A molding apparatus, a graphite product, and a molded product.

Abstract

This utility model provides a molding device, a graphite product, and a molded product, relating to the field of graphite product manufacturing. It is used to produce large-format graphite products. The molding device includes a mold, an inner mold core, an outer mold, and a flexible membrane. The inner mold core is fixed to the bottom of the outer mold, and an opening is provided at the top of the outer mold. The mold is pressed down to connect with the opening of the outer mold. The flexible membrane covers the outer surface of the inner mold core, and the flexible membrane is sealed to the inner mold core. A pressure cavity is formed between the flexible membrane and the inner mold core. A mold cavity adapted to the molded product is formed between the flexible membrane, the outer mold, and the mold. The mold, inner mold core, flexible membrane, and outer mold jointly extrude material to form the molded product.

Description

Technical Field

[0001] This utility model relates to the manufacture of graphite products, and more particularly to a large-scale forming device. Background Technology

[0002] Lithium-ion batteries are widely used in automobiles, energy storage, and other fields. Positive and negative electrode materials are the main components of lithium-ion batteries and also constitute the majority of their production cost. The production of positive and negative electrode materials for lithium-ion batteries requires a large number of carbon-graphite crucibles and graphite saggers.

[0003] Existing production methods for forming carbon graphite crucibles, such as Figure 1 As shown, currently, the mixed crucible paste 1 is poured into the mold cavity, which is formed by the outer mold 2 of the crucible. The crucible pressing mold 3 is pressed down into the mold cavity to compress the crucible paste 1 into shape. The upper part of the formed crucible is formed by the upward flow of the crucible paste 1 under the extrusion of the crucible pressing mold 3. However, the fluidity of the crucible paste 1 is poor, and during the extrusion process, it is affected by the friction of the inner wall of the crucible pressing mold 3 and the outer mold 2, resulting in a large density difference between the upper and lower parts of the crucible and poor structural uniformity. As a result, the upper part of the crucible is easily damaged during use, and even longitudinal cracks may appear.

[0004] Due to the poor quality of existing carbon graphite crucibles, the production of positive and negative electrode materials for lithium batteries requires a larger quantity of carbon graphite crucibles, resulting in persistently high production costs for lithium batteries. Utility Model Content

[0005] The purpose of this invention is at least to provide a molding device that eliminates the need for extensive material flow during extrusion, resulting in stable structure and uniform performance of the molded products. Furthermore, the extrusion molding process ensures that the shape and size of the molded products do not affect their performance and quality.

[0006] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0007] One embodiment of this utility model provides a molding device, which includes a mold, an inner mold core, an outer mold, and a flexible membrane. The inner mold core is fixed to the bottom of the outer mold, and the top of the outer mold has an opening. The mold is pressed down to connect with the opening of the outer mold. The flexible membrane covers the outer surface of the inner mold core and is sealed to the inner mold core. A pressure cavity is formed between the flexible membrane and the inner mold core. A mold cavity adapted to the molded product is formed between the flexible membrane, the outer mold, and the mold. The mold, the inner mold core, the flexible membrane, and the outer mold jointly extrude the material to form the molded product.

[0008] In some embodiments, the inner mold core is a hollow structure with a cavity. The inner mold core is provided with a through hole, and the pressure chamber is connected to the cavity through the through hole. The inner mold core is provided with a pressure channel for communicating with a pressure member. The pressure member is used to introduce gas, liquid, or a gas-liquid mixture into the pressure chamber for pressurization. The cavity of the inner mold core is connected to the pressure member through the pressure channel.

[0009] In some embodiments, the flexible membrane is a uniform structure with elasticity, and the shape of the flexible membrane is adapted to the shape of the inner mold core.

[0010] In some embodiments, the edge of the flexible membrane covering the inner mold core is pressed against the bottom of the inner mold core to achieve a sealed connection between the flexible membrane and the inner mold core.

[0011] In some embodiments, the outer shape of the inner mold core is consistent with the inner shape of the molded article.

[0012] In some embodiments, the inner shape of the outer mold is consistent with the outer shape of the molded article.

[0013] In some embodiments, the cross-sectional shape of the inner mold core includes at least one of circular, square, honeycomb, grid, annular, or gear-shaped.

[0014] In some embodiments, the outer mold includes a side mold and a bottom mold, the inner mold core is disposed on the bottom mold, the side mold has a structure that extends through both ends, the first end of the side mold is detachably connected to the periphery of the bottom mold, and the pressing mold can seal the opening at the second end of the side mold.

[0015] In some embodiments, a heating component is provided at least one of the mold, inner mold core, and outer mold, and the heating component is used to heat the corresponding mold temperature.

[0016] In some embodiments, the molding apparatus includes a support column and a first power member, the die is movably connected to the support column, and the die moves away from or towards the outer mold along the support column under the drive of the first power member.

[0017] In some embodiments, the molding apparatus includes a fixing seat for fixing the first power member, and the fixing seat is fixed to the support column.

[0018] In some embodiments, the molding apparatus includes a support base for supporting the outer mold.

[0019] In some embodiments, the outer mold includes a side mold and a bottom mold, the inner mold core is disposed on the bottom mold, the side mold has a structure that is through at both ends, the first end of the side mold is detachably connected to the periphery of the bottom mold, and the pressing mold can cover the second end of the side mold; the molding device includes a support base for supporting the outer mold, the bottom mold is mounted on the support base, the support base is provided with a positioning structure, and the side mold is positioned and docked with the bottom mold through the positioning structure.

[0020] In some embodiments, the material includes organic matter, inorganic matter, or mixtures thereof, including coke powder, bitumen, graphite powder, alloy powder, powdered, granular, or fibrous plastics, or combinations thereof.

[0021] In some embodiments, the material includes a dispersant used to distribute the material evenly within the mold cavity; the molding apparatus includes an adsorption filter disposed on the inner wall of the mold cavity formed by the compression mold and the outer mold, and the adsorption filter is used to adsorb and filter the dispersant contained in the material when the material is extruded.

[0022] In some embodiments, the dispersant includes, but is not limited to, water, alcohol, methanol, formaldehyde, benzene, toluene, and phenol.

[0023] The embodiments of this specification also relate to a molding method, which is applied to the molding apparatus described above; the molding method includes: filling material into the mold cavity; pressing down the die to connect with the opening of the outer mold; under the pressure of the die, the die, the inner mold core and the outer mold jointly extrude the material to form a molded product.

[0024] In some embodiments, the molding apparatus includes a flexible membrane, which covers the outer surface of the inner mold core and is sealed to the inner mold core, forming a pressure cavity between the flexible membrane and the inner mold core; the molding method includes: pressing the mold down to connect with the opening of the outer mold, increasing the pressure in the pressure cavity to the required pressure value, and the pressure in the pressure cavity causing the flexible membrane to expand, thereby extruding the material in the mold cavity to form a molded product.

[0025] In some embodiments, the outer mold includes a side mold and a bottom mold, the inner mold core is disposed on the bottom mold, the side mold has a structure that is through at both ends, the first end of the side mold is detachably connected to the periphery of the bottom mold, and the pressing mold can cover the second end of the side mold; the molding method includes: after the material is extruded and molded, the pressure in the pressurizing chamber is released, the side mold and the bottom mold are disassembled, and the side mold is removed to obtain the molded product.

[0026] The embodiments of this specification also relate to a graphite product prepared by the above-described molding apparatus or by the above-described molding method. The graphite product includes a graphite crucible, a graphite tube, and a graphite sagger.

[0027] In some embodiments, the length of the graphite article is greater than or equal to 500 mm, the width of the graphite article is greater than or equal to 500 mm, and the height of the graphite article is greater than or equal to 800 mm.

[0028] In some embodiments, the overall bulk density difference of the graphite product is less than 0.02 g / cm³.

[0029] The embodiments of this specification also relate to a molded article prepared according to the molding apparatus described above, or prepared according to the molding method described above. The molded article is extruded from at least one of organic matter, inorganic matter, or a mixture thereof. The organic matter, inorganic matter, or a mixture thereof includes coke powder, asphalt, graphite powder, alloy powder, and powdered, granular, or fibrous plastic.

[0030] In some embodiments, the overall bulk density difference of the molded article is less than 0.02 g / cm³.

[0031] The molding device of this utility model quantitatively fills the mold cavity formed between the inner mold core and the outer mold through an opening at the top of the outer mold. The material flows naturally under the influence of gravity and is initially shaped under the constraint of the mold cavity. The die is then pressed down to connect with the opening at the top of the outer mold, extruding the material. During the extrusion process, the material does not involve large-scale flow, the extrusion pressure is uniform, and the resulting molded product has good structural uniformity, stable performance, and a service life extended by more than 20%.

[0032] Because the material does not require extensive flow during extrusion, there is little or no friction between the inner and outer mold cores, thus not limiting the size and structure of the molded product. Existing round crucibles can be replaced by square crucibles produced by this device. In addition to increasing the number of uses, the capacity of a square crucible of the same size is 25% greater than that of a round crucible, significantly reducing graphitization production costs. Furthermore, the molded products prepared using the molding device designed in this invention show significantly improved quality, longer service life, and a significantly increased number of uses compared to existing products. When these molded products are used to produce positive and negative electrode materials for lithium batteries, the number of molded products required to produce the same amount of lithium battery positive and negative electrode materials is greatly reduced, lowering the production cost of lithium batteries and demonstrating significant economic value. Attached Figure Description

[0033] The above-described features and advantages of this invention can be better understood after reading the following detailed description of the embodiments of this disclosure in conjunction with the accompanying drawings. In the drawings, the components are not necessarily drawn to scale, and components having similar related characteristics or features may have the same or similar reference numerals. Wherein: Figure 1 This is a schematic diagram of the crucible manufacturing equipment; Figure 2 This is a schematic diagram of the molding apparatus shown in some embodiments; Figure 3 This is a schematic diagram of the cross-sectional shape of the inner mold core according to some embodiments; Figure 4 This is a schematic diagram of the cross-sectional shape of the inner mold core according to some other embodiments; Figure 5 This is a schematic diagram of the cross-sectional shape of the inner mold core according to some embodiments; Figure 6 The inner mold core has Figure 5 A schematic diagram of the cross-sectional shape shown; Figure 7 This is a schematic diagram of the connection structure between the flexible membrane and the inner mold core, as shown in some embodiments; Figure 8 This is a schematic diagram of the adsorption filter setup shown in some embodiments.

[0034] Explanation of reference numerals in the attached figures: 100 - Molding device; 110 - Press mold; 120-Inner mold core; 130 - Outer mold; 131 - Bottom mold; 1311-Workpiece holder; 132-Side mold; 140 - Mold cavity; 150 - Flexible membrane; 160-Pressure channel; 170 - Support column; 180 - First power component; 181-Fixed base; 190-Support base; 61 - Adsorption filter. Detailed Implementation

[0035] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should be noted that the aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention in any way.

[0036] It should be understood that the terms “system,” “device,” “unit,” and / or “module” used herein are one method of distinguishing different components, elements, parts, sections, or assemblies at different levels. However, if other words can achieve the same purpose, they may be replaced by other expressions.

[0037] It is understood that the technical terms that may be involved in the description of this specification, such as “center,” “longitudinal,” “lateral,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer,” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the implementation method and do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of the utility model.

[0038] It should be noted that the use of terms such as "first" and "second" to define features in this article is merely for the purpose of distinguishing the corresponding features. Unless otherwise stated, the above terms have no special meaning and therefore cannot be construed as limiting the scope of protection of this utility model.

[0039] In the description of this specification, it should also be noted that, unless otherwise expressly specified or limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, an integral connection, or a detachable connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection through an intermediate medium, or a connection within two components, etc. Those skilled in the art can understand the specific meaning of the above terms in this specification according to the specific circumstances.

[0040] This specification provides a molding apparatus comprising a die, an inner core, and an outer mold. The inner core is fixed to the bottom of the outer mold, and the top of the outer mold has an opening. A cavity adapted to the molded product is formed between the periphery of the inner core and the outer mold. The die is pressed down to connect with the opening of the outer mold, and the die, inner core, and outer mold jointly extrude material to form the molded product. The molded product is a hollow structure with an inner wall and an outer wall. The inner wall of the outer mold conforms to the shape of the outer wall of the molded product, and the outer surface of the inner core conforms to the shape of the inner wall of the molded product.

[0041] In some embodiments, the outer mold is a cylindrical structure with a bottom and an open top. The inner mold core is a columnar structure with a square, circular, or triangular cross-section, or it may be a cylindrical structure without a top. The side of the pressing mold near the outer mold is adapted to the opening of the outer mold. When the pressing mold is pressed down to engage with the opening of the outer mold, it can seal the opening near the outer mold, so that the pressing mold and the outer mold together form a sealed space. In some embodiments, at least a portion of the peripheral side of the pressing mold is adapted to the opening of the outer mold, and at least a portion of the peripheral side of the pressing mold contacts the opening of the outer mold, thereby achieving the connection between the pressing mold and the outer mold. In some embodiments, the peripheral side of the pressing mold protrudes outward relative to the outer mold, and the side of the pressing mold near the outer mold contacts the top of the outer mold, sealing the opening of the outer mold, thereby achieving the connection between the pressing mold and the outer mold.

[0042] Specifically, materials capable of being extruded into molded products are quantitatively filled into the cavity formed between the inner mold core and the outer mold, where the material is initially shaped under the constraint of the cavity. The die is then pressed down to connect with the opening of the outer mold, and the die, inner mold core, and outer mold work together to extrude the material and form the product. During the extrusion process, the material does not involve large-scale flow, resulting in uniform extrusion pressure, good structural uniformity, stable performance, and extended service life of the molded product. Furthermore, because the material does not require large-scale flow during extrusion, there is almost no or no frictional force relative to the inner mold core and outer mold, thus not limiting the size and structure of the molded product. However, with existing crucible manufacturing equipment, when extruding crucibles, the crucible height exceeds 800mm, leading to a significant decrease in crucible quality, a short service life, and a substantial impact on the cost of lithium battery production. Under pressure limitations, the maximum extrusion height achievable with existing crucible manufacturing equipment is 1200mm. In some production processes, to address quality issues with molded products, the wall thickness is increased, and / or the size of the molded product is reduced. However, with 100% extrusion using the molding device, the quality of the molded product is unaffected by its wall thickness or size.

[0043] The forming apparatus described in this specification can be used not only to extrude carbon graphite crucibles, but also to extrude graphite saggers, alloy parts, plastic parts and other hollow structural parts that can be extruded, such as silicon carbide protective tubes, refractory crucibles for holding high-temperature molten metal, refractory guide tubes, and protective tubes for refractory materials (such as silicon carbide, silicon nitride and various mixtures).

[0044] In some embodiments, the molding apparatus can be used not only for the production of lithium batteries, but also for the manufacture of automobiles, aircraft, and sporting goods.

[0045] It should be noted that the application scenarios of the molding apparatus described herein are merely illustrative and not intended to be limiting. Based on the structure and working principle of the molding apparatus described in this specification, the molding apparatus can be used in a wider range of work scenarios aimed at improving the quality of molded products, rather than being limited to the scenarios listed herein. For ease of explanation, the following description, in conjunction with the accompanying drawings, will use the molding apparatus for extruding crucibles as an example.

[0046] Figure 2 This is a structural schematic diagram of a molding apparatus according to some embodiments. For example... Figure 2As shown in the embodiments of this specification, a molding apparatus 100 is proposed. The molding apparatus 100 includes a mold 110, an inner mold core 120, and an outer mold 130. The inner mold core 120 is fixed to the bottom of the outer mold 130, and the top of the outer mold has an opening. A mold cavity 140 adapted to the molded product is formed between the inner mold core 120 and the outer mold 130. The mold 110 is pressed down to connect with the opening of the outer mold 130. The mold 110, the inner mold core 120, and the outer mold 130 jointly extrude material to form a molded product. The molded product has a hollow structure with an inner wall and an outer wall. The inner wall surface of the outer mold 130 is adapted to the shape of the outer wall of the molded product, and the outer surface of the inner mold core 120 is adapted to the shape of the inner wall of the molded product.

[0047] In some embodiments, the outer mold 130 is a cylindrical structure with a cross-sectional shape such as circular, square, triangular, polygonal, gear-shaped, etc. In some embodiments, the outer mold 130 has a bottom and an opening at the top. In some embodiments, the inner mold core 120 is a columnar structure with a cross-sectional shape such as circular or square. In some embodiments, the inner mold core 120 is a cylindrical structure with a cross-sectional shape such as circular, square, triangular, polygonal, gear-shaped, honeycomb-shaped, grid-shaped, etc. It may have a top and a bottom, or only a bottom or a top. The inner mold core 120 may also be a cylindrical structure with both ends extending through it, i.e., without a bottom and a top. When extruded using the molding device 100, the quality of the molded product is not affected by its shape. However, existing crucible manufacturing equipment is generally only used for extruding round crucibles. For square crucibles, due to the flowability issues of the material, the extrusion effect using existing crucible manufacturing equipment is even worse. However, square crucibles have a longer service life and larger volume than round crucibles of the same size. Using the forming device 100 to extrude square crucibles can increase the furnace loading capacity by more than 25%. When producing the same amount of negative electrode material, the production cost of square crucibles extruded using the forming device 100 is reduced by more than 20%. Furthermore, the production of ultra-large metal smelting crucibles, such as those with a diameter greater than 1.5 meters and a height greater than 2.5 meters, typically involves isostatic pressing to produce a solid body, followed by calcination and graphitization. However, due to the excessively large volume required, calcination and graphitization are prone to cracking, resulting in unsatisfactory product quality. Using the forming device 100 described in this specification to produce ultra-large metal smelting crucibles, after testing, its forming performance basically meets the requirements of isostatic pressing. The formed products have excellent quality and good structural uniformity, are not constrained by the size of the formed blank, and the product quality meets the requirements.

[0048] Figure 3 This is a schematic diagram of the cross-sectional shape of the inner mold core according to some embodiments. Figure 4 This is a schematic diagram of the cross-sectional shape of the inner mold core according to other embodiments. In some embodiments, the cross-sectional shape of the inner mold core 120 includes a honeycomb pattern. For example, as... Figure 3 As shown, the cross-sectional shape of the inner mold core 120 is a 9-hole circular honeycomb pattern. In some other embodiments, the cross-sectional shape of the inner mold core 120 includes a grid-like or other irregular shape. For example, as... Figure 4 As shown, the inner mold core 120 has a cross-sectional shape of a 7-hole grid. In some embodiments, the inner mold core 120 includes multiple sub-mold cores, enabling the production of multiple molded articles in a single molding process. In this case, the inner mold core 120 has a through-end structure, meaning it does not have a bottom or top, allowing material to enter the inner mold core 120, for example, between the grid openings of the inner mold core 120, and be extruded and molded under the action of the mold 110 or the flexible membrane 150 described later.

[0049] Figure 5 This is a schematic diagram of the cross-sectional shape of the inner mold core according to some embodiments; Figure 6 The inner mold core has Figure 5 A schematic diagram of the cross-sectional shape shown.

[0050] In some embodiments, such as Figure 5 and Figure 6 As shown, the inner mold core 120 has a square grid-like cross-section. The inner mold core 120 has internal partitions that divide its cross-section into four parts. The inner mold core 120 is a through-hole structure, meaning it lacks a bottom and top, allowing material to enter. The flexible membrane, described later, is arranged along the inner mold core 120, including the internal partition surfaces, which strengthens the structural strength of the inner mold core 120. Molded products produced using the inner mold core 120 have a built-in reinforcing grid, resulting in better performance, especially when the overall size of the molded product is large. It also further increases the effective volume of the product inside the molded product, reducing graphitization production costs.

[0051] Some embodiments in this specification can adapt to the needs of different quantities, structures and shapes of molded products by changing the shape and structure of the inner mold core 120, thereby increasing the effective volume inside the molded product.

[0052] In the application of graphite sagger forming, there are two existing methods for producing graphite saggers. One method is to make graphite material into solid blocks and then carve them into saggers, resulting in material loss of up to 80%. The other method is to use extrusion equipment similar to existing crucible manufacturing equipment, which also suffers from problems such as uneven structure and inconsistent density, making the saggers easy to damage in actual use.

[0053] In some embodiments, see continue to see Figure 2The molding apparatus 100 includes a flexible membrane 150, which covers the outer surface of the inner mold core 120. A mold cavity 140 is located between the flexible membrane 150 and the outer mold 130. The flexible membrane 150 is sealed to the inner mold core 120, forming a pressure chamber between them. By applying pressure to the pressure chamber, the flexible membrane 150 uniformly extrudes material towards the outer mold 130 and the compression mold 110. A mold cavity adapted to the molded product is formed between the flexible membrane 150, the outer mold 130, and the compression mold 110. The compression mold 110, the inner mold core 120, the flexible membrane 150, and the outer mold 130 jointly extrude material to form the molded product. In some embodiments, the shape and structure of the flexible membrane 150 are adapted to the shape and structure of the inner mold core 120. In some embodiments, the flexible membrane 150 is made of expandable rubber or composite rubber material (e.g., silicone rubber, fluororubber, nitrile rubber, natural rubber, etc.).

[0054] Figure 7 This is a schematic diagram of the connection structure between the flexible membrane and the inner mold core, as shown in some embodiments. Figure 7 What is shown is Figure 2 Enlarged view of the connection between the flexible membrane and the inner mold core.

[0055] In some embodiments, such as Figure 7 As shown, the inner mold core 120 is fixed to the bottom of the outer mold 130. The flexible membrane 150 that wraps the inner mold core 120 has an edge portion 151 near the bottom of the outer mold 130. In order to maintain the uniformity of the pressure chamber, the edge portion 151 of the flexible membrane 150 near the bottom of the outer mold 130 is pressed between the inner mold core 120 and the outer mold 130. Specifically, the edge portion 151 of the flexible membrane 150 is pressed between the bottom of the inner mold core 120 and the bottom of the outer mold 130, so that the flexible membrane 150 and the inner mold core 120 are sealed together.

[0056] In some embodiments, the flexible membrane 150 has an elastic, uniform structure. When pressurized in the pressurizing chamber, the flexible membrane 150 deforms under the pressure of the pressurizing chamber, uniformly pressing the material located in the mold cavity 140, and cooperating with the die 110 to extrude and shape the material. In some embodiments, after the die 110 is pressed down to connect with the outer mold 130, it pressurizes the pressurizing chamber. Under the extrusion of the die 110, the flexible membrane 150 uniformly presses the material located in the mold cavity 140.

[0057] In some embodiments, the molding apparatus 100 includes a pressurizing component for pressurizing a pressurizing chamber. In some embodiments, the pressurizing component introduces gas, liquid, or a gas-liquid mixture into the pressurizing chamber to achieve pressurization. For example, the gas includes air, inert gas, etc., and the liquid includes water, hydraulic oil, etc. In some embodiments, the pressurizing component has a preset pressure. After pressurizing the pressurizing chamber to the preset pressure, the pressurizing component stops pressurizing to ensure the safety of the apparatus operation and protect the structure of the molding apparatus 100 and the molded product. In some embodiments, the pressurizing component includes a hydraulic pressurizing system, a gas-liquid booster pressurizing system, a servo-electric pressurizing system, etc.

[0058] There are several ways to pressurize the pressure chamber; two are listed here as examples. In some embodiments, the pressure chamber is directly pressurized. For example only, a pressure channel is provided on the inner mold core 120; for instance, the pressure channel is a hydraulic pipe. The pressure channel communicates with the pressure chamber and is connected to a pressure-pressurizing component. The pressure-pressurizing component introduces gas, liquid, or a gas-liquid mixture into the pressure chamber through the pressure channel, thereby pressurizing the pressure chamber.

[0059] In some embodiments, pressure is indirectly applied to the pressurization chamber. Specifically, such as Figure 2 As shown, the inner mold core 120 is a hollow structure with a cavity. A through hole 121 is provided on the inner mold core 120, penetrating the sidewall of the inner mold core 120. The pressure chamber communicates with the cavity of the inner mold core 120 through the through hole 121, and pressure is applied to the pressure chamber by applying pressure to the cavity of the inner mold core 120. In some embodiments, the inner mold core 120 is provided with multiple through holes 121, which are evenly distributed on the inner mold core 120. The cavity of the inner mold core 120 acts as a buffer for the pressure in the pressure chamber, keeping the pressure within the pressure chamber uniform, thereby ensuring that the flexible membrane 150 applies uniform pressure to the material from the beginning. A pressurizing channel 160 is provided on the inner mold core 120. The pressurizing channel 160 is connected to a pressurizing component. The pressurizing component introduces gas, liquid or gas-liquid mixture into the cavity of the inner mold core 120 through the pressurizing channel. Then, the gas, liquid or gas-liquid mixture enters the pressurizing cavity through the through hole 121 on the inner mold core 120, thereby pressurizing the pressurizing cavity.

[0060] In some embodiments, such as Figure 7As shown, the outer mold 130 includes a bottom mold 131 and a side mold 132. The bottom mold 131 is disposed at the bottom of the outer mold 130, and the inner mold core 120 is fixedly installed on the bottom mold 131. The side mold 132 has a through-end structure, with the first end of the side mold 132 detachably connected to the periphery of the bottom mold 131. The pressure mold 110 can cover the opening at the second end of the side mold 132. In some embodiments, the outer mold 130 includes a workpiece seat 1311, which is attached to the bottom mold 131 and arranged around the periphery of the inner mold core 120. The material in the mold cavity 140 contacts the workpiece seat 1311, facilitating demolding of the extruded material. After the material in the mold cavity 140 is extruded and formed, the pressure in the pressure chamber is released, the side mold 132 is moved upward to separate it from the bottom mold 131, and the workpiece seat 1311 is raised to obtain the molded product.

[0061] In some embodiments, a boss is provided on the lower side of the die 110, that is, the side near the outer die 130, and the boss protrudes toward the outer die 130. When the lower side of the die 110 is close to and in contact with the outer die 130, the boss is used to embed into the interior of the outer die 130, that is, to extend into the mold cavity 140 and squeeze the material in the mold cavity 140.

[0062] In some embodiments, the molding apparatus includes a support column 170, a die 110 movably connected to the support column 170, the support column 170 being fixed, and the die 110, driven by a first power member 180, moving along the support column 170 towards the outer die 130 to maintain the stability of the die 110 during the connection process with the outer die 130. In some embodiments, the support columns 170 are vertically arranged on both sides of the outer die 130. In some embodiments, guide sleeves are provided at the corresponding two ends of the die 110, forming a clearance fit with the support column 170 to achieve the movable connection between the die 110 and the support column 170.

[0063] In some embodiments, the first power member 180 drives the die 110 to move vertically. For example, the first power member 180 is a servo hydraulic cylinder or an electric ball screw mechanism. In some embodiments, the molding apparatus 100 includes a fixed base 181 for fixing the first power member 180, and the fixed base 181 is fixed to the support column 170. In some embodiments, the molding apparatus 100 includes a mechanical locking device, and the pressure between the die 110 and the outer die 130 is provided not only by the first power member 180 but also by the mechanical locking device. In some embodiments, during the molding process, the first power member 180 drives the side die 132 to move upward, causing the side die 132 to disengage from the bottom die 131, and lifts the workpiece seat 1311 to obtain the molded product.

[0064] In some embodiments, the molding apparatus 100 includes a support base 190 for supporting the outer mold 130. In some embodiments, to facilitate the setting of the pressure member, when a pressure channel is provided on the inner mold core 120, the outer mold 130 and the support base 190 are respectively connected through the pressure channel, and the pressure channel pressurizes the pressure chamber through or connected to the pressure member.

[0065] In some embodiments, the molding apparatus 100 includes a stirring rod or a vibrating rod for uniformly dispersing materials in the mold cavity 140. After the materials are quantitatively filled into the mold cavity 140, the stirring rod or vibrating rod is activated. The stirring rod or vibrating rod penetrates into the materials to assist in uniform material filling, which helps to ensure the uniform structure of the molded product.

[0066] In some embodiments, a heating component is provided at least one of the mold 110, inner mold core 120, and outer mold 130. The heating component is used to heat the corresponding mold temperature to heat the temperature of the material inside the mold cavity 140, facilitating the stirring, mixing, and extrusion of the material. For example, heating components are provided on the mold 110, inner mold core 120, and outer mold 130, respectively heating the mold temperature of the mold 110, inner mold core 120, and outer mold 130. In some embodiments, the heating component can be a heating component using water, oil, or the like as the heating medium, or it can be an electric heating component using resistance heating as the medium.

[0067] In some embodiments, the material includes a dispersant used to ensure uniform distribution of the material within the mold cavity 140. Alloy powders, powdered, granular, or fibrous plastics are extruded into sheet-like or tubular composite materials with the aid of a dispersant, followed by heat treatment and other processing to produce highly elastic, high-flexural-strength, and lightweight materials. Under the pressure of the die 110 and the flexible membrane 150, the dispersant is extruded from the material, requiring assistance in discharging the dispersant from the material.

[0068] Figure 8 This is a schematic diagram of the adsorption filter setup shown in some embodiments.

[0069] In some embodiments, such as Figure 8 As shown, the molding device 100 includes an adsorption filter 61, which is disposed on the inner wall of the mold cavity 140 formed by the mold 110 and the outer mold 130. That is, the adsorption filter 61 is located inside the mold cavity 140. Figure 8The diagram shows a partial area between the mold 110 and the inner mold core 120 in the molding apparatus 100, illustrating the arrangement of the adsorption filter 61 on the inner wall of the mold 110. A similar arrangement is shown on the inner wall of the outer mold 130. When the mold 110 and the flexible membrane 150 jointly extrude the material, the adsorption filter 61 adsorbs and filters the dispersant contained in the material, helping the material to expel the dispersant. In some embodiments, the adsorption filter 61 is attached to the inner wall of the cavity 140 formed by the mold 110 and the outer mold 130, covering the entire inner wall of both molds, increasing the adsorption and filtration area. The adsorption filter 61 can filter out liquid or gas components in the material during molding and pressurization. For multiple materials with different surface properties that are difficult to mix evenly, a third medium with dispersing properties (which does not affect product performance), either liquid or gas, helps to mix the materials evenly before they are fed into the molding mold cavity and then pressurized.

[0070] This specification also relates to a graphite product prepared by the molding apparatus 100 described above. In some embodiments, the graphite product includes a graphite crucible, a graphite tube, and a graphite sagger. In some embodiments, the molding apparatus 100 extrudes the material, not limited by the size of the graphite product. The molding apparatus 100 can extrude graphite products of non-standard sizes, with a length dimension greater than or equal to 500 mm, a width dimension greater than or equal to 500 mm, and a height dimension greater than or equal to 800 mm. It is understood that the molding apparatus 100 can of course extrude graphite products of conventional sizes.

[0071] In some embodiments, the overall bulk density difference of the graphite product is less than 0.02 g / cm³. In some embodiments, the overall bulk density difference of the graphite product is less than 0.01 g / cm³, avoiding structural delamination caused by flow and effectively extending the service life of the graphite product. As an example only, the production of a graphite crucible with a length of 600 mm, a width of 600 mm, and a height of 1200 mm shows that the overall bulk density difference of the graphite crucible is less than 0.01 g / cm³, preventing structural delamination caused by flow, and the service life of the graphite crucible is 5-6 cycles.

[0072] Currently, due to limitations in molding equipment, the vast majority of graphite crucibles are round. Graphitization production primarily uses crucibles with a diameter of 600mm and a height of 1200mm, a wall thickness of 35mm-40mm, and a lifespan of approximately 4 uses. The production cost is about 1400 yuan per crucible (including the lid). During production, these crucibles occupy a 600mm×600mm×1200mm space within the furnace, representing 57.2% of the effective volume. Furthermore, the crucible height is limited; 1200mm is the upper limit, and further increases would severely impact lifespan. If existing extrusion equipment is used to manufacture square crucibles, the difficulty of extrusion molding results in low yield, high cost, and lower quality compared to round crucibles. The required wall thickness is greater (approximately 60-80mm), and the lifespan is only 2-3 uses.

[0073] The graphite crucible produced using the forming device 100 has a length of 600mm, a width of 600mm, and a height of 1200mm. During production, it occupies a space of 600×600×1200mm within the furnace, representing 72.8% of the crucible's effective volume. The graphite crucible is not limited by the forming device 100 and can be made to approximately 1500mm or even higher, depending on the requirements of different graphitization furnaces. This primarily depends on the size of the forming device 100, but it does not affect the quality of the graphite crucible. Graphite crucibles can also be larger, for example, with a length of 1000mm, a width of 1000mm, and a height of 1200mm. The comprehensive cost of graphitization production is approximately 9000 yuan / ton. Using the forming device 100, a production cost of 9000 yuan can produce 1.25 tons of graphite anodes. Under the same production conditions, the production cost can be directly reduced to below 7200 yuan / ton. Currently, the production of anode materials using graphitization in round crucibles is 2.5 million tons per year. However, the use of molding equipment 100 to manufacture high-quality square crucibles has increased service life and number of uses, which greatly reduces production costs.

[0074] This specification also relates to a molded article prepared by the molding apparatus 100 described above. In some embodiments, the molded article is extruded from at least one of coke powder, asphalt, graphite powder, alloy powder, and powdered, granular, or fibrous plastic. In some embodiments, the molding apparatus 100 extrudes the material without being limited by the size of the molded article. The molding apparatus 100 can extrude molded articles of non-standard sizes, with a length dimension greater than or equal to 500 mm, a width dimension greater than or equal to 500 mm, and a height dimension greater than or equal to 800 mm. It is understood that the molding apparatus 100 can of course extrude molded articles of conventional sizes. In some embodiments, the overall bulk density difference of the molded article is less than 0.02 g / cm³. In some embodiments, the overall bulk density difference of the molded article is less than 0.01 g / cm³, avoiding structural delamination caused by flow and effectively extending the service life of the graphite product.

[0075] The basic concepts have been described above. It is clear that the detailed disclosure above is merely illustrative and does not constitute a limitation of this specification, especially for those skilled in the art. Furthermore, unless expressly stated in the claims, the order of elements and sequences, the use of numbers and letters, or other names in this specification are not intended to limit the order of the processes and methods described herein. Although various examples of utility model embodiments that are currently considered useful have been discussed in the foregoing disclosure, it should be understood that such details are for illustrative purposes only, and the appended claims are not limited to the disclosed embodiments. Rather, the claims are intended to cover all modifications and equivalent combinations that conform to the substance and scope of the embodiments described herein.

Claims

1. A molding apparatus characterized by comprising: The forming device includes a mold, an inner mold core, an outer mold, and a flexible film; The inner mold core is fixed to the bottom inside the outer mold, and the top of the outer mold is provided with an opening. The pressing mold is pressed down to connect with the opening of the outer mold. The flexible membrane is wrapped around the outer surface of the inner mold core, and the flexible membrane is sealed to the inner mold core. A pressure cavity is formed between the flexible membrane and the inner mold core, and a mold cavity adapted to the molded product is formed between the flexible membrane, the outer mold, and the pressure mold. The material extruded by the mold, the inner mold core, the flexible membrane, and the outer mold together forms the molded product.

2. The forming device of claim 1, wherein The inner mold core is a hollow structure with a cavity. The inner mold core is provided with a through hole. The pressure chamber is connected to the cavity through the through hole. The inner mold core is provided with a pressure channel for communicating with a pressure member. The pressure member is used to introduce gas, liquid, or a gas-liquid mixture into the pressure chamber to pressurize it. The cavity of the inner mold core is connected to the pressure member through the pressure channel.

3. The forming device according to claim 1 or 2, characterized in that The flexible membrane has a uniform structure with elasticity, and its shape is adapted to the shape of the inner mold core.

4. The forming device according to claim 1 or 2, characterized in that The flexible membrane covers the edge of the inner mold core and presses it against the bottom of the inner mold core to achieve a sealed connection between the flexible membrane and the inner mold core.

5. The forming device according to any one of claims 1-2, characterized in that, The outer shape of the inner mold core is consistent with the inner shape of the molded product.

6. The forming device of any one of claims 1-2, wherein, The inner shape of the outer mold is consistent with the outer shape of the molded product.

7. The forming device according to any one of claims 1-2, characterized in that, The cross-sectional shape of the inner mold core includes at least one of the following: circular, square, honeycomb, grid, annular, or gear-shaped.

8. The forming device of any of claims 1-2, wherein, The outer mold includes a side mold and a bottom mold. The inner mold core is disposed on the bottom mold. The side mold has a structure that is open at both ends. The first end of the side mold is detachably connected to the periphery of the bottom mold. The pressing mold can seal the opening at the second end of the side mold.

9. The forming device of any of claims 1-2, wherein, At least one of the compression mold, the inner mold core, and the outer mold is provided with a heating component, which is used to heat the corresponding mold to the required temperature.

10. The forming device of any of claims 1-2, wherein, The molding device includes a support column and a first power component. The mold is movably connected to the support column. Under the drive of the first power component, the mold moves away from or towards the outer mold along the support column.

11. The forming device of claim 10, wherein The molding device includes a fixing base for fixing the first power component, and the fixing base is fixed to the support column.

12. The forming device of any of claims 1-2, wherein, The molding device includes a support base for supporting the outer mold.

13. The forming device of any of claims 1-2, wherein, The outer mold includes a side mold and a bottom mold. The inner mold core is disposed on the bottom mold. The side mold has a structure that is open at both ends. The first end of the side mold is detachably connected to the periphery of the bottom mold. The pressing mold can cover the second end of the side mold. The molding device includes a support base for supporting the outer mold, the bottom mold is mounted on the support base, and a positioning structure is provided on the support base. The side mold is positioned and docked with the bottom mold through the positioning structure.

14. The forming device of any of claims 1-2, wherein, The material includes organic matter, inorganic matter, or mixtures thereof, including coke powder, asphalt, graphite powder, alloy powder, and powdered, granular, or fibrous plastics.

15. The forming device of any of claims 1-2, wherein, The material includes a dispersant, which is used to make the material uniformly distributed within the mold cavity; The forming device includes an adsorption filter screen, which is disposed on the inner wall of the mold cavity formed by the compression mold and the outer mold. When the material is extruded, the adsorption filter screen is used to adsorb and filter the dispersant contained in the material.

16. The forming device of claim 15, wherein, Dispersants include water, alcohol, methanol, formaldehyde, benzene, toluene, and phenol.

17. A graphite article, characterized by, The graphite product is prepared by the molding apparatus according to claim 1, and includes a graphite crucible, a graphite tube, and a graphite sagger.

18. The graphite article of claim 17, wherein, The length of the graphite product is greater than or equal to 500 mm, the width of the graphite product is greater than or equal to 500 mm, and the height of the graphite product is greater than or equal to 800 mm.

19. The graphite article of claim 17, wherein, The overall bulk density difference of the graphite product is less than 0.02 g / cm³.

20. A shaped article characterized by, According to the molding apparatus of claim 1, the molded article is extruded from at least one of organic matter, inorganic matter, or a mixture thereof, wherein the organic matter, inorganic matter, or a mixture thereof includes coke powder, asphalt, graphite powder, alloy powder, and powdery, granular, or fibrous plastic.

21. The shaped article of claim 20, wherein, The overall bulk density difference of the molded product is less than 0.02 g / cm³.

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