Mold for integrally molding magnetic core and method for producing integrated magnetic core

Abstract

The application discloses a magnetic core integrated forming die and a method for producing an integrated magnetic core. In the open mold state of the magnetic core integrated forming die, magnetic powder is filled into a column part forming through hole, then the first forming plate and the first forming column are lowered, so that the first forming plate and the second forming plate are closed, then the second forming column is raised relative to the second forming plate to transfer part of the magnetic powder to the swing part forming through hole, then the first forming column is lowered relative to the first forming plate, and the second forming column is raised relative to the second forming plate to press and form the magnetic core, then the magnetic core integrated forming die is reset, opened and the magnetic core is removed; the mold press and the magnetic core do not use a tube structure, so that the durability of the mold is improved, and the rebound directions of the swing part forming surface and the column part forming surface are opposite when the mold is opened, so that the swing part and the column part of the magnetic core are not prone to hidden cracks.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of magnetic cores, in particular to a magnetic core integrated forming die and a method for producing an integrated magnetic core. BACKGROUND

[0002] Magnetic cores are usually provided in electronic devices, and the magnetic cores serve to guide magnetic flux. Some existing magnetic cores include a swing portion and a column portion. The swing portion is relatively flat and has a large width. The column portion is connected to one side of the swing portion, and the width of the column portion is relatively small, so that the magnetic core is approximately T-shaped. At present, when such a magnetic core is produced, a die can be used to press the magnetic powder material to form the magnetic core. The die for producing the magnetic core currently includes a forming plate, an upper forming column, a lower tube body, and a lower inner column. The forming plate is provided with a forming through hole in the up-down direction. The lower inner column is slidably arranged in the lower tube body, and the lower tube body is slidably arranged in the forming through hole. The upper forming column can be inserted into or separated from the forming through hole, and the upper forming column is located above the lower tube body. During production, the magnetic powder material is filled into the forming through hole, and then the upper forming column is pressed downward to be inserted into the forming through hole. The upper forming column, the lower tube body, and the lower inner column are close to each other to press the magnetic powder material to form the magnetic core. Then, the upper forming column is separated from the forming through hole, and the lower tube body and the lower inner column are moved upward relative to the forming plate to eject the magnetic core. Since the wall thickness of the lower tube body is relatively thin, the lower tube body is easily worn or deformed and damaged during production, which leads to insufficient durability of the magnetic core integrated forming die, and the swing portion and the column portion of the produced magnetic core are prone to have a dark crack at the joint. SUMMARY

[0003] The present application aims to at least solve one of the problems in the prior art. To this end, the present application provides a magnetic core integrated forming die, which can have high durability and reduce the risk of dark cracks at the joint of the swing portion and the column portion of the magnetic core.

[0004] The present application also provides a method for producing an integrated magnetic core using the above-mentioned magnetic core integrated forming die.

[0005] The magnetic core integrated forming die according to the first aspect of the present application comprises a first forming plate, a first forming column, a second forming plate and a second forming column. The first forming plate is provided with a swing part forming through hole in the up-down direction; the first forming column is slidably arranged in the swing part forming through hole in the up-down direction, and the lower end of the first forming column is provided with a swing part forming surface; the second forming plate is located below the first forming plate, and the second forming plate is provided with a column part forming through hole in the up-down direction; the second forming column is slidably arranged in the column part forming through hole in the up-down direction, and the second forming column is located below the first forming column, and the upper end of the second forming column is provided with a column part forming surface; wherein the magnetic core integrated forming die has an open mold state and a closed mold state, in the open mold state, the first forming plate is separated from the second forming plate; in the closed mold state, the first forming plate abuts against the second forming plate, the lower end of the swing part forming through hole abuts against and communicates with the upper end of the column part forming through hole, the swing part forming surface, the hole wall of the swing part forming through hole and the upper surface of the second forming plate can form a swing part forming cavity, and the hole wall of the column part forming through hole and the column part forming surface can form a column part forming cavity, and the lower end of the swing part forming cavity communicates with the upper end of the column part forming cavity.

[0006] The magnetic core integrated forming die according to the first aspect of the present application has at least the following beneficial effects: in the open mold state, the magnetic core integrated forming die fills the magnetic powder material into the column part forming through hole, then the first forming plate and the first forming column are lowered to make the first forming plate and the second forming plate closed, then the second forming column is raised relative to the second forming plate to transfer and fill part of the magnetic powder material into the swing part forming through hole, then the first forming column is lowered relative to the first forming plate and the second forming column is raised relative to the second forming plate to press and form the magnetic core, then the magnetic core integrated forming die is reset to open mold and the magnetic core is removed; the above-mentioned mold does not use a pipe body structure to press the magnetic core, so that the durability of the mold is improved, and the rebound directions of the swing part forming surface and the column part forming surface are opposite in the open mold state, so that the swing part and the column part of the magnetic core are not easy to have hidden cracks.

[0007] According to some embodiments of the present application, the thickness of the swing part forming cavity is A, and A≥0.25mm is satisfied.

[0008] According to some embodiments of the present application, the column part forming through hole is a circular hole, the diameter of the column part forming through hole is B, and B≥1.5mm is satisfied.

[0009] According to some embodiments of the present application, the cross-sectional area of the column part forming through hole is C, the cross-sectional area of the swing part forming through hole is D, and 3C=D is satisfied.

[0010] According to some embodiments of the present application, the first forming plate is provided with at least two swing portion forming through holes, the first forming column is provided with at least two and is correspondingly arranged in the swing portion forming through holes, the second forming plate is provided with at least two column portion forming through holes, the second forming column is provided with at least two and is correspondingly arranged in the column portion forming through holes, and the swing portion forming through holes and the column portion forming through holes are opposite to each other in the up-down direction.

[0011] According to some embodiments of the present application, all the column portion forming through holes are arranged uniformly in the left-right direction, the second forming plate is provided with a discharging plate portion, the discharging plate portion is located on one side of the column portion forming through holes in the front-back direction, and the discharging plate portion is arranged downwardly in a direction away from the column portion forming through holes.

[0012] According to some embodiments of the present application, all the column portion forming through holes form a through hole row, and the left-right width of the discharging plate portion is greater than the left-right width of the through hole row.

[0013] According to some embodiments of the present application, a powder spreading box is further arranged on the upper side of the second forming plate in the front-back direction, and the powder spreading box is provided with a powder outlet.

[0014] According to some embodiments of the present application, a first mold frame, a second mold frame and a third mold frame are arranged in sequence in the up-down direction, the first mold frame and the second mold frame are connected to the third mold frame in the up-down direction, the first forming column is arranged in the first mold frame, the first forming plate is arranged in the first mold frame in the up-down direction, an elastic member is arranged between the first forming plate and the first mold frame, the second forming plate is arranged in the second mold frame, and the second forming column is arranged in the third mold frame.

[0015] According to the integrated magnetic core production method of the second aspect of the present application, the magnetic core integrated forming die is used, and the method comprises the following steps: powder feeding: the magnetic core integrated forming die is in an open mold state, and the magnetic powder is filled into the column forming through hole; powder transfer: the first forming plate and the first forming column are synchronously lowered, so that the first forming plate abuts against the second forming plate and enters a closed mold state, and then the first forming plate, the first forming column and the second forming plate are synchronously lowered, so that part of the magnetic powder in the column forming through hole is transferred to the swing part forming through hole; magnetic core pressing: the first forming column is lowered and the magnetic powder in the swing part forming through hole is pressed to form a magnetic core swing part, and then the first forming plate, the first forming column and the second forming plate are synchronously lowered and the magnetic powder in the column forming through hole is pressed to form a magnetic core column part; mold opening and discharging: the first forming plate, the first forming column and the second forming plate are reset to move to separate the first forming plate from the second forming plate, and the second forming column is raised relative to the second forming plate to eject the magnetic core, and then the second forming column is reset.

[0016] According to the integrated magnetic core production method of the second aspect of the present application, at least the following beneficial effects are achieved: since the magnetic core integrated forming die is used, the junction between the swing part and the column part of the magnetic core is not prone to hidden cracks, and the yield of the produced magnetic core is improved.

[0017] Additional aspects and advantages of the present application will be in part apparent and in part pointed out hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0018] The above and / or additional aspects and advantages of the present application will become apparent and be readily appreciated from the following description, taken in conjunction with the accompanying drawings, in which:

[0019] Figure 1 It is a schematic diagram of the principle of the magnetic core integrated forming die of the embodiment of the present application in the powder feeding step;

[0020] Figure 2 It is a schematic diagram of the principle of the magnetic core integrated forming die of the embodiment of the present application in the powder transfer step;

[0021] Figure 3 It is a schematic diagram of the principle of the magnetic core integrated forming die of the embodiment of the present application in the magnetic core pressing step;

[0022] Figure 4 It is a schematic diagram of the principle of the magnetic core integrated forming die of the embodiment of the present application in the mold opening and discharging step;

[0023] Figure 5A three-dimensional schematic view of a magnetic core integrated molding die according to an embodiment of the present application;

[0024] Figure 6 A flowchart of a magnetic core integrated production method according to an embodiment of the present application.

[0025] Reference signs:

[0026] A first molding plate 100, a swing portion molding through hole 110;

[0027] A first molding column 200, a swing portion molding surface 210;

[0028] A second molding plate 300, a column portion molding through hole 310, a discharge plate portion 320, a positioning column 330;

[0029] A second molding column 400, a column portion molding surface 410;

[0030] A powder laying box 500;

[0031] A first mold frame 610, a second mold frame 620, a third mold frame 630, an elastic member 640, a vibrator 650;

[0032] A magnetic core 700, a swing portion 710, a column portion 720;

[0033] A magnetic powder material 800. DETAILED DESCRIPTION

[0034] Embodiments of the present application are described in detail below with reference to the accompanying drawings, in which the same or similar components or components having the same or similar functions are denoted by the same or similar reference numerals throughout. The embodiments described below by reference to the accompanying drawings are exemplary and are intended to explain the present application, and should not be construed as limiting the present application.

[0035] In the description of the present application, it should be understood that the orientation description, such as the orientation or position relationship indicated by up, down, etc. is based on the orientation or position relationship shown in the drawings, and is only for the purpose of describing the present application and simplifying the description, and does not indicate or imply that the device or component referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore should not be construed as limiting the present application.

[0036] In the description of the present application, the plural refers to two or more. If there is a description of first, second, etc., it is only for the purpose of distinguishing technical features, and should not be construed as indicating or implying relative importance or implying the number of technical features indicated or the order of technical features indicated.

[0037] In the description of the present application, the words such as arrangement, installation, connection and the like should be understood in a broad sense unless otherwise explicitly limited, and the skilled in the art can reasonably determine the specific meaning of the above words in the present application in combination with the specific content of the technical solution.

[0038] Referring to Figures 1 to 5 For the magnetic core integrated forming die of the embodiment of the present application, the first forming plate 100 is provided with a swing part forming through hole 110 in the up-down direction; the first forming column 200 is slidably arranged in the swing part forming through hole 110 in the up-down direction, and the lower end of the first forming column 200 is provided with a swing part forming surface 210; the second forming plate 300 is located below the first forming plate 100, and the second forming plate 300 is provided with a column part forming through hole 310 in the up-down direction; the second forming column 400 is slidably arranged in the column part forming through hole 310 in the up-down direction, and the second forming column 400 is located below the first forming column 200, and the upper end of the second forming column 400 is provided with a column part forming surface 410; wherein the magnetic core integrated forming die has a mold opening state and a mold closing state, in the mold opening state, the first forming plate 100 is separated from the second forming plate 300; in the mold closing state, the first forming plate 100 abuts against the second forming plate 300, the lower end of the swing part forming through hole 110 is connected and communicated with the upper end of the column part forming through hole 310, the swing part forming surface 210, the hole wall of the swing part forming through hole 110 and the upper surface of the second forming plate 300 can form a swing part forming cavity, and the hole wall of the column part forming through hole 310 and the column part forming surface 410 can form a column part forming cavity, and the lower end of the swing part forming cavity is communicated with the upper end of the column part forming cavity.

[0039] When the magnetic core integrated forming die is in the mold opening state, the magnetic powder material is filled into the column part forming through hole 310, then the first forming plate 100 and the first forming column 200 are lowered to make the first forming plate 100 and the second forming plate 300 close the mold, then the second forming column 400 is raised relative to the second forming plate 300 to transfer part of the magnetic powder material to fill into the swing part forming through hole 110, then the first forming column 200 is lowered relative to the first forming plate 100, and the second forming column 400 is raised relative to the second forming plate 300 to press and form the magnetic core, then the magnetic core integrated forming die is reset to open the mold and remove the magnetic core; the mold press and form the magnetic core without using a tube structure, so that the durability of the mold is improved, and the rebound directions of the swing part forming surface 210 and the column part forming surface 410 are opposite when the mold is opened, so that the swing part and the column part of the magnetic core are not easy to have hidden cracks.

[0040] Specifically, the generally elongated mold structure is prone to a slight elastic deformation when subjected to a force, while the plate body is difficult to elastically deform. When the mold is closed, the first forming column 200 and the second forming column 400 are subjected to a force and are slightly elastically deformed. In the initial stage of the reset opening movement, the first forming column 200 has a downward rebounding trend through the swing portion forming surface 210, and the second forming column 400 has an upward rebounding trend through the column portion forming surface 410. Since the rebounding directions of the swing portion forming surface 210 and the column portion forming surface 410 are opposite, the forces of the two on the magnetic core cancel each other out, and at this time, the swing portion and the column portion are not prone to a crack at the joint.

[0041] Specifically, in the prior art, in the initial stage of the reset opening movement, the lower tube body and the lower inner column are both elastically rebounded upward. At this time, the rebounding amplitudes of the upper end of the lower tube body and the upper end of the lower inner column are different, but the rebounding directions are the same, which is prone to rebounding and pushing the swing portion and the column portion of the magnetic core to different degrees. At this time, the swing portion and the column portion of the magnetic core at the joint may be cracked.

[0042] Specifically, the swing portion forming surface 210 is generally higher than the lower end of the swing portion forming through hole 110 to allow the magnetic powder material to enter the swing portion forming through hole 110; the column portion forming surface 410 is generally lower than the upper end of the column portion forming through hole 310 to allow the magnetic powder material to enter the column portion forming through hole 310. When the magnetic core needs to be ejected, the column portion forming surface 410 can be higher than the upper end of the column portion forming through hole 310.

[0043] In an embodiment, the thickness of the swing portion forming cavity is A, which satisfies A≥0.25 mm. Specifically, the thickness of the swing portion forming cavity, i.e., the up-down dimension between the swing portion forming surface 210 and the upper surface of the second forming plate 300. If the thickness of the swing portion forming cavity is too small, i.e., the thickness of the swing portion of the finally formed magnetic core is too thin, the swing portion of the magnetic core is prone to breakage in the magnetic core compression molding and demolding process, i.e., the magnetic core processing and production is relatively difficult. Therefore, the thickness of the swing portion forming cavity is limited to be not less than 0.25 mm, which can prevent the swing portion of the magnetic core from being broken in the magnetic core compression molding and demolding process, and improve the production yield of the magnetic core.

[0044] Specifically, the thickness of the swing portion forming cavity can be 0.3 mm, 0.4 mm, 0.5 mm, 1 mm, 2 mm, or other values, which can be specifically configured according to actual needs by those skilled in the art.

[0045] In an embodiment, the column portion forming through hole 310 is a circular hole, and the diameter of the column portion forming through hole is B, which satisfies B≥1.5 mm. If the diameter of the column portion of the magnetic core is too small, the column portion is prone to breakage in the compression molding and demolding process, and the second forming column 400 is also prone to damage. Therefore, when the diameter of the column portion forming through hole 310 is not less than 1.5 mm, it is beneficial to improve the production yield of the magnetic core, reduce the risk of breakage of the column portion of the magnetic core, reduce the risk of damage to the second forming column 400, and further improve the durability of the magnetic core integrated forming mold.

[0046] In the embodiments, the cross-sectional area of the columnar portion forming through hole 310 is C, the cross-sectional area of the swing portion forming through hole 110 is D, and 3C=D is satisfied. The columnar portion forming through hole 310 and the swing portion forming through hole 110 described above are beneficial to the magnetic powder material in the columnar portion forming through hole 310 moving into the swing portion forming through hole 110 and filling the swing portion forming cavity, so that a magnetic core with reasonable structure and good durability is produced.

[0047] Specifically, in some embodiments, the cross sections of the columnar portion and the swing portion of the magnetic core can be non-circular, i.e., the cross section of the columnar portion can be polygonal or elliptical, or other shapes, and the cross section of the swing portion can be polygonal or elliptical, or other shapes; the skilled in the art can configure according to actual needs.

[0048] In the embodiments, the first forming plate 100 is provided with four swing portion forming through holes 110, the first forming column 200 is provided with four and is correspondingly arranged in the swing portion forming through hole 110, the second forming plate 300 is provided with four columnar portion forming through holes 310, the second forming column 400 is provided with four and is correspondingly arranged in the columnar portion forming through hole 310, and the swing portion forming through hole 110 and the columnar portion forming through hole 310 are opposite to each other along the up-down direction. The arrangement of four swing portion forming through holes 110, four first forming columns 200, four columnar portion forming through holes 310 and four second forming columns 400 can produce four magnetic cores at one time, so that the production efficiency of the magnetic core is high. It can be understood that two, three or more swing portion forming through holes 110 can also be arranged, and the corresponding first forming columns 200, columnar portion forming through holes 310 and second forming columns 400 are also arranged in two, three or more numbers, which are not limited here.

[0049] In the embodiments, all the columnar portion forming through holes 310 are arranged uniformly along the left-right direction, the second forming plate 300 is provided with a discharging plate portion 320, the discharging plate portion 320 is located on one side of the columnar portion forming through hole 310 along the front-rear direction, and the discharging plate portion 320 is arranged obliquely downward along the direction away from the columnar portion forming through hole 310. The above layout mode facilitates the transfer of all the magnetic cores to the discharging plate portion 320 at one time, avoids interference between different magnetic cores during the transfer of the magnetic cores, and the distance of each magnetic core transferred to the discharging plate portion 320 is relatively short.

[0050] In the embodiments, all the columnar portion forming through holes 310 form a through hole row, and the left-right width of the discharging plate portion 320 is greater than the left-right width of the through hole row. When the pushing mechanism pushes the magnetic core to the discharging plate portion 320, the magnetic core can directly reach the discharging plate portion 320, avoiding the residual of the magnetic core and reducing the risk of the magnetic core not entering the discharging plate portion 320.

[0051] In the embodiment, the powder spreading box 500 is arranged on the upper side of the second forming plate 300 in the front-rear direction and is provided with a powder outlet. When the magnetic powder needs to be filled, the powder spreading box 500 is moved to align the powder outlet with the columnar forming through hole 310, and then the magnetic powder in the powder spreading box 500 is filled into the columnar forming through hole 310.

[0052] Specifically, the upper side of the second forming plate 300 is formed with a sliding groove, and the powder spreading box 500 is slidingly connected to the sliding groove. It can be imagined that in other embodiments, the powder spreading box 500 can also be slidingly connected to the second forming plate 300 through a guide column and guide sleeve structure.

[0053] In the embodiment, the first mold frame 610, the second mold frame 620 and the third mold frame 630 are arranged in sequence in the up-down direction, the first mold frame 610 and the second mold frame 620 are slidingly connected to the third mold frame 630 in the up-down direction, the first forming column 200 is arranged in the first mold frame 610, the first forming plate 100 is slidingly arranged in the first mold frame 610 in the up-down direction, the elastic member 640 is arranged between the first forming plate 100 and the first mold frame 610, the second forming plate 300 is arranged in the second mold frame 620, and the second forming column 400 is arranged in the third mold frame 630. The above-mentioned magnetic core integrated forming mold can adopt a three-layer mold frame to complete the entire production process, and has the advantages of simple structure and easy implementation.

[0054] Specifically, the second mold frame 620 is connected with the vibrator 650. The vibrator 650 can make the magnetic powder fully fill the columnar forming through hole 310, so that the quality of the compressed magnetic core product is better.

[0055] Specifically, the powder spreading box 500 is also connected with the vibrator 650, which facilitates the flow of the magnetic powder to fill the columnar forming through hole 310.

[0056] Specifically, the upper side of the second forming plate 300 is provided with the positioning column 330, and the lower side of the first forming plate 100 is provided with the positioning hole, and the positioning column 330 is matched with the positioning hole. The positioning column 330 and the positioning hole are arranged, which is beneficial to keeping the first forming plate 100 and the second forming plate 300 aligned when they are in contact.

[0057] Specifically, the positioning column 330 is opposite to the columnar forming through hole 310 in the left-right direction, and the positioning column 330 is located at the bottom wall of the sliding groove, so that the positioning column 330 also has the function of limiting the powder spreading box 500, and when the powder spreading box 500 contacts the positioning column 330, the powder outlet aligns with the columnar forming through hole 310.

[0058] Specifically, the pushing mechanism is used to drive the magnetic core to move towards the discharging plate part 320. After the magnetic core is pushed out of the column part forming through hole 310 by the second forming column 400, the pushing mechanism can move the magnetic core to the discharging plate part 320 at one time, and the discharging plate part 320 guides the magnetic core to the designated position for collection, facilitating continuous production. Specifically, the pushing mechanism can adopt a pneumatic way to push the magnetic core, for example, the pushing mechanism includes a pushing seat and an air pump, the pushing seat is arranged with a plurality of air blowing holes in the horizontal direction, and the air pump blows air through the air blowing holes, so as to directly blow the magnetic core staying on the second forming plate 300 to the discharging plate part 320, and then move to the designated position through the discharging plate part 320, which is simple in structure and easy to implement. It can be imagined that the pushing mechanism can also use a physical way to push the magnetic core, for example, the pushing mechanism includes a push plate and a pneumatic cylinder, the piston rod of the pneumatic cylinder is connected with the push plate, and the push plate is driven to move along the upper surface of the second forming plate 300, so as to push the magnetic core into the discharging plate part 320, so that the magnetic core moves to the designated position through the discharging plate part 320 for collection.

[0059] Referring to Figure 6 The embodiment also discloses a one-piece magnetic core production method, which adopts the magnetic core one-piece forming die and comprises the following steps:

[0060] S10: powder feeding: the magnetic core one-piece forming die is in an open mold state, and the magnetic powder is filled into the column part forming through hole 310;

[0061] S20: powder transfer: the first forming plate 100 and the first forming column 200 are synchronously lowered, so that the first forming plate 100 abuts against the second forming plate 300 and enters a closed mold state, and then the first forming plate 100, the first forming column 200 and the second forming plate 300 are synchronously lowered, so that part of the magnetic powder in the column part forming through hole 310 is transferred to the swing part forming through hole 110;

[0062] S30: pressing the magnetic core: the first forming column 200 is lowered and the magnetic powder in the swing part forming through hole 110 is pressed to form a swing part of the magnetic core, and then the first forming plate 100, the first forming column 200 and the second forming plate 300 are synchronously lowered and the magnetic powder in the column part forming through hole 310 is pressed to form a column part of the magnetic core;

[0063] S40: mold opening and discharging: the first forming plate 100, the first forming column 200 and the second forming plate 300 are reset to move to separate the first forming plate 100 from the second forming plate 300, and the second forming column 400 is moved upwards relative to the second forming plate 300 to eject the magnetic core, and then the second forming column 400 is moved to reset.

[0064] The one-piece magnetic core production method adopts the magnetic core one-piece forming die, so that the joint between the swing part and the column part of the magnetic core is not prone to hidden cracks, and the yield of the produced magnetic cores is improved.

[0065] Specifically, in the pressing core step, the core swing part and the core column part are segmented and pressed and formed, which can reduce the risk of uneven density of the whole core.

[0066] Specifically, in the swing part pressing step, the pressing speed of the first forming plate 100, the first forming column 200 and the second forming plate 300 is E, which satisfies 10mm / s≤E≤20mm / s. During the mold closing process, the first forming plate 100, the first forming column 200, the second forming plate 300 and the second forming column 400 need to press and form the magnetic powder material into a core. If the pressing speed is too fast, it may cause the core to be not compacted enough. If the pressing speed is too slow, it will affect the production efficiency. Therefore, the pressing speed is 10mm / s≤E≤20mm / s, at this time, the compaction effect of the core is better, and the production efficiency can be relatively high.

[0067] Specifically, the pressing speed E can be any value in the above range, for example, 15mm / s, etc., which can be specifically selected by those skilled in the art according to actual needs.

[0068] In the embodiment, in the swing part pressing step, it further includes: after pressing, the swing part forming cavity and the column part forming cavity are pressure-kept, and the pressure-keeping time is F, which satisfies 1s≤F≤5s. After pressing, the swing part forming cavity and the column part forming cavity are pressure-kept, which is beneficial to the relatively compact pressing between the magnetic powder materials, and reduces the risk of core cracking.

[0069] In the description of the present specification, the description of the terms "one embodiment", "some embodiments", "exemplary embodiment", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the exemplary description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0070] Although the embodiments of the present application have been shown and described, those skilled in the art can understand that various changes, modifications, replacements and variations can be made to the embodiments without departing from the principles and purposes of the present application, and the scope of the present application is defined by the claims and their equivalents.

Claims

1. A mold for integral molding of magnetic cores, characterized in that, include: The first forming plate (100) is provided with swing forming through holes (110) in the vertical direction; The first forming column (200) slides through the swing part forming through hole (110) in the vertical direction, and the lower end of the first forming column (200) has a swing part forming surface (210). The second forming plate (300) is located below the first forming plate (100), and the second forming plate (300) is provided with column forming through holes (310) in the vertical direction; The second forming column (400) slides through the column forming through hole (310) in the vertical direction. The second forming column (400) is located below the first forming column (200). The upper end of the second forming column (400) has a column forming surface (410). The integrated core molding mold has an open state and a closed state. In the open state, the first molding plate (100) and the second molding plate (300) are separated. In the closed state, the first molding plate (100) and the second molding plate (300) abut against each other. The lower end of the swing part molding through hole (110) is connected to the upper end of the column part molding through hole (310). The swing part molding surface (210), the hole wall of the swing part molding through hole (110) and the upper surface of the second molding plate (300) can form a swing part molding cavity. The hole wall of the column part molding through hole (310) and the column part molding surface (410) can form a column part molding cavity. The lower end of the swing part molding cavity is connected to the upper end of the column part molding cavity. It also includes a first mold frame (610), a second mold frame (620) and a third mold frame (630) arranged sequentially in the vertical direction. The first mold frame (610) and the second mold frame (620) are slidably connected to the third mold frame (630) in the vertical direction. The first forming column (200) is disposed on the first mold frame (610). The first forming plate (100) is slidably disposed on the first mold frame (610) in the vertical direction. An elastic element (640) is disposed between the first forming plate (100) and the first mold frame (610). The second forming plate (300) is disposed on the second mold frame (620). The second forming column (400) is disposed on the third mold frame (630).

2. The integral molding die for magnetic cores according to claim 1, characterized in that: The thickness of the swing part forming cavity is A, which satisfies A≥0.25mm.

3. The integral molding die for magnetic cores according to claim 1, characterized in that: The column forming through hole (310) is a round hole, and the diameter of the column forming through hole is B, which satisfies B≥1.5mm.

4. The integral molding die for magnetic cores according to claim 1, characterized in that: The cross-sectional area of ​​the column forming through hole (310) is C, and the cross-sectional area of ​​the swing forming through hole (110) is D, satisfying 3C=D.

5. The integral molding die for magnetic cores according to claim 1, characterized in that: The first forming plate (100) is provided with at least two swing part forming through holes (110), the first forming column (200) is provided with at least two and correspondingly pass through the swing part forming through holes (110), the second forming plate (300) is provided with at least two column forming through holes (310), the second forming column (400) is provided with at least two and correspondingly pass through the column forming through holes (310), and the swing part forming through holes (110) and the column forming through holes (310) are opposite each other in the vertical direction.

6. The integral molding die for magnetic cores according to claim 5, characterized in that: All the column forming through holes (310) are evenly arranged in the left-right direction. The second forming plate (300) is provided with a discharge plate (320). The discharge plate (320) is located on one side of the column forming through hole (310) in the front-back direction. The discharge plate (320) is inclined downward in the direction away from the column forming through hole (310).

7. The integral molding die for magnetic cores according to claim 6, characterized in that: All the column forming through holes (310) form through hole rows, and the left and right width of the discharge plate part (320) is greater than the left and right width of the through hole rows.

8. The integral molding die for magnetic cores according to claim 6, characterized in that: It also includes a powder spreading box (500), which is slidably disposed on the upper side of the second forming plate (300) in the front-back direction, and the powder spreading box (500) is provided with a powder outlet.

9. A method for producing an integrated magnetic core, using the integrated core molding mold according to any one of claims 1 to 8, characterized in that, Includes the following steps: Powder feeding: When the integrated molding mold of the magnetic core is in the open state, the magnetic powder is filled into the forming through hole (310) of the column part; Powder transfer: The first molding plate (100) and the first molding column (200) move down synchronously, so that the first molding plate (100) abuts against the second molding plate (300) and enters the mold closing state. Then, the first molding plate (100), the first molding column (200) and the second molding plate (300) move down synchronously, so that part of the magnetic powder in the column forming through hole (310) is transferred to the swing forming through hole (110). Pressing the magnetic core: The first forming column (200) moves down and presses the magnetic powder in the forming through hole (110) of the swing part to form the magnetic core swing part. Then the first forming plate (100), the first forming column (200) and the second forming plate (300) move down synchronously and press the magnetic powder in the forming through hole (310) of the column part to form the magnetic core column part. Mold opening and material ejection: The first molding plate (100), the first molding column (200) and the second molding plate (300) are reset and moved to separate the first molding plate (100) from the second molding plate (300) from the mold. The second molding column (400) moves upward relative to the second molding plate (300) to eject the magnetic core. Then the second molding column (400) moves and resets.

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