A molding apparatus for producing T-core and U-core

Abstract

This invention relates to a molding apparatus for producing T-core and U-core inductors, comprising: a molding housing and a molding apparatus body. The molding apparatus body includes a production molding mold movably installed inside the molding housing. An upper drive unit and a lower drive unit are respectively provided at the top and bottom of the production molding mold. A magnetic mold-changing system is provided between the production molding mold and the upper and lower drive units. The design of the magnetic mold-changing system allows the entire apparatus to switch between T-core and U-core molds, enabling the T-core and U-core molds to be molded on a single machine. This integrates and optimizes resources, reduces the number of devices on the inductor production line, increases the utilization rate of the molding equipment for inductor production by merging processing steps, reduces coordination and management between inductor production equipment, lowers equipment and maintenance costs of the inductor production line, improves the overall performance of the apparatus, integrates functions, optimizes efficiency, and saves land area.

Description

Technical Field

[0001] This invention relates to the field of semiconductor manufacturing technology, and more specifically to a molding apparatus for producing T-core and U-core semiconductors. Background Technology

[0002] The emergence of molded inductors is thanks to the development of computer motherboard and power supply technology. As CPU clock speeds increase, there are higher requirements for stable power supply and filtering. Molded inductors solve this problem. They can work for a long time under high current conditions and provide stable power to the CPU. Of course, the most important function of an inductor is filtering. In this aspect, molded inductors are also excellent. Good material properties and special design make the inductor structure more stable and the impedance lower, thus achieving higher efficiency.

[0003] Currently, the T-Core process has significant advantages in manufacturing ultra-thin, small-sized integrated inductors. Traditional design methods involve winding the coil first and then pressing the magnetic core. T-Core's advantage lies in cold-pressing the magnetic core first, followed by coil winding. This not only shortens the manufacturing process and saves costs but also provides superior performance. Utilizing a proprietary formula of ultra-high permeability magnetic powder, it deeply integrates magnetic powder optimization with wire design, achieving a thinner design while providing high-performance products with low impedance and low loss characteristics. Low impedance and low loss inductors meet the stringent requirements of electronic devices. However, the production of such inductors requires a combination of T-Core and U-Core processes. To meet the production needs of these integrated inductors, separate T-Core and U-Core process equipment are set up in the inductor production line. This results in high equipment and maintenance costs for the entire integrated inductor production line, cumbersome management between inductor production equipment, and a large land area required. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a molding apparatus for T-core and U-core inductor production. Through a magnetic mold-changing system, the entire apparatus can switch between T-core and U-core molds, enabling both to be molded on a single machine. This resource integration and optimized configuration reduces the number of devices on the inductor production line. By merging processing steps, the utilization rate of the inductor molding equipment increases, reducing coordination and management between inductor production equipment, lowering equipment and maintenance costs, and ultimately improving the overall performance, functionality, and efficiency of the apparatus. This method is more efficient and saves land area, making full use of the production workshop. It uses a magnetic mold-changing method to switch between T-core and U-core molds. The junction box is electrically connected to the control circuit, and the control circuit enables power-on and power-off. When powered on, several groups of equally spaced magnetic modules with detection coils generate magnetic force, which is used to magnetically connect the magnetic template to the adjacent mold base for rapid assembly. When powered off, the several groups of equally spaced magnetic modules with detection coils demagnetize, and the magnetic template disconnects from the adjacent mold base for rapid disassembly. This method is more convenient and faster than traditional mold assembly and disassembly methods.

[0005] The present invention provides the following technical solution: a molding device for producing T-core and U-core, comprising: a molding machine housing and a molding device body, the molding device body including a production molding mold movably installed inside the molding machine housing, an upper drive unit and a lower drive unit respectively provided at the top and bottom of the production molding mold, a magnetic mold changing system provided between the production molding mold and the upper drive unit and the lower drive unit, and an automatic powder feeding module movably installed at the rear side of the production molding mold;

[0006] The production molding mold can be either a T-core mold or a U-core mold;

[0007] The upper drive unit is used to drive the upper mold of the production molding die to move.

[0008] The lower drive unit is used to drive the lower mold of the production molding die to move.

[0009] The magnetic mold changing system is used to magnetically change the production mold.

[0010] As a preferred embodiment of the present invention, the production molding die includes a middle mold fixing plate. The top and bottom of the middle mold fixing plate are respectively provided with an upper mold base and a lower mold base in parallel. The upper mold base and the lower mold base are connected through four sets of limiting guide columns, and the four sets of limiting guide columns are respectively located near the four corners. Anti-detachment end seats are fixedly installed at both the upper and lower ends of the four sets of limiting guide columns. The four sets of limiting guide columns are fixedly connected to the middle mold fixing plate, and the four sets of limiting guide columns are slidably connected to the upper mold base and the lower mold base.

[0011] As a preferred embodiment of the present invention, the upper mold base and the lower mold base are respectively fixedly installed with corresponding upper punches and lower punches on one side near the middle mold fixing plate through punch mounting plates, and the middle mold is fixedly installed on the middle mold fixing plate near the upper punches and lower punches.

[0012] As a preferred embodiment of the present invention, the upper drive unit and the lower drive unit are arranged symmetrically. Both the upper drive unit and the lower drive unit include a drive platform fixedly installed inside the molding machine housing. A reducer is fixedly installed on the side of the drive platform away from the production molding mold by fixing bolts. A servo motor is fixedly installed on one side of the reducer. A drive connecting seat is movably installed on the side of the drive platform close to the production molding mold by a transmission screw.

[0013] As a preferred embodiment of the present invention, the input shaft of the reducer and the output shaft of the servo motor are fixedly connected by a coupling, and the output shaft of the reducer and the end of the transmission screw away from the drive connection seat are fixedly connected by a coupling.

[0014] As a preferred embodiment of the present invention, the magnetic mold changing system is composed of an upper magnetic mold changing component and a lower magnetic mold changing component that are symmetrically distributed on the upper and lower sides of the production molding mold. Both the upper and lower magnetic mold changing components include a magnetic template and a mounting magnetic mold base arranged in parallel. The magnetic template is located between the production molding mold and the mounting magnetic mold base. The mounting magnetic mold base and the drive connecting seat are fixedly connected at the end near the production molding mold.

[0015] As a preferred embodiment of the present invention, a number of magnetic modules with detection coils are embedded inside the magnetic template. The magnetic modules with detection coils are electrically connected to junction boxes on both sides. Mounting seats are fixedly installed at the center of the magnetic template. Mounting holes are opened through the mounting seats near both ends. First guide slots are opened through the four corners of the magnetic template.

[0016] As a preferred embodiment of the present invention, magnetic grooves are provided around any one of the several groups of equally spaced magnetic modules with detection coils on the side closest to the production molding mold, and an electromagnetic coil and a magnetic flux detection coil are fixedly installed inside any one of the several groups of equally spaced magnetic modules with detection coils.

[0017] As a preferred embodiment of the present invention, the mounting magnetic mold base has a mounting groove on one side near the magnetic template, and the mounting groove corresponds to the mounting hole. The mounting magnetic mold base has a second guide hole groove through each of the four corners, and the second guide hole groove corresponds to the first guide hole groove.

[0018] As a preferred embodiment of the present invention, a mold changing window is provided on the front side of the molding machine box near the magnetic mold changing system.

[0019] The beneficial effects of this invention are:

[0020] 1. In this invention, the design of the magnetic mold-changing system allows the overall device to switch between T-core molds and U-core molds, enabling both T-core and U-core molds to be formed on a single machine. This resource integration and optimized configuration reduces the number of devices on the inductor production line. By merging processing techniques, the utilization rate of the inductor forming equipment increases, reducing the coordination and management between inductor production equipment, lowering the equipment and maintenance costs of the inductor production line, improving the overall device's performance, integrating functions, and optimizing efficiency, while also saving land area and making full use of the production workshop.

[0021] 2. In this invention, the magnetic mold-changing system is designed to switch between T-core and U-core molds using a magnetic mold-changing method. The junction box is electrically connected to the control circuit, and the control circuit enables power-on and power-off. When powered on, several groups of equally spaced magnetic modules with detection coils generate magnetic force, which is used to magnetically connect the magnetic template with the adjacent mold base for rapid assembly. When powered off, the several groups of equally spaced magnetic modules with detection coils are demagnetized, and the magnetic template is disconnected from the adjacent mold base for rapid disassembly. This method is more convenient and faster than traditional mold assembly and disassembly methods. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the three-dimensional structure of the molding device in this invention. Figure 1 ;

[0024] Figure 3 This is a schematic diagram of the three-dimensional structure of the molding device in this invention. Figure 2 ;

[0025] Figure 4 This is a schematic diagram of the three-dimensional structure of the production molding die in this invention;

[0026] Figure 5 This is a schematic diagram of the three-dimensional structure of the driving unit in this invention;

[0027] Figure 6 This is a three-dimensional structural diagram of the magnetic mold-changing system in this invention;

[0028] Figure 7 This is a three-dimensional enlarged structural diagram of the magnetic template in this invention;

[0029] Figure 8 This is a three-dimensional enlarged schematic diagram of the magnetic mold mounting base in this invention;

[0030] In the diagram: 1. Molding machine housing; 2. Molding device main body; 3. Production molding die; 31. Middle die fixing plate; 32. Upper die base; 33. Lower die base; 34. Limiting guide column; 35. Punch mounting plate; 36. Upper punch; 37. Lower punch; 38. Middle die; 4. Upper drive unit; 5. Lower drive unit; 451. Drive platform; 452. Fixing bolt; 453. Reducer; 454. Servo motor; 455. Transmission. 456. Lead screw; 6. Drive connector; 6. Magnetic mold changing system; 61. Upper magnetic mold changing assembly; 62. Lower magnetic mold changing assembly; 63. Magnetic template; 631. Magnetic module with detection coil; 631. Magnetic groove; 632. Junction box; 633. Mounting base; 634. Mounting hole; 635. First guide hole groove; 64. Mounting magnetic mold base; 641. Mounting slot; 642. Second guide hole groove; 7. Automatic powder feeding module. Detailed Implementation

[0031] To make the technical problems solved by the present invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Example

[0033] like Figures 1 to 8 As shown, a molding device for producing T-core and U-core includes: a molding housing 1 and a molding device body 2. The molding device body 2 includes a production molding mold 3 movably installed inside the molding housing 1. An upper drive unit 4 and a lower drive unit 5 are respectively provided at the top and bottom of the production molding mold 3. A magnetic mold changing system 6 is provided between the production molding mold 3 and the upper drive unit 4 and the lower drive unit 5. A mold changing window is opened on the front side of the molding housing 1 near the magnetic mold changing system 6. An automatic powder feeding module 7 is movably installed on the rear side of the production molding mold 3. The design of the mold changing window facilitates the disassembly and replacement of the production molding mold 3, and the automatic powder feeding module 7 is used to convey powder to the production molding mold 3, mainly through a pneumatic vibrator.

[0034] The production molding mold 3 can be either a T-core mold or a U-core mold. The production molding mold 3 includes a middle mold fixing plate 31. The top and bottom of the middle mold fixing plate 31 are respectively provided with an upper mold base 32 and a lower mold base 33. The upper mold base 32 and the lower mold base 33 are connected by four sets of limiting guide columns 34. The four sets of limiting guide columns 34 are located near the four corners. Anti-detachment end seats are fixedly installed at both the upper and lower ends of the four sets of limiting guide columns 34. The four sets of limiting guide columns 34 are fixedly connected to the middle mold fixing plate 31, and the four sets of limiting guide columns 34 are slidably connected to the upper mold base 32 and the lower mold base 33. The middle mold fixing plate 31, the upper mold base 32, the lower mold base 33 and the four sets of limiting guide columns 34 can make the T-core mold and the U-core mold assemble into one piece, which facilitates mold changing.

[0035] The upper die holder 32 and the lower die holder 33 are respectively fixedly installed with corresponding upper punches 36 and lower punches 37 on one side of the middle die fixing plate 31 via punch mounting plate 35. The middle die 38 is fixedly installed on the middle die fixing plate 31 between the upper punches 36 and lower punches 37. During the molding process, the upper punches 36 and lower punches 37 extrude and mold the powder material in the middle die 38.

[0036] The upper drive unit 4 is used to drive the upper mold of the production molding mold 3 to move; the lower drive unit 5 is used to drive the lower mold of the production molding mold 3 to move; the upper drive unit 4 and the lower drive unit 5 are arranged symmetrically. Both the upper drive unit 4 and the lower drive unit 5 include a drive platform 451 fixedly installed inside the molding machine housing 1. A reducer 453 is fixedly installed on the side of the drive platform 451 away from the production molding mold 3 by fixing bolts 452. A servo motor 454 is fixedly installed on one side of the reducer 453. A drive connecting seat 456 is movably installed on the side of the drive platform 451 close to the production molding mold 3 by transmission screw 455. The design of the drive platform 451 facilitates the installation and fixing of the reducer 453 and the servo motor 454.

[0037] The input shaft of the reducer 453 and the output shaft of the servo motor 454 are fixedly connected by a coupling. The output shaft of the reducer 453 and the end of the transmission screw 455 away from the drive connecting seat 456 are fixedly connected by a coupling. When the servo motor 454 is working, the reducer 453 runs under its action. Under the action of the reducer 453, the transmission screw 455 starts to rotate, achieving linear motion through rotational motion. At this time, the drive connecting seat 456 moves closer to the production forming mold 3. Under the action of the upper drive unit 4 and the lower drive unit 5, the upper mold and lower mold on the production forming mold 3 move towards the middle mold. The use of servo screw pressing has advantages such as high precision, energy saving and environmental protection, intelligence, reduced mold damage, low noise, flexible operation, and high production efficiency.

[0038] The magnetic mold changing system 6 is used to magnetically change the production mold 3. The magnetic mold changing system 6 is composed of an upper magnetic mold changing component 61 and a lower magnetic mold changing component 62, which are symmetrically distributed on the upper and lower sides of the production mold 3. Both the upper magnetic mold changing component 61 and the lower magnetic mold changing component 62 include a magnetic template 63 arranged in parallel and a mounting magnetic mold base 64. The magnetic template 63 is located between the production mold 3 and the mounting magnetic mold base 64. The mounting magnetic mold base 64 and the drive connection seat 456 are fixedly connected to one end of the production mold 3. The mounting magnetic mold base 64 facilitates the installation of the magnetic template 63 and the connection with the drive connection seat 456 in the drive unit. The design of the upper magnetic mold changing component 61 and the lower magnetic mold changing component 62 allows for quick assembly and disassembly of the upper and lower ends of the production mold 3.

[0039] The magnetic template 63 has several sets of equidistantly distributed magnetic modules 631 with detection coils embedded inside. These modules are electrically connected to junction boxes 632 on both sides. The junction boxes 632 are electrically connected to a control circuit, which controls power on and off. When powered on, the magnetic modules 631 generate magnetism, which magnetically connects the magnetic template 63 to adjacent mold bases for rapid assembly. When powered off, the magnetic modules 631 demagnetize, and the magnetic template 63 then connects to adjacent mold bases. Disconnection enables rapid disassembly, facilitating mold replacement for production molding die 3. Furthermore, switching between T-core and U-core molds allows both to be molded on a single machine, integrating and optimizing resources. This reduces the number of devices on the inductor production line. By merging processing steps, the utilization rate of inductor molding equipment increases, reducing coordination and management between inductor production equipment. This lowers equipment and maintenance costs on the inductor production line, resulting in improved overall device performance, functional integration, and efficiency optimization. It also saves space, ensuring full utilization of the production workshop.

[0040] Among several groups of equally spaced magnetic modules 631 with detection coils, each group has magnetic grooves 6311 around its perimeter on the side closest to the production mold 3. Each group of equally spaced magnetic modules 631 with detection coils has an electromagnetic coil and a magnetic flux detection coil fixedly installed inside. The design of the magnetic grooves 6311 controls the direction of the magnetic lines of force, preventing a vacuum from forming between the magnetic template 63 and the mold base. Simultaneously, the electromagnetic coil and magnetic flux detection coil allow the magnetic module 631 to detect the clamping force when adsorbing and releasing the mold base. The modular design facilitates installation and maintenance.

[0041] A mounting base 633 is fixedly installed at the center of each of the four sides of the magnetic template 63. Mounting holes 634 are formed through the mounting bases 633 near both ends. First guide slots 635 are formed through the four corners of the magnetic template 63. A mounting groove 641 is formed on the side of the mounting magnetic mold base 64 near the magnetic template 63, and the mounting groove 641 corresponds to the mounting hole 634. Second guide slots 642 are formed through the mounting magnetic mold base 64 near the four corners, and the second guide slots 642 correspond to the first guide slots 635. The mounting bases 633, mounting holes 634, and mounting grooves 641 facilitate the fixed connection between the magnetic template 63 and the mounting magnetic mold base 64. The design of the first guide slots 635 and the second guide slots 642 facilitates precise mold changing and prevents misalignment, while also avoiding obstruction during the inductor forming process, thus facilitating its production and processing.

[0042] Implementation Plan: During T-core molding, the T-core mold can be placed between the upper magnetic mold changing assembly 61 and the lower magnetic mold changing assembly 62, with the limiting guide post 34 corresponding to the first guide slot 635 and the second guide slot 642. Then, under the control of the circuit, power is applied. When powered on, several groups of equidistantly distributed magnetic modules 631 with detection coils generate magnetic force. This magnetic force is used to magnetically connect the magnetic template 63 to the adjacent mold base, achieving rapid assembly. Subsequently, the servo motor 454 operates, and the reducer 453... Under the action of the reducer 453, the transmission screw 455 starts to rotate, achieving linear motion through rotational motion. At this time, the drive connecting seat 456 moves closer to the production forming mold 3. Under the action of the upper drive unit 4 and the lower drive unit 5, the upper and lower molds on the production forming mold 3 move towards the middle mold. The displacement stops after the lower punch 37 partially enters the middle mold. At this time, the automatic powder feeding module 7 conveys powder to the production forming mold 3, mainly through a pneumatic vibrator. After the powder is conveyed, the upper and lower molds continue to move until the upper punch... The upper punch 36 and lower punch 37 extrude the powder material into the middle die 38. After molding, the upper punch 36 resets, and the lower punch 37 continues to move upward to export the molded inductor base. Then, it automatically resets. After the T-core molding is completed, the magnetic module 631 can be de-energized. At this time, several groups of equally spaced magnetic modules 631 with detection coils are demagnetized. At the same time, the magnetic template 63 is disconnected from the adjacent mold base for quick disassembly. The required U-core mold with embedded inductor coil is then installed in the same way as the T-core mold. The above operation is repeated for molding and production. The whole device can realize the molding and processing of T-core mold and U-core mold. Compared with the existing integrated inductor molding equipment, this invention reduces the number of equipment in the inductor production line through resource integration and optimized configuration. By merging processing technology, the utilization rate of the inductor molding equipment increases, reducing the coordination and management between inductor production equipment, reducing the equipment cost and maintenance cost of the inductor production line, improving the overall device performance, integrating functions and optimizing efficiency, and saving land area, making full use of the production workshop.

[0043] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0044] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A molding apparatus for producing T-core and U-core, characterized in that, include: The molding machine housing and molding device body include a production molding mold that is movably installed inside the molding machine housing. An upper drive unit and a lower drive unit are respectively provided at the top and bottom of the production molding mold. A magnetic mold changing system is provided between the production molding mold and the upper drive unit and the lower drive unit. An automatic powder feeding module is movably installed at the rear of the production molding mold. The production molding mold can be either a T-core mold or a U-core mold; The production molding die includes a middle mold fixing plate. The top and bottom of the middle mold fixing plate are respectively arranged in parallel with an upper mold base and a lower mold base. The upper mold base and the lower mold base are connected by four sets of limiting guide columns. The four sets of limiting guide columns are located near the four corners. Anti-detachment end seats are fixedly installed at both ends of the four sets of limiting guide columns. The four sets of limiting guide columns are fixedly connected to the middle mold fixing plate, and the four sets of limiting guide columns are slidably connected to the upper mold base and the lower mold base. The upper and lower die bases are respectively fixedly installed with corresponding upper and lower punches on one side of the middle die fixing plate via punch mounting plates. The middle die is fixedly installed on the middle die fixing plate between the upper and lower punches. The upper drive unit is used to drive the upper mold of the production molding die to move. The lower drive unit is used to drive the lower mold of the production molding die to move. The magnetic mold changing system is used to magnetically change production molds; The magnetic mold changing system is composed of an upper magnetic mold changing component and a lower magnetic mold changing component that are symmetrically distributed on the upper and lower sides of the production mold. Both the upper and lower magnetic mold changing components include a magnetic template and a mounting magnetic mold base arranged in parallel. The magnetic template is located between the production mold and the mounting magnetic mold base. The mounting magnetic mold base and the drive connection seat are fixedly connected at the end closest to the production mold. The magnetic template has several sets of equally spaced magnetic modules with detection coils embedded inside. The two sides of the several sets of equally spaced magnetic modules with detection coils are electrically connected to junction boxes. Mounting bases are fixedly installed at the center of the magnetic template. Mounting holes are opened through the mounting bases near both ends. First guide slots are opened through the four corners of the magnetic template. Among several groups of equally spaced magnetic modules with detection coils, magnetic grooves are provided around the side of the production mold on the side of any one group, and an electromagnetic coil and a magnetic flux detection coil are fixedly installed inside any one of the several groups of equally spaced magnetic modules with detection coils. The mounting magnetic mold base has an installation groove on one side near the magnetic template, and the installation groove corresponds to the installation hole. The mounting magnetic mold base has a second guide hole groove through each of the four corners, and the second guide hole groove corresponds to the first guide hole groove.

2. The molding apparatus for producing T-core and U-core according to claim 1, characterized in that, The upper drive unit and the lower drive unit are arranged symmetrically. Both the upper drive unit and the lower drive unit include a drive platform that is fixedly installed inside the molding machine box. A reducer is fixedly installed on the side of the drive platform away from the production molding mold by fixing bolts. A servo motor is fixedly installed on one side of the reducer. A drive connecting seat is movably installed on the side of the drive platform close to the production molding mold by a transmission screw.

3. The molding apparatus for producing T-core and U-core according to claim 2, characterized in that, The input shaft of the reducer and the output shaft of the servo motor are fixedly connected by a coupling. The output shaft of the reducer and the end of the transmission screw away from the drive connection seat are fixedly connected by a coupling.

4. The molding apparatus for producing T-core and U-core according to claim 1, characterized in that, A mold changing window is provided on the front side of the molding machine housing near the magnetic mold changing system.

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