Cold-pressed integrated high-strength inductor and its forming process

Abstract

The present application discloses a cold-pressed integrally formed high-strength inductor and its forming process, which relates to the field of electronic component processing technology. The cold-pressed integrally formed high-strength inductor includes an inductor body and a wire winding. The wire winding is buried inside the inductor body. The wire winding includes a spiral main body part, and extension connection segments are respectively arranged at both ends of the spiral main body part. The outer diameters of adjacent spiral coils of the spiral main body part are different; the inductor body has two opposite pressure-bearing surfaces, and the center line of the spiral main body part is perpendicular to the pressure-bearing surface of the inductor body. In the present application, the different outer diameters of adjacent spiral coils of the spiral main body part enable the powder material between adjacent two spiral coils located in the spiral main body part to be pressed as fully as possible, which is beneficial to ensuring the structural strength of the inductor body.

Description

Technical Field

[0001] This application relates to the field of electronic device processing technologies, and particularly to cold-pressed integrally formed high-strength inductors and their forming processes. Background Art

[0002] An inductor is an important component of a circuit board and is used to store and release magnetic energy. An integrally formed inductor is a relatively common type of inductor. The integrally formed inductor includes an inductor body and a wire winding. The inductor body is formed by cold-pressing the wire winding into a magnetic powder material.

[0003] In the process of cold-pressing and forming an integrally formed inductor, since the wire winding will form a certain obstructive effect on the movement of the magnetic powder material, it is difficult for the magnetic powder material to fully wrap the coils of the wire winding under the action of the pressure of the forming equipment, resulting in poor uniformity of the material distribution inside the inductor body. As a result, during the cold-pressing process and the subsequent use of the integrally formed inductor after cold-pressing, cracking is more likely to occur. Summary of the Invention

[0004] In order to reduce the cracking during the cold-pressing process and the subsequent use of the cold-pressed integrally formed inductor, this application provides a cold-pressed integrally formed high-strength inductor and its forming process.

[0005] The cold-pressed integrally formed high-strength inductor and its forming process provided by this application adopt the following technical solutions:

[0006] The cold-pressed integrally formed high-strength inductor includes an inductor body and a wire winding. The wire winding is embedded inside the inductor body. The wire winding includes a spiral main body portion, and extension connection segments are respectively provided at both ends of the spiral main body portion. The outer diameters of adjacent spiral coils of the spiral main body portion are different; the inductor body has two oppositely arranged pressure-bearing surfaces, and the center line of the spiral main body portion is perpendicular to the pressure-bearing surface of the inductor body.

[0007] By adopting the above technical solutions, the inductor body is integrally cold-pressed and formed by powder materials, and the inductor body mainly bears the pressure of the pressure equipment through the pressure-bearing surfaces. The wire winding is pre-embedded in the powder materials. When the powder materials are cold-pressed to form the inductor body, the pressure received by the powder materials acts on both the spiral main body portion and the extension connection segments of the wire winding at the same time. Since the outer diameters of adjacent spiral coils of the spiral main body portion are different, the powder materials located between adjacent two spiral coils of the spiral main body portion are pressed as fully as possible, which is beneficial to making the material distribution more uniform after the powder materials are cold-pressed to form the inductor body, and thus is beneficial to ensuring the structural strength of the inductor body.

[0008] Optionally, the diameter of the spiral coils of the spiral main body portion gradually increases from the middle to both ends.

[0009] By adopting the above technical solution, the diameter of the spiral coils at both ends of the spiral body is larger than the diameter of the spiral coil in the middle, so that before the inductor body is cold-pressed, the wire winding can be placed in the mold cavity of the mold more stably.

[0010] Optionally, a radius difference between two adjacent spiral coils of the spiral main body is greater than a wire diameter of the spiral coil.

[0011] By adopting the above technical solution, the radius difference between two adjacent spiral coils of the spiral main body is greater than the wire diameter of the spiral coil, which can ensure that the two adjacent spiral coils of the spiral main body are staggered at a large distance in the radial direction, so that the powder between the two adjacent spiral coils is compressed as fully as possible. Furthermore, the radius difference between two adjacent spiral coils is greater than the wire diameter of the spiral coil, which can enable the spiral main body to be wound to form more coils under the premise of a certain length.

[0012] Optionally, the axial distance between two adjacent spiral coils is smaller than the wire diameter of the wire winding.

[0013] By adopting the above technical solution, under the premise that the axial length of the spiral body is constant, the distance between adjacent spiral coils of the spiral body is made smaller than the wire diameter of the wire winding, so that the spiral body can be wound to form more spiral coils.

[0014] The forming process of the cold-pressed one-piece high-strength inductor includes the following steps: first, pre-adding some powder into the mold cavity of the mold, the pre-added powder needs to be able to fully cover the bottom surface of the mold cavity, and vibrating the powder in the mold using an ultrasonic vibration device; placing the wire winding into the mold cavity, and then filling the remaining powder; continuing to vibrate the powder using an ultrasonic vibration device; and closing the mold for pressing and forming.

[0015] By adopting the above technical solution, when cold-pressing the inductor, the powder is vibrated by an ultrasonic vibration device, so that the distribution of the powder can be more dense. Before placing the wire winding into the mold cavity, a part of the powder is pre-added into the mold cavity of the mold, and the ultrasonic vibration device is used to vibrate, so that a uniform powder layer can be formed at the bottom of the mold cavity, so that when the wire winding is placed into the mold cavity, a certain distance can be formed between the wire winding and the bottom surface of the mold cavity. By controlling the thickness of the pre-filled powder, the minimum distance between the wire winding and the two pressure-bearing surfaces of the inductor body can be controlled, so as to reduce the situation of thin walls formed between the wire winding and the pressure-bearing surface of the inductor body, which is beneficial to ensure the structural strength of various parts of the inductor.

[0016] Optionally, after all the powders are filled, a cavity adapter is placed on the cavity of the mold, and then the powders are vibrated using an ultrasonic vibration device.

[0017] By adopting the above technical solution, during the process of vibrating the powder material by the ultrasonic vibration device, the upper die can confine the powder material within a certain space range together with the die cavity, which is beneficial to improving the compactness of the powder material after vibration.

[0018] Optionally, during the process of vibrating all the loaded powder material by the ultrasonic vibration device, an elastic buffer is placed above the die cavity adapter, and the upper end of the elastic buffer abuts against the upper die in the installed state. During the process of vibrating the powder material by the ultrasonic vibration device, the installed upper die is driven to gradually move downward, so that the compression amount of the elastic buffer gradually increases.

[0019] By adopting the above technical solution, during the process of vibrating the powder material by the ultrasonic vibration device, the upper die in the installed state, the elastic buffer and the die cavity adapter can apply pressure to the powder material in sequence. By gradually moving the upper die in the installed state downward, the compression amount and elastic deformation force of the elastic buffer can be gradually increased, so that the pressure on the powder material is gradually increased, which is beneficial to gradually increasing the compactness of the powder material. The elastic deformation force of the spring is much smaller than the pressure of the pressure device. Applying pressure to the powder material by using the elastic force of the spring can reduce the situation that the frictional resistance between the powder materials is too large and affects the flow of the powder material, so that the ultrasonic vibration device can fully play the role of vibrating and compacting the powder material.

[0020] Optionally, the elastic buffer includes a helical compression spring, end plates are respectively arranged at both ends of the helical compression spring, and a telescopic guide is connected between the two end plates.

[0021] By adopting the above technical solution, the telescopic guide can play a guiding role in the telescopic deformation of the helical compression spring, so that the direction of the elastic deformation force of the helical compression spring can be kept as consistent as possible with the length direction of the helical compression spring, which is beneficial to keeping the elastic force direction of the elastic buffer on the die cavity adapter stable.

[0022] Optionally, a magnet is fixedly arranged at one end of the elastic buffer, the magnet is used for adsorbing the upper die in the installed state, and a rubber damping layer is arranged at the end of the magnet away from the elastic buffer.

[0023] By adopting the above technical solution, when installing the elastic buffer, one end of the elastic buffer is adsorbed on the upper die in the installed state by the magnet, which is beneficial to controlling the relative position between the elastic buffer and the die cavity adapter. In addition, by arranging a rubber damping layer at the end of the magnet away from the rubber damping layer, the situation that the elastic buffer displaces under the action of the ultrasonic vibration device can be reduced.

[0024] Optionally, during the process of pressing and forming, the pressing and forming of the powder material is carried out in sections, and the pressure in the latter-stage pressing and forming is greater than that in the former-stage pressing and forming.

[0025] By adopting the above technical solution, segmentally cold-pressing and forming the powder material at different pressure values is beneficial to ensuring the effect of cold-pressing and forming.

[0026] In summary, the present application includes at least one of the following beneficial technical effects:

[0027] Since the outer diameters of adjacent spiral coils of the spiral main body are different, the powder material located between two adjacent spiral coils of the spiral main body is pressed as fully as possible, which is beneficial to making the material distribution more uniform after the powder material is cold-pressed to form the inductor main body, thereby being beneficial to ensuring the structural strength of the inductor main body.

[0028] On the premise that the axial length of the spiral main body is certain, by making the distance between adjacent spiral coils of the spiral main body less than the wire diameter of the wire winding, more spiral coils can be formed by winding the spiral main body.

[0029] Before placing the wire winding into the cavity, first add part of the powder material into the cavity of the mold in advance to form a uniform powder material layer at the bottom of the cavity, which can control the minimum distance between the wire winding and the two bearing surfaces of the inductor main body, and is beneficial to ensuring the structural strength of each part of the inductor. Description of the Drawings

[0030] Figure 1 is a schematic structural diagram of the cold-pressing integrated high-strength inductor of this embodiment.

[0031] Figure 2 is a schematic structural diagram of the wire winding of this embodiment.

[0032] Figure 3 is a schematic flow diagram of the forming process of the cold-pressing integrated high-strength inductor of this embodiment.

[0033] Figure 4 is a schematic diagram showing the process of cold-pressing and forming the inductor in this embodiment.

[0034] Description of the Reference Numerals:

[0035] 1. Inductor main body; 11. Bearing surface; 2. Wire winding; 21. Spiral main body; 211. Spiral coil; 22. Extended connection section; 23. Flexible partition strip; 3. Terminal; 4. Cavity; 5. Cavity adapter; 6. Upper mold; 7. Elastic buffer; 71. Spiral compression spring; 72. End plate; 73. Telescopic rod; 74. Magnet; 75. Rubber damping layer. Detailed Embodiment

[0036] The following will further describe the present application in detail Figures 1-4 with reference to the attached drawings.

[0037] This embodiment of the present application discloses a cold-pressing integrated high-strength inductor. Refer toFigure 1 and Figure 2 A cold-pressed integrally formed high-strength inductor, comprising an inductor body 1 and a wire winding 2. The wire winding 2 is embedded inside the inductor body 1. The wire winding 2 includes a spiral main body portion 21. Extension connection segments 22 are respectively provided at both ends of the spiral main body portion 21. A terminal 3 is connected to the end of the extension connection segment 22. The terminal 3 is located outside the inductor body 1. The inductor body 1 has two oppositely arranged pressure-bearing surfaces 11. The center line of the spiral main body portion 21 is perpendicular to the pressure-bearing surface 11 of the inductor body 1. During the cold pressing process of the inductor body 1, the inductor body 1 mainly bears the pressure of the pressure device through the pressure-bearing surface 11.

[0038] The diameter of the spiral coil 211 of the spiral main body portion 21 gradually increases from the middle to both ends, that is, the outer diameters of adjacent spiral coils 211 of the spiral main body portion 21 are different. The radius difference between adjacent two spiral coils 211 of the spiral main body portion 21 is greater than the wire diameter of the spiral coil 211. The axial distance between adjacent two spiral coils 211 is less than the wire diameter of the wire winding 2. In another embodiment, the spiral main body portion 21 can be arranged in a form that gradually decreases from the middle to both ends, and can also be arranged in a conical or waveform changing form.

[0039] In order to keep the relative positions of adjacent spiral coils 211 of the spiral main body portion 21 stable, a flexible partition strip 23 is provided on the spiral main body portion 21. The flexible partition strip 23 successively bypasses each spiral coil 211 of the spiral main body portion 21.

[0040] The implementation principle of the cold-pressed integrally formed high-strength inductor in the embodiment of the present application is as follows: The inductor body 1 is integrally cold-pressed from powder materials. Since the outer diameters of adjacent spiral coils 211 of the spiral main body portion 21 are different, the powder materials located between adjacent two spiral coils 211 of the spiral main body portion 21 are pressed as fully as possible, which is beneficial to making the material distribution more uniform after the powder materials are cold-pressed to form the inductor body 1, thereby being beneficial to ensuring the structural strength of the inductor body 1.

[0041] This embodiment also discloses the forming process of the above-mentioned cold-pressed integrally formed high-strength inductor. Referring to Figure 3 and Figure 4 , it includes the following steps:

[0042] Step 1, first pre-add part of the powder material into the mold cavity 4 of the mold. The pre-added powder material needs to be able to fully cover the bottom surface of the mold cavity 4, and use an ultrasonic vibration device to vibrate the powder material in the mold.

[0043] Step 2, put the wire winding 2 into the mold cavity 4, and then fill in the remaining powder material.

[0044] Step 3: After all the powder materials are loaded, first place a cavity adapter 5 on the cavity 4 of the mold, place an elastic buffer 7 above the cavity adapter 5, and make the upper end of the elastic buffer 7 abut against the upper mold 6 in the installed state. Then, use the ultrasonic vibration device to vibrate the powder materials. During the process of vibrating the powder materials by the ultrasonic vibration device, drive the upper mold 6 in the installed state to gradually move downward, so that the compression amount of the elastic buffer 7 gradually increases;

[0045] Step 4: Take out the cavity adapter 5 placed in the cavity 4, close the mold for compression molding; during the compression molding process, the compression molding of the powder materials is carried out in segments, and the pressure in the latter-stage compression molding is greater than that in the former-stage compression molding.

[0046] In the forming process of the cold-pressed integrated high-strength inductor of the present application, before cold-pressing and forming the inductor, first pre-add part of the powder materials into the cavity 4 of the mold to form a uniform powder layer at the bottom of the cavity 4. By controlling the thickness of the pre-loaded powder materials, the minimum distance between the wire winding 2 and the two bearing surfaces 11 of the inductor body 1 can be controlled, which is beneficial to reducing the situation of forming a thin wall between the wire winding 2 and the bearing surfaces 11 of the inductor body 1, and is beneficial to ensuring the structural strength of each part of the inductor.

[0047] In addition, before closing the mold for cold pressing, use the ultrasonic vibration device to vibrate the powder materials in the cavity 4 to make the powder materials more dense. During the process of vibrating the powder materials by the ultrasonic vibration device, at the same time, control the pressure device to move downward, so that the upper mold 6 in the installed state presses the elastic buffer 7 downward, so that the elastic deformation amount of the elastic buffer 7 gradually increases, so that the pressure of the cavity adapter 5 on the powder materials gradually increases, enabling the ultrasonic vibration device to fully play the role of vibrating and densifying the powder materials. By vibrating and densifying the powder materials in advance before cold pressing, it is beneficial to improving the cold pressing effect of the inductor as much as possible.

[0048] The elastic buffer 7 used in Step 3 of the present application includes a helical compression spring 71. End plates 72 are respectively provided at both ends of the helical compression spring 71. A telescopic guide member is connected between the two end plates 72. The telescopic guide member is a telescopic rod 73. A magnet 74 is fixedly provided on one end plate 72 of the elastic buffer 7. The magnet 74 is located on the side of the end plate 72 away from the helical compression spring 71. A rubber damping layer 75 is provided on the side of the magnet 74 away from the helical compression spring 71. The elastic buffer 7 is adsorbed on the lower surface of the upper mold 6 installed on the pressure device through the magnet 74. The rubber damping layer 75 can increase the stability of the position of the elastic buffer 7 and reduce the displacement of the elastic buffer 7.

[0049] The above are all the preferred embodiments of the present application, and the protection scope of the present application is not limited accordingly. Therefore, all equivalent changes made according to the structure, shape, and principle of the present application should be covered within the protection scope of the present application.

Claims

1. The forming process of a cold-pressed integrally formed high-strength inductor, characterized in that, The cold-pressed integrally formed high-strength inductor includes an inductor body (1) and a wire winding (2). The wire winding (2) is buried inside the inductor body (1). The wire winding (2) includes a spiral main body portion (21). Extension connection segments (22) are respectively provided at both ends of the spiral main body portion (21). The outer diameters of adjacent spiral coils (211) of the spiral main body portion (21) are different. The inductor body (1) has two oppositely arranged pressure-bearing surfaces (11). The center line of the spiral main body portion (21) is perpendicular to the pressure-bearing surface (11) of the inductor body (1). A flexible separation strip (23) is provided on the spiral main body portion (21). The flexible separation strip (23) successively bypasses each spiral coil (211) of the spiral main body portion (21). The forming process of the cold-pressed integrally formed high-strength inductor includes the following steps: First, partially add powder into the cavity (4) of the mold. The powder added in advance needs to be able to fully cover the bottom surface of the cavity (4). Use an ultrasonic vibration device to vibrate the powder in the mold. Place the wire winding (2) into the cavity (4), and then fill in the remaining powder. When all the powder is filled, first place a cavity adapter (5) on the cavity (4) of the mold. Place an elastic buffer (7) above the cavity adapter (5), and make the upper end of the elastic buffer (7) abut against the upper mold (6) in the installed state. Use the ultrasonic vibration device to continue vibrating the powder. During the process of the ultrasonic vibration device vibrating the powder, drive the upper mold (6) in the installed state to gradually move downward, so that the compression amount of the elastic buffer (7) gradually increases. Close the mold for compression molding.

2. The forming process of the cold-pressed integrally formed high-strength inductor according to claim 1, characterized in that: The elastic buffer (7) includes a spiral compression spring (71). End plates (72) are respectively provided at both ends of the spiral compression spring (71). A telescopic guide is connected between the two end plates (72).

3. The forming process of the cold-pressed integrally formed high-strength inductor according to claim 1, characterized in that: A magnet (74) is fixedly provided at one end of the elastic buffer (7). The magnet (74) is used to adsorb the upper mold (6) in the installed state. A rubber damping layer (75) is provided at the end of the magnet (74) away from the elastic buffer (7).

4. The forming process of the cold-pressed integrally formed high-strength inductor according to claim 1, characterized in that: During the compression molding process, the compression molding of the powder is carried out in segments, and the pressure in the latter-stage compression molding is greater than that in the former-stage compression molding.

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