3 wherein the injected powder suspension has filled the mold cavity.

Figure 5 is a side view of the elastomeric bladder of Figures 1-4 containing a molded powder greenware composite formed from the injected powder suspension. The elastomeric bladder is sealed at an inlet end and at an outlet end for drying of the molded powder greenware composite.

Figure 6 is a section view of a second embodiment of the present invention wherein the elastomeric bladder is formed of two sheets of material

that are disposed within a mold cavity defined by a mold and wherein the elastomeric bladder is supported within the mold cavity at an inlet end and an outlet end of the elastomeric bladder.

Figure 7 is a plan view of the embodiment of Figure 6 illustrating a peripheral seal of the elastomeric bladder and a flange disposed about the elastomeric bladder.

Figure 8 is a section view of the embodiment of Figures 6 and 7 during injection of a powder suspension into the elastomeric bladder.

The above features and other details of the method and apparatus of the invention are now more particularly described with reference to the accompanying drawings and pointed out in the claims. The same number present in different figures represents the same item. The particular embodiments of the invention are shown by way of illustration and not as limitations of the invention. The principle features of this invention may be employed in various embodiments without departing from the scope of the invention.

In one preferred embodiment of the present invention, shown in Figure 1, an injection molding apparatus 10 includes an elastomeric bladder 12 in a relaxed state. Elastomeric bladder 12 can be tubular in the relaxed state. Elastomeric bladder 12 has an inlet end 16 and an outlet end 18 and is disposed within a mold cavity 20 of mold 22. Mold cavity 20 is defined by mold cavity walls 24 and 26 of mold 22. Mold halves 28 and 30 of mold 22 are held in an assembled position, as shown in Figure 1, by mold clamps 32 and 34. Inlet end

16 of elastomeric bladder 12 is supported between fill tube 36 and nozzle bushing 38. Fill tube 36 provides fluid communication between a nozzle 40 and elastomeric bladder 12. Valve 42 of nozzle 40 provides fluid communication between a powder suspension source 44 and fill tube 36. Valve 42 also regulates the flow of a powder suspension 46 from powder suspension source 44 through nozzle 40 to elastomeric bladder 12. Outlet end 18 of elastomeric bladder 12 is supported between a vacuum tube 48 and a split core 50. Vacuum tube 48 provides fluid communication between elastomeric bladder 12 and a vacuum source 52. Vents 54 provide fluid communication between mold cavity 20 and the atmosphere. A heat transfer fluid can be conducted through channels 56 in mold 22 to thereby control the temperature of powder suspension 46 introduced to elastomeric bladder 12.

In a preferred embodiment, a method for injection molding a powder suspension to form a molded powder greenware composite includes disposing elastomeric bladder 12 within mold cavity 20 of mold 22, as shown in Figure 1. Vacuum can be applied to evacuate elastomeric bladder 12 through vacuum tube 48 by vacuum source 52. Elastomeric bladder 12 thereby collapses, as can be seen in Figure 2. Evacuation of elastomeric bladder 12 maximizes contact between elastomeric bladder 12 and powder suspension 46 and prevents development of air pockets within elastomeric bladder 12 during injection of powder suspension 46 into elastomeric bladder 12. As shown in Figure 3, powder suspension 46 is injected into elastomeric bladder 12 through nozzle 40 and fill tube 36. Means for injection of powder suspension 46 from powder suspension source 44 can be,

for example, a reciprocating screw, or a plunger-type machine not shown. Elastomeric bladder 12 is distended during injection of powder suspension 46. Distention of elastomeric bladder 12 causes elastomeric bladder 12 to apply a significant force to powder suspension 46 within elastomeric bladder 12, thereby preventing jetting of powder suspension 46 and formation of knit lines within the injected powder suspension 46. Injection of powder suspension 46 into mold cavity 20 directs elastomeric bladder 12 against mold cavity walls 24 and 26. Powder suspension 46 is injected into mold cavity 20 until elastomeric bladder 12 and powder suspension 46 conform to mold cavity 20, as shown in Figure 4. Air or other gas is displaced from mold cavity 20 through vents 54 by injection of powder suspension 46 into elastomeric bladder 12.

Continued injection of powder suspension 46 into elastomeric bladder 12 through fill tube 36, after mold cavity 20 is filled, will direct powder suspension 46 from elastomeric bladder 12 through vacuum tube 48. Valve 42 is closed upon filling of mold cavity 20 with powder suspension 46. Pressure within elastomeric bladder 12 during injection of powder suspension 46 is at least partially determined by the cross-sectional area of vacuum tube 48. For example, pressure within elastomeric bladder 12, when mold cavity 20 has been filled by powder suspension 46, can be increased by reducing the cross-sectional area of vacuum tube 48. Once mold cavity 20 has been filled, vacuum through vacuum tube 48 can be secured, either before or after valve 42 is closed. Vacuum can be secured by sealing vacuum tube 48 from vacuum source 52 by a suitable means, such as by closing a valve, not shown, or by

terminating the vacuum source. The temperature of mold 22 and powder suspension 46 can be controlled by conducting a heat transfer fluid through channels 56.

Powder suspension 46 comprises a powder and a binder system. The powder is desirably selected from ceramics, metals or cermets. The powder is preferably a ceramic powder. As such, the resultant greenware is preferably a molded ceramic greenware composite. The ceramic powder is selected from alumina, silicon carbide, silicon nitride, aluminum nitride, boron nitride, boron carbide or zirconia. Powders other than ceramic including cermets, such as chromium-alumina; and powdered metals, such as ferrous-based alloys can be used in the disclosed process. The binder system comprises a suitable binder and a suitable carrier. The binder can comprise, for example, an organic material such as methylcellulose or wax. The binder can also comprise a thermoplastic. Suitable carriers include water and organic solvents, such as methanol or methyl ethyl ketone.

Elastomeric bladder 12 can be formed of polyurethane or another elastomeric material. Elastomeric bladder 12 can, in the alternative, be formed of an elastic material. In a preferred embodiment, elastomeric bladder 12 is formed of an elastomeric material that is relatively abrasion resistant and resilient and exhibits high extensibility. An example of a suitable elastomeric material includes polyurethane, such as aromatic polyether polyurethane. In a preferred embodiment, the thickness of elastomeric bladder 12 is in a range of between one mil (2.54 x 10~3 cm) and ten mils (25.4 x 10~3 cm). Elastomeric bladder 12 is permeable by the selected carrier in the binder

system of the ceramic suspension. In a particularly preferred embodiment, elastomeric bladder 12 has a thickness of about one mil (2.54 x 10~3 cm) and has a water vapor permeability of less than about one hundred and forty grams per twenty-four hours through a one hundred square inch (645 cm ² ) matrix area at a temperature of about 50°C.

Mold 22 can be formed of a thermally conductive material such as steel or aluminum. The temperature of powder suspension 46 in mold 22 can be controlled, for example, by conducting a suitable heat transfer fluid through channels 56 in mold 22. For a powder suspension 46 that includes an aqueous methylcellulose polymer binder system, the temperature of powder suspension 46 within elastomeric bladder 12 during injection is maintained in the range of between 1°C and 25°C. Means for injection of powder suspension 46 from powder suspension source 44 can be, for example, a reciprocating screw, not shown. Powder suspension 46 can be heated within mold cavity 20 to gel the binder, whereby the binder comes out of solution to provide rigidity to ceramic suspension 46. Heating to a temperature within a range of from 30°C to 60°C is generally sufficient to cause the binder to gel. Molded powder greenware composite 58 is thereby formed from powder suspension 46. Molded powder greenware composite 58 is sufficiently rigid to allow its removal from mold cavity 20 without substantial distortion.

When the binder is a thermoplastic, the temperature of powder suspension 46 within mold cavity 20 during injection can be maintained in the range of between 30°C and 60°C. Mold 22 can be cooled to cool the powder suspension 46 to a temperature in the range of,

for example, between 1°C and 25°C. Powder suspension 46 thereby forms molded powder greenware composite 58, that is sufficiently rigid for removal from mold cavity 20 without substantial distortion.

In another preferred embodiment, mold 22 is formed of a microwave-transparent material. Examples of microwave-transparent materials include thermoplastics, such as polyetherimine (PEI), and thermosets, such as a polyurethane tooling resin system formed of, for example, a polymeric methylenediisocyanate solution and a polyol solution. Gellation of the binder in powder suspension 46 can be achieved by application of microwave energy where, for example, powder suspension 46 includes an aqueous methylcellulose polymer binder system. Molded powder greenware composite 58 can thereby be formed from powder suspension 46 by application of microwave energy to powder suspension 46. Molded powder greenware composite 58 is sufficiently rigid for removal from mold cavity 20 without substantial distortion.

Molded powder greenware composite 58 and elastomeric bladder 12 are removed from mold cavity 20 by releasing mold clamps 3 and 34 and disassembling mold halves 28 and 30. Elastomeric bladder 12 is sealed at inlet end 16 and outlet end 18. Inlet end 16 and outlet end 18 of elastomeric bladder 12 are sealed, as shown in Figure 5, by heat-sealing, or by another suitable method. Heat sealing can be accomplished by squeezing inlet end 16 and outlet end 18 between bars, not shown, that are sufficiently hot to soften elastomeric bladder 12 and seal inlet end 16 and outlet end 18.

Molded powder greenware composite 58 is then dried by a suitable method, such as by disposing molded powder greenware composite 58 in a suitable oven, not shown. The carrier is volatilized in the oven and transported across elastomeric bladder 12, thereby drying molded powder greenware composite 58 to form a dried, molded powder greenware composite. If the binder system is an aqueous methylcellulose polymer binder system, molded powder greenware composite 58 within elastomeric bladder 12 can be dried at a temperature within a range of 30°C and 70°C. Elastomeric bladder 12 is then removed from the dried, molded powder greenware composite 58. A finished, molded powder part is formed by suitably debindering the dried, molded powder greenware composite and then densifying the debindered, molded powder greenware composite by a conventional method such as sintering.

In another preferred embodiment of the present invention, shown in Figure 6, an injection molding apparatus 60 has an elastomeric bladder 62 that can be formed by sheets 64 and 66. Elastomeric bladder 62 also has an inlet end 70 and an outlet end 72. Sheets 64 and 66 are supported within mold 74 between mold halves 76 and 78. Elastomeric bladder 62 can be formed of the same material as elastomeric bladder 12.

Mold 74 is maintained in an assembled condition by mold clamps 80 and 82. Elastomeric bladder 62 is disposed within a mold cavity 84 defined by mold cavity walls 86 and 88 of mold halves 76 and 78, respectively. Mold 74 can be formed of the same materials as mold 22.

Inlet end 70 of elastomeric bladder 62 is supported between fill tube 90 and mold halves 76 and

78. Fill tube 90 provides fluid communication between a nozzle 92 and elastomeric bladder 62. A valve 94 at nozzle 92 provides fluid communication between a powder suspension source 44 and elastomeric bladder 62, and can regulate the flow of powder suspension 46 from powder suspension source 44 into elastomeric bladder 62. Outlet end 72 is supported between a vacuum tube 100 and mold halves 76 and 78. Vacuum tube 100 provides fluid communication between elastomeric bladder 62 and vacuum source 52. Vents 104 provide fluid communication between mold cavity 84 and the atmosphere. A heat transfer fluid can be conducted through channels 106 to control the temperatures of mold 74 and of powder suspension 46 within elastomeric bladder 62.

Sheets 64 and 66 can be bonded together to form a peripheral seal 108, shown in Figure 7, by heat- sealing or by some other conventional method. Flange halves 110 and 112 can be disposed about peripheral seal 108 of elastomeric bladder 62 to prevent puckering of elastomeric bladder 62 during injection, from powder suspension source 44, of powder suspension 46 into elastomeric bladder 62.

In a preferred embodiment, a method of injection molding a powder suspension to form a molded powder greenware composite includes drawing vacuum within elastomeric bladder 62 through vacuum tube 100 by vacuum source 52. Evacuation causes collapse of elastomeric bladder 62, as seen in Figure 6, thereby maximizing contact between elastomeric bladder 62 and powder suspension 46 during injection of powder suspension 46. Powder suspension 46 is injected from powder suspension source 44 through nozzle 92 and fill

tube 90 into elastomeric bladder 62, thereby distending elastomeric bladder 62, as shown in Figure 8.

As elastomeric bladder 62 is distended, a significant force is applied by elastomeric bladder 62 to powder suspension 46 within elastomeric bladder 62, thereby preventing jetting of powder suspension 46 and formation of knit lines within injected powder suspension 46. Air or other gas within mold cavity 84 of mold 74 is displaced by elastomeric bladder 62 and powder suspension 46 through vents 104. Continued distention of elastomeric bladder 62 by injection of powder suspension 46 directs elastomeric bladder 62 against mold cavity walls 86 and 88. Elastomeric bladder 62 and powder suspension 46 contained within elastomeric bladder 62 thereby conform to mold cavity walls 86 and 88.

Powder suspension 46 is directed through vacuum tube 100 when mold cavity 84 has been filled. Pressure within elastomeric bladder 62 is at least partially limited by the cross sectional area of vacuum tube 100. When powder suspension 46 has filled mold cavity 84, valve 94 is closed to secure flow of powder suspension 46 into elastomeric bladder 62. Once mold cavity 84 has been filled, vacuum through vacuum tube 100 can be secured either before or after valve 94 is closed. Vacuum can be secured by sealing vacuum tube 100 from vacuum source 52 by a suitable means, such as by a valve, not shown, or by terminating the vacuum source. Nozzle 92 is then disconnected from fill tube 90 and elastomeric bladder 62. Vacuum tube 100 is disconnected from vacuum source 52.

Powder suspension 46 is then exposed to conditions sufficient to form molded powder greenware composite 114. The conditions described for formation of molded powder greenware composite 58 provide satisfactory results. Molded powder greenware composite 114 can then be removed from mold 74. Inlet end 70 and outlet end 72 of elastomeric bladder 62 can then be sealed by a suitable method, such as heat sealing. Molded powder greenware composite 114 within elastomeric bladder 62 can then be dried by sufficiently heating molded powder greenware composite 114 to cause moisture within molded powder greenware composite 114 to volatilize and thereby be transported across elastomeric bladder 62. Flange halves 110 and 112 and elastomeric bladder 62 are then removed from dried molded ceramic greenware composite 114. Puckering of elastomeric bladder 62 at flange halves 110 and 112 can be trimmed from dried molded powder greenware composite 114 during removal of elastomeric bladder 62 from dried molded powder greenware part 114. Dried molded powder greenware composite 114 can then be debindered and densified to form a finished molded powder part.

Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiment of the invention described specifically herein. Such equivalents are intended to be encompassed in the scope of the following claims.