Die for extrusion of fine grained green carbon
United States Patent [191 Jamieson Apr. 1,1975  
 l l DIE FOR EXTRUSION OF FINE GRAINED GREEN CARBON [75] Inventor: Charles P. Jamieson, Buffalo, NY.  
 [73] Assignee: Airco Inc., New York, NY.  
 [22] Filed: Sept. 18, 1972 [2]] Appl. No.: 290,200  
 OTHER PUBLICATIONS Sortais, H. C. et al., An Optimum Die Profile for Axi symmetric Extrusion, Int. J. Mach. Tool Des. Res, 8: p. 6l-72, July, I968.TJ1180.AL  
 Primary Examiner-R. Spencer Annear Assistant Examiner-Mark Rosenbaum Attorney, Agent, or Firm-H. Hume Mathews; Edmund W. Bopp [57] ABSTRACT A die for the extrusion of a fine-grained calcine-binder mix to form a green carbon, shaped body. The die profile is optimized according to the criteria that shear be minimized in a perfectly plastic material passed therethrough. A stress relief die extension is fitted to the end of the die for enabling a gradual expansion of the extrudate, and means are provided for cooling the die extension to control the extrudate flow field 5 Claims, 5 Drawing Figures DIE FOR EXTRUSION OF FINE GRAINED GREEN CARBON BACKGROUND OF INVENTION This invention relates generally to apparatus and methodology for use in forming green carbon bodies, and more specifically relates to apparatus and methodology for use in forming brush-grade materials from fine-grained mixtures of a calcine with a coal tar pitch binder.  
  At the present time the most widely used technique for manufacturing brush-grade carbon bodies consists of preparing a fine-grained particulate carbon by calcining a product such as raw lampblack, to eliminate residual tars and oils, mixing the resulting &#34;calcine&#34; He, the product of calcination) with coal tar pitch, extruding this mix, cooling the green material to room temperature, crushing the green material into flour, and finally, molding the flour into blocks which are baked and graphitized. While it has from time to time been proposed that one might extrude mixes of such a calcine and coal tar pitch into plates which could then be immediately baked and graphitized, such techniques have not in the past been particularly successful. Although in principle these techniques would seem highly desirable in that the resultant simplification of processing would vastly reduce costs and improve quality in the ensuing products, prior techniques for extrusion of fine-grained carbon materials have tended to produce coring&#34; in the extruded bodies. By such term is meant a phenomenon wherein the center of the extrudate tends to advance ahead of the surface layers, with consequent flaws in the formed bodies.  
  In the paper by H. C, Sortais and S. Kobayashi, An Optimum Die Profile for Axisymmetric Extrusion, Int. J. Mach. Tool Des. Res, Volume 8, pp. 61-72, Pergamon Press, I968, the authors have set forth optimum die profiles for the extrusion of a perfectly plastic ex trudate with good lubrication of the die surface. The die profiles therein described are such as to minimize the work expended in shearing the extrudate. This opti mum die profile might be thought in principle to be serviceable for eliminating coring in the present application. In practice, however, it is found that for extruding fine-grained calcine-pitch mixes the said optimum die profiles actually over-compensate so that the core lags the periphery a phenomenon which is referred to herein as anti-coring. This, in turn, can result in anacceptable defects in the resultant materials.  
  In accordance with the foregoing, it may be regarded as an object ofthe present invention to provide apparatus and methodology enabling extrusion of mixtures of a fine-grained calcine and coal tar pitch into plates which may be immediately baked and graphitized.  
  It is a further object of the present invention to provide apparatus and methods, according to which the theoretically optimum die profiles for a perfect plastic material may be utilized in extrusion of fine-grained calcine-coal tar pitch compositions, without introducing over-compensation such that anti-coring effects occur.  
 SUMMARY OF INVENTION Now, in accordance with the present invention, the foregoing objects, and others as will become apparent in the course of the ensuing specification, are achieved by the use, firstly, ofa die profile which is optimized ac- LII cording to the criteria that shear be minimized in the extrusion of a perfectly plastic material passed therethrough. in order to avoid the defects that frequently occur where the extrudate expands suddenly upon leaving the die, a stress relief die extension is fitted to the end of the die to allow a gradual expansion of the extrudate. In order, furthermore, to eliminate the anticoring effects that may occur due to the overcompensation of the die profile utilized means are provided for cooling the die extension to thereby control the extrudate flow field. By imposing a desired degree of such cooling, compensation can be introduced which is appropriate to the extrudate being utilized.  
 BRIEF DESCRIPTION OF DRAWINGS The invention is diagrammatically illustrated by way of example in the drawings appended hereto in which:  
  FIG. 1 is a longitudinal schematic cross-section through an extrusion press utilizing the principles of the present invention;  
  FIGS, 2 and 2A are respectively plan and end views of one-half of the extrusion die utilized in accordance with the invention; and  
  FIGS. 3 and 3A are respectively plan and elevational views of the stress relief section joined to the extrusion die of FIGS. 2 and 2A.  
 DESCRIPTION OF PREFERRED EMBODIMENT In FIG. 1 herein an extrusion press I is set forth by way of highly schematic longitudinal cross-section. The apparatus depicted is in most respects of conventional construction, and therefore is not set forth with more detail than is required to enable a complete understanding of the invention. As thus seen in FIG I, press includes a casing 12 in which is mounted a hydraulic driven plunger 14, which reciprocates through bearing block I6 to permit filling of the mudpot 24 with the material to be extruded which in the present instance may comprise a fine-grained lampblack based brushgrade material. In a typical instance, for example, the mix thus utilized may consist of a blend of lampblack calcine and Allied Chemical Nos. I and/or 1 l0 rod pitch, together with quantities of stearic acid. The pitch levels range from about pph to 75 pph, with about 55 pph being typical, and the stearic acid, which is added as an extrusion aid and a wetting agent, may have levels ranging from O to as high as It) percent by weight of the composition.  
  Mudpot 24 containing the said extrudate is surrounded by an oil heating channel 28 and enables the temperature of the extrudate to be maintained according to desired temperatures for processing. In practice, it is found that generally best results are achieved when during extrusion of the calcine and pitch mix, the temperature of the extrusion chamber, mix and the main body of the die are kept at approximately the same temperature.  
  Toward the forward end of press 10 a die adapter 30 surrounds and holds a die holder 32, which in turn carries the die 35. In order to provide appropriate temperatures for the die an annular electrical heater 34 is provided as well as a flame heater 36. These heaters are controlled, as is known in the art to maintain the selected temperatures. Adjoining the die and at the exit of the press 10, a stress relief section 38 is provided, which is seen to include annular cooling means 40. The latter may, for example, comprise a simple channel through which oil or other liquid coolant may be made to pass. Means 40 is sufficiently close to the adjacent end of die 35, that this exit portion of the die is also cooled by the said means.  
 rials often show chevron-shaped cracks with the points of the chevrons pointing back into the extrusion press. It appears that this result is caused by the periphery of the extrudate tending to move ahead ofthe core. a pheln FIGS. 2 and 2A herein, plan and end views respec- 5 nomcnon which may be called &#34;anti-coring&#34;. The existively appear of the die half 42. which. in combination tence of anti-coring implies that the shear resistance with an identical member, may comprise the die 35 of b t een extrudate d h di Surface i l h h F10. l. The die half-l2 is seen to include a pair of posishear resistance within the extrudate. This is a result of tioning pins 52, as well as bolt holes 50. During the the extrudate not being the perfectly plastic material course of normal use thereof. the two identical halves m a ed in th Calculation f h optimum di I are bolted together and placed within the die holder 32. ticular. the carbon mixes utilized herein are not per- In accordance with the embodiment of the invention fectly plastic material because particles in the mix imillustrated. the extrudate is ultimately formed into a d h i i ll h h i i under pres. platelike body. which in a typical application [after Sure durin extrusion, Accordingly. the optimum die suitable baking and graphitizing schedule) is cut into 5 fil ll oyrcr-cumpgngutgs f curing i h individual rectangulanlike slabs for use as brush eleparticlecontaining extrudates. in accordance with the Achhrdlhgl}? lhh hhlhht from Scch invention the ensuing anti-coring phenomenon is overend 46, is shaped in a generally rectangular form. At comc b li th end ofthe die to increase the shear the input end 44 f th die. 11 C n cal urfa 48 i8 P resistance between extrudate and die surface. effec- \&#39;lLlL Ll \VlllCll llClS during the first SllllgC Ul l&#39;CLlUCllOll it) 2U tivgly ingrguging extrusion prcgsurc establish the width of the plate to he extruded. The extrudate thereupon enters the channel 54 wherein duri h Second Stage f rcductimh the hi k f h ln FlGS. 3 and 3A herein, plan and clevational views l uj hi mhhh h d respectively appear of the stress reliefsection 38 previln accordance with the present invention, the profile l referral 10 in Chhhechhh The P of channel 54 is determinatively formed so as to minil5 hlkch from the will end ofthe ahpllrillhsv In mire shear in a passing extrudate. Profile 56 is actually Sldcrhlg H633 and it will firstly he holed lhhl the designed in accordance with the principles set forth in generally rectangular Chhhhcl 58 Pmvlded thmugh the Sortais and Kobayashi paper previously referred to. 38 diverges lh CYQSS-Scchhhfll arch lhwih&#39;d the the Actual dimensions of the profile in a representative 3() Fechhh hf Pmgressihh ofthe B P In a yp case are illustrated by the table herein set forth wherein lhfihlhcfi @Xllhlplfl the l&#39;hphl dlmehlilhh the coordinates X and Y are profile coordinates, X have of L000 lhchr Whereas the hull)ul dhhch&#39; being measured from the exit end of the die in inches. Slohh 62 of 1026 hlches- This dlwrg&#39; and Y being the profile coordinate measured from the g ti n allows the green plate to expand relacenterline in inches: the corresponding values of the lively slowly as h P115565 through lhE distance 64, p marked dimensions D., D: and D in FIGS. 2 and 2A senting the length of SEChOfl 3- ht a ypic l upplicw are respectively D 9 /i inches, D 1 2.50 in he d tion. for example, the latter distance 64 may be of the D3 7 inches order of 2 inches. The width of the opening at the exit TABLE I X Y X Y X t X X as us to (1756 Hit) l.ll8 fill-83 i350 33$ uslo 4.25 usis 535 l is} it it M75 450 own 5.5a tzou 3 75 (H158 4.75 ruin 5.75 1 22s \(ll l ultli oi Plate establi hed lroni tllt cut The profile 56 utilized herein is, as has b n pre i end of the stress relief section is typically determined ously discussed. designed for extrusion of a perfectly by measuring the thickness ofthe expanded green plate plastic extrudate with good lubrication of the die Surextruded without the stress relief section. Holes 68 are face. This optimized die profile is one WhlCh minimizes provided in section 38 which are threaded at one end. the work done on the extrudate by eliminating the rcthese holes permitting bolting of the section to the die. dundant work expended in shearing the extrudatev The I accordance with the principles previously set deformation ofthe extrudate closely approximates sim- SS forth, stress relief section 38, as well as the adjacent ple elongation, the condition of minimum work. These end of die 35, are cooled, In a representative instance, optimum die profiles have the interesting characteristic the die extension is maintained at a temperature apthat the radius of curvature at the entrance section of i t ly 30C cooler than the main body ofthe die, the die is considerably greater than the radius ofcurvaextrusion h mb t th t r elements i ll ture at the exit end of the die. being maintained at about to C. This is accomplished in apparatus 10 by permitting the escape of It might be expected that an optimum die profile of high pressure carbon dioxide from small holes in a copthe above type should serve to eliminate the coring per tube 66 (FIG. I) wrapped around the stress relief phenomenon, according to which it has previously section Temperature sensing means together with atbeen found that extruded materials of the present type 65 tendant requisition of the flow and emission of the said are defective in consequence of the center of the extrudate advancing more rapidly than layers contained near the walls of the die. Where die profiles as illustrated herein are utilized without further modification, however, it is found that extruded plates of green matecarbon dioxide, is automatically controlled by techniques well known in the art. to maintain the selected temperature at section 38. In general, the die extension is maintained at a temperature at least 5C cooler than the said main die body. It will be appreciated. however,  
 106026 01;) I49 [ll that the actual temperature maintained at section 38, may be appropriately selected in order to achieve a required compensation for a particular extrudate composition and processing conditions (pressure. etc.) utilized. This is an important advantage of the present invention, as compared, for example, to use of an idealized die profile which necessarily has its particular construction optimized for specific extrudate compositions and flow parameters.  
  The present invention is applicable to any cxtrudate consisting of particles in a binder where coring is objectionable. Th us. the invention applies to the extrusion of pieces with other cross-sections than those specifically set forth herein such as. for example, circles, squares and other rectangular forms. Extrusion pressures utilized in the course ofthe present invention typically are of the order of L750 to 3,000 psi. lf pressures are too low. the particles will not generally be thoroughly enough bonded together. On the other hand, if pressures are excessive. cracks may occur in later processing,  
  When materials are processed in accordance with the principles set forth herein. it is found that the ensuing baked and graphitized products have superior mechanical properties, and are markedly free from flaws particularly of the type heretofore known to be introduced as a result of the coring phenomenon previously discussed.  
  While the present invention has been particularly set forth in terms of specific embodiments thereof, it will be understood in view of the present disclosure that numerous variations upon the invention are now enabled to those skilled in the art. which variations yet reside within the scope of the instant teaching. Accordingly.  
 the invention is to be broadly construed and limited only by the scope and spirit of the claims now appended hereto.  
 I claim:  
  1. In a die for the extrusion of a calcine-binder mix to form a green carbon, shaped extrudate, the improvement wherein: said die includes a channel. the profile of which is converged to satisfy the criteria that shear be minimized for a perfectly plastic material passed therethrough; a stress relief die extension being fitted to the output end ofthe die and comprising the exit section for said shaped extrudate, said die extension including a second channel diverging slightly in crosssection from the input to output ends of said extension for enabling a constrained gradual expansion ofthe extrudate to its final expanded thickness. so as to avoid defects generated by sudden expansion of said extrudate; and wherein means are provided for cooling said die extension to control the extrudate flow field.  
  2. Apparatus in accordance with claim 1, wherein said die is adapted for extrusion of plates having gener ally rectangular cross-sections. and wherein a first portion of said die toward the input end thereof establishes the width of said plates and a second downstream portion of said die establishes the thickness of said plates.  
  3. Apparatus in accordance with claim 2, wherein said second portion comprises said converged channel.  
  4. Apparatus in accordance with claim 3, wherein said second channel is of generally rectangular crosssection.  
  S. Apparatus in accordance with claim 4, wherein said means for cooling said extension are further adapted to cool adjacent portions of said die.