Integrated inductor die-casting method and die-casting die thereof

Abstract

The invention discloses an integrated inductor die-casting method and die-casting die thereof, and the method comprises the steps: placing a first pressing rod into one end of a cavity of a surrounding die, and stopping the first pressing rod at a first stopping position; filling the cavity for the first time; the positioning grooves are assembled with coils; filling the cavity for the second time; the second pressing rod is arranged at the other end of the cavity and is stopped at a second stopping position; the first pressing rod and the second pressing rod synchronously and oppositely move in and park at a target parking position; the first pressing rod and the second pressing rod are separated from the cavity; separating the surrounding mold, and demolding the inductor blank; and carrying out terminal bending and surface treatment on the inductor blank. Compared with a traditional inductor production process, according to the scheme, multiple sets of molds do not need to be adopted for prefabricating the sub-modules, the sub-modules do not need to be assembled before die casting, the powder and the coil are directly subjected to overall hot die-casting forming, the machining procedures and equipment are greatly simplified, and the production cost is reduced; and displacement and deformation of the sub-module and the coil during die casting are avoided, and the yield is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of inductor processing, and in particular to an integrated inductor die-casting method and a die-casting mold thereof. Background Art

[0002] The basic inductor product consists of an iron core and a coil. The production process usually involves dividing the iron core into two or more sub-modules. The sub-modules are pre-pressed into molds from powder materials for assembly and placement of coils. After the coils and sub-modules are assembled into a combination, the combination is hot-pressed as a whole to form an inductor blank. Finally, the inductor blank is subjected to surface treatment and finishing such as spraying paint, stripping paint, and electroplating to obtain an inductor product with regular dimensions.

[0003] In the above production process, each sub-module needs to use a special pressing mold, that is, it is necessary to use multiple pressing molds to repeatedly prepare the sub-module, and before the final overall hot pressing, the coil needs to be assembled to a specific position on the sub-module, and each sub-module needs to be assembled in place.

[0004] It can be seen that the material preparation stage of the above-mentioned traditional inductor production process involves multiple molds and multiple processes, and the process is relatively complicated. In addition, during the hot pressing process, the combination of each submodule and the coil has a certain proportion of displacement and deformation between each other, and the yield rate is difficult to guarantee. Summary of the invention

[0005] A first aspect of an embodiment of the present invention discloses an integrated inductive die-casting method, comprising:

[0006] 101. Control a first pressing rod to be placed into one end of a cavity of a surrounding mold and to stop at a first stop position of the cavity;

[0007] 102. Filling the cavity for the first time;

[0008] 103. Assembling the coil based on the positioning groove on the inner wall of the cavity;

[0009] 104. Fill the cavity with a secondary filler;

[0010] 105. Control the second pressing rod to be placed into the other end of the cavity and to stop at a second stop position of the cavity;

[0011] 106. Control the first pressing rod and the second pressing rod to move synchronously toward each other and stop at a target stop position of the cavity;

[0012] 107. Control the first pressing rod and the second pressing rod to separate from the mold cavity;

[0013] 108. Control the surrounding mold to separate and demold the inductor blank located inside the cavity;

[0014] 109. Perform terminal bending and surface treatment on the inductor blank to obtain an integrated inductor.

[0015] Preferably, the inner contour of the positioning groove on the inner wall of the cavity is adapted to the outer contour of the two ends of the flattened coil;

[0016] The inner contour of the cavity is adapted to the axial outer contour of the integrated inductor;

[0017] The edge contour of the target parking position corresponds to the lateral outer contour of the integrated inductor.

[0018] Preferably, the cavity component is provided with a side wall on one side of the enclosure component, so as to cooperate with the first pressing rod parked at the first parking position to accommodate the powder material for the first filling;

[0019] A side groove is provided on one side of the enclosure component that is in contact with the cavity component, so as to accommodate the protruding side wall.

[0020] Preferably, a heating device is installed inside the surrounding mold;

[0021] For coils with enameled surfaces, the upper limit of the heating temperature of the heating device is 180°C.

[0022] Preferably, a boss is provided inside the cavity, and the positioning groove is located on the boss;

[0023] Based on the boss, the surface of the hot-pressed inductor blank is provided with a groove corresponding to the boss.

[0024] Preferably, the groove is used to accommodate the bent terminal;

[0025] The surface of the bent terminal should not be higher than the surface of the integrated inductor.

[0026] A second aspect of an embodiment of the present invention discloses a die-casting mold, characterized in that:

[0027] A surrounding mold (1) having a mold cavity (111) extending therethrough, wherein a first pressure rod (2) is disposed at one axial end of the mold cavity (111) and a second pressure rod (3) is disposed at the other axial end;

[0028] The first pressure rod (2) and the second pressure rod (3) both run along the axial direction of the cavity (111);

[0029] The enclosure mold (1) is composed of a cavity component (11) and an enclosure component (12) assembled together;

[0030] The cavity (111) is provided on a side of the cavity component (11), and the enclosure component (12) is fitted on one side of the cavity (111) of the cavity component (11);

[0031] A boss (121) is disposed inside the enclosure component (12), and a positioning groove (122) is provided on the surface of the boss (121);

[0032] A side wall (112) is provided on one side of the cavity component (11) that is in contact with the enclosure component (12), and a side groove (123) is provided on one side of the enclosure component (12) that is in contact with the cavity component (11) for accommodating the protruding side wall (112);

[0033] The cavity component (11) and the enclosure component (12) are both equipped with heating devices (4).

[0034] Preferably, the positioning groove (122) is used for positioning and assembling a coil with flattened ends.

[0035] Preferably, the first pressure rod (2) and the second pressure rod (3) are used to synchronously run towards each other from both ends of the cavity (111) to perform die-casting on the powder contained in the cavity (111) and the coil covered by the powder, and the heating device (4) simultaneously performs heating treatment.

[0036] Compared with the prior art, the embodiments of the present invention have the following beneficial effects:

[0037] Compared with the traditional inductor production process, this solution does not need to use multiple sets of molds to prefabricate sub-modules, and there is no need to assemble the sub-modules before die-casting. Instead, the powder and coil are directly hot-die-cast as a whole, which greatly simplifies the processing procedures and equipment, reduces production costs, and avoids the displacement and deformation of the sub-modules and coils during die-casting, greatly improving the yield rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0039] Figure 1 It is a schematic diagram of a process of an integrated inductive die-casting method disclosed in the present invention;

[0040] Figure 2 It is a three-dimensional structural schematic diagram of a die-casting mold disclosed in the present invention;

[0041] Figure 3 It is a structural schematic diagram of the top surface of a die-casting mold disclosed in the present invention;

[0042] Figure 4It is a partial structural schematic diagram of a die-casting mold disclosed in the present invention;

[0043] Figure 5 is another partial structural schematic diagram of a die-casting mold disclosed in the present invention;

[0044] Figure 6 It is a structural schematic diagram of an inductor blank disclosed in the present invention;

[0045] Figure 7 It is a structural schematic diagram of an integrated inductor obtained by bending terminals and performing surface treatment on an inductor blank disclosed in the present invention.

[0046] The main structural symbols are described in the following table:

[0047]

[0048] DETAILED DESCRIPTION

[0049] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0050] Embodiment 1

[0051] See also Figure 1 , the integrated inductor die-casting method may include the following contents.

[0052] 101. Control the first pressing rod to be placed into one end of the cavity of the surrounding mold and stop at a first stop position of the cavity.

[0053] In this embodiment, the first pressing rod is first placed into the bottom of the cavity to seal the bottom of the cavity and form a closed filling space with the cavity and the side wall, so as to provide a first filling space for step 102 .

[0054] Here, the first parking position is set based on the specification of the inductor, which is used to ensure that after the first filling, the surface of the powder does not shield the positioning groove, which is convenient for the subsequent assembly of the coil.

[0055] 102. Fill the cavity for the first time.

[0056] In this embodiment, powder material for die-casting the iron core on one side of the inductor is filled into the cavity, so as to be used for assembling the coil inside the inductor in step 103 .

[0057] 103. The coil is assembled based on the positioning groove on the inner wall of the cavity.

[0058] In this embodiment, a positioning groove is provided on the inner wall of the cavity, and the positioning groove is used to limit the position of the coil to ensure that the coil is fixed in position and does not shift during the subsequent die-casting process. The coil can be positioned accordingly, and the powder can be die-casted synchronously from both sides to the middle to avoid the situation where the coil and the pre-pressed sub-module generate rigid extrusion friction and displacement deformation during the die-casting process, thereby obtaining an inductor blank with accurate coil positioning, high consistency and high yield rate.

[0059] As an optional implementation, both ends of the coil are flattened.

[0060] The inner contour of the positioning groove on the inner wall of the cavity is adapted to the outer contours of the two ends of the flattened coil.

[0061] Here, the two ends of the coil are not pre-bent, but are retained to extend outward and are flattened. The two ends of the coil after flattening are adapted to the inner contour of the positioning groove and can be smoothly assembled in the positioning groove to achieve coil positioning and limiting.

[0062] In addition, after the inductor is formed, the two ends of the flattened coil can be conveniently bent onto the surface of the inductor, reducing the number of subsequent fine processing steps.

[0063] 104. Fill the cavity with secondary filling.

[0064] In this embodiment, powder material for die-casting the iron core on the other side of the inductor is filled into the cavity so that the coil assembled and limited in the cavity is surrounded by the powder material.

[0065] As an optional implementation, the surrounding mold may also be equipped with a vibration device, which is used to vibrate the powder in the cavity after filling, to ensure that the powder specifications on both sides of the coil are consistent as much as possible, and to improve the yield and consistency of the finished product.

[0066] 105. Control the second pressing rod to be placed into the other end of the cavity and stop at a second stop position of the cavity.

[0067] In this embodiment, for the cavity in which the coil has been assembled and filled, the second pressing rod is inserted from the unsealed end of the cavity and stops at the second stopping position.

[0068] Here, the first stop position is symmetrical with the first stop position based on the positioning groove, so that the first pressing rod and the second pressing rod are in a synchronous state, waiting for synchronous die-casting of the powder and the coil in the powder.

[0069] 106. Control the first pressing rod and the second pressing rod to move synchronously toward each other and stop at a target stop position of the cavity.

[0070] Here, the target stopping position is the final specification of the die casting, that is, the outer shape specification of the inductor.

[0071] During the synchronous die-casting process, the powder materials are uniform in material and their shapes change in a consistent manner. There is no friction or crushing between the pre-pressed sub-modules and the coils, and the coil body will not be damaged. This effectively ensures the consistent performance of the finished inductor and greatly improves the yield rate.

[0072] As an optional embodiment, a heating device is installed inside the surrounding mold.

[0073] Here, depending on the composition ratio of the powder and the process requirements, the die casting process can choose whether to perform hot die casting on the powder.

[0074] That is, when only die casting is performed, the heating device is not operated. However, when hot die casting is performed, the heating device is operated at the same time as die casting, and the powder is subjected to high temperature and high pressure treatment to obtain a compact integrated inductor blank.

[0075] As an optional implementation, for the coil with enameled surface, the upper limit of the heating temperature of the heating device is 180°C.

[0076] In this embodiment, during the die-casting process, the surrounding mold heats the powder in a high-pressure state simultaneously, and the powder is densely combined and fused by high temperature and high pressure to form a green body of the integrated inductor.

[0077] Here, some inductor products use enameled coils, so it is necessary to limit the upper limit of the heating temperature to avoid excessively high temperatures from damaging the enameled layer and affecting the insulation effect.

[0078] 107. Control the first pressing rod and the second pressing rod to separate from the cavity.

[0079] Here, the first pressing rod and the second pressing rod are separated from the mold cavity first.

[0080] 108. Control the separation of the surrounding mold to demould the inductor blank located inside the cavity.

[0081] Here, after the first pressing rod and the second pressing rod are separated from the cavity, the two ends of the coil of the inductor blank are still placed in the positioning groove, so the surrounding mold is separated here so that the inductor blank can be separated from the positioning groove and fall off as a whole.

[0082] 109. Perform terminal bending and surface treatment on the inductor blank to obtain an integrated inductor.

[0083] In this embodiment, the inductor blank has been formed into a standard specification, and can be subjected to surface painting, paint stripping and other operations, and the vertical terminals can be bent to form a standard inductor product.

[0084] As an optional implementation, a boss is provided inside the cavity, and the positioning groove is located on the boss;

[0085] Based on the bosses, the surface of the hot-pressed inductor blank is provided with grooves corresponding to the bosses.

[0086] The groove is used to accommodate the bent terminal;

[0087] The surface of the bent terminal should not be higher than the surface of the integrated inductor.

[0088] Here, a boss may be provided at the positioning groove according to the specifications and shapes of the inductor, so as to press a groove into the inductor.

[0089] Based on this, the terminal can be bent and placed in the groove to obtain an inductor product with a regular appearance and no protrusions, which can be used in special scenarios.

[0090] In summary, compared with the traditional inductor production process, this solution does not need to use multiple sets of molds to prefabricate sub-modules, and there is no need to assemble the sub-modules before die-casting. Instead, the powder and coil are directly hot-die-cast as a whole, which greatly simplifies the processing procedures and equipment, reduces production costs, and avoids the displacement and deformation of the sub-modules and coils during die-casting, greatly improving the yield rate.

[0091] Embodiment 2

[0092] See also Figures 2 to 7 , the die casting mold may include the following contents.

[0093] A surrounding mold 1 is provided through the cavity 111, a first pressing rod 2 is provided at one axial end of the cavity 111, and a second pressing rod 3 is provided at the other axial end;

[0094] The first pressing rod 2 and the second pressing rod 3 both run along the axial direction of the cavity 111;

[0095] The surrounding mold 1 is composed of a cavity component 11 and a surrounding component 12;

[0096] A cavity 111 is formed on the side of the cavity component 11 , and one side of the cavity 111 of the cavity component 11 is fitted with the enclosure component 12 ;

[0097] A boss 121 is disposed inside the enclosure component 12, and a positioning groove 122 is formed on the surface of the boss 121;

[0098] A side wall 112 is disposed on one side of the cavity component 11 that is in contact with the enclosure component 12 , and a side groove 123 is disposed on one side of the enclosure component 12 that is in contact with the cavity component 11 to accommodate the protruding side wall 112 ;

[0099] The heating device 4 is installed inside the cavity component 11 and the enclosure component 12 .

[0100] In this embodiment, the cavity assembly and the enclosure assembly constitute a surrounding mold of the through-type cavity, and the first pressure rod and the second pressure rod are inserted from both ends of the cavity, and cooperate with the heating device to perform hot die casting on the powder in the cavity and the coil covered therein.

[0101] During the die-casting process, both ends of the coil are placed in positioning grooves to achieve positioning and limiting, thereby ensuring that the coil does not move under high pressure and high temperature conditions. The powder material gradually solidifies around the periphery of the coil to obtain an inductor with uniform core material density, complete coil and high consistency.

[0102] Compared with the traditional process of prefabricating sub-modules and then assembling coils, the method of hot die-casting powder and coils effectively avoids direct extrusion and scratching between the coils and the hard sub-modules. The impact of the powder curing process on the coils is significantly reduced, and the coil offset, deformation, breakage, etc. are greatly reduced, thereby improving the yield rate.

[0103] At the same time, the process flow of prefabricated submodules has been streamlined, which also means that various molds and die-casting equipment for preparing submodules have been streamlined. Taking the simplest case of using two submodules to press together a coil as an example, the traditional process requires the prefabrication of two submodules, so two molds corresponding to the two submodules are required. In the case of mass production, the number of molds is relatively large, the equipment cost is high, and the labor cost and time occupied by assembling the mold cannot be ignored. This solution directly performs die-casting on the powder, eliminating the equipment cost, labor cost and time cost required by the previous process, which is conducive to reducing production costs and improving production efficiency.

[0104] As an optional implementation, the positioning groove 122 is used for positioning and assembling a coil with flattened ends.

[0105] Here, the positioning groove is used to position the limit coil, so that during the hot die casting process, the position of the coil remains unchanged, and the first pressure rod and the second pressure rod die-cast the powder around the coil from both sides to obtain an inductor product with high consistency and high yield.

[0106] In addition, when producing the coil winding, the two ends of the coil are flattened simultaneously, so that after the powder is die-cast, the two ends of the coil can be directly bent to form inductor terminals, which simplifies the subsequent fine processing process and effectively improves production efficiency.

[0107] As an optional embodiment, the first pressure rod 2 and the second pressure rod 3 are used to synchronously run towards each other from both ends of the cavity 111 to perform die-casting on the powder contained in the cavity 111 and the coil covered by the powder, and are simultaneously heated by the heating device 4.

[0108] Here, in the process of synchronous die-casting, the material of the powder is uniform and the shape changes are consistent. There is no friction or crushing between the pre-pressed sub-modules and the coil, and the coil body will not be damaged, which effectively ensures the consistent performance of the finished inductor and greatly improves the yield rate.

[0109] The heating device 4 is placed inside the surrounding mold, and can be a heating device such as an electric heating wire or an electric heating tube, which can solidify the powder in the cavity at high temperature through heat conduction.

[0110] Compared with the prior art, the embodiments of the present invention have the following beneficial effects:

[0111] Compared with the traditional inductor production process, this solution does not need to use multiple sets of molds to prefabricate sub-modules, and there is no need to assemble the sub-modules before die-casting. Instead, the powder and coil are directly hot-die-cast as a whole, which greatly simplifies the processing procedures and equipment, reduces production costs, and avoids the displacement and deformation of the sub-modules and coils during die-casting, greatly improving the yield rate.

Claims

1. An integrated inductor die-casting method, characterized in that: The method comprises:

101. Control a first pressing rod to be placed into one end of a cavity of a surrounding mold and to stop at a first stop position of the cavity; 102. Filling the cavity for the first time; 103. Assembling the coil based on the positioning groove on the inner wall of the cavity; 104. Fill the cavity with a secondary filler; 105. Control the second pressing rod to be placed into the other end of the cavity and to stop at a second stop position of the cavity; 106. Control the first pressing rod and the second pressing rod to move synchronously toward each other and stop at a target stop position of the cavity; 107. Control the first pressing rod and the second pressing rod to separate from the mold cavity; 108. Control the surrounding mold to separate and demold the inductor blank located inside the cavity; 109. Perform terminal bending and surface treatment on the inductor blank to obtain an integrated inductor.

2. The integrated inductive die-casting method according to claim 1, characterized in that: include: Both ends of the coil are flattened.

3. The integrated inductive die-casting method according to claim 2, characterized in that: include: The inner contour of the positioning groove on the inner wall of the cavity is adapted to the outer contours of the two ends of the flattened coil; The inner contour of the cavity is adapted to the axial outer contour of the integrated inductor; The edge contour of the target parking position corresponds to the lateral outer contour of the integrated inductor.

4. The integrated inductive die-casting method according to claim 1, characterized in that: include: The cavity component is provided with a side wall on one side of the enclosure component, so as to cooperate with the first pressing rod parked at the first parking position to accommodate the powder material for the first filling; A side groove is provided on one side of the enclosure component that is in contact with the cavity component, so as to accommodate the protruding side wall.

5. The integrated inductive die-casting method according to claim 1, characterized in that: include: A heating device is installed inside the surrounding mold; For coils with enameled surfaces, the upper limit of the heating temperature of the heating device is 180°C.

6. The integrated inductive die-casting method according to claim 1, characterized in that: include: A boss is arranged inside the cavity, and the positioning groove is located on the boss; Based on the boss, the surface of the hot-pressed inductor blank is provided with a groove corresponding to the boss.

7. The integrated inductive die-casting method according to claim 6, characterized in that: include: The groove is used to accommodate the bent terminal; The surface of the bent terminal should not be higher than the surface of the integrated inductor.

8. A die-casting mold used in the integrated inductor die-casting method according to any one of claims 1 to 7, characterized in that: A surrounding mold (1) having a mold cavity (111) extending therethrough, wherein a first pressure rod (2) is disposed at one axial end of the mold cavity (111) and a second pressure rod (3) is disposed at the other axial end; The first pressure rod (2) and the second pressure rod (3) both run along the axial direction of the cavity (111); The enclosure mold (1) is composed of a cavity component (11) and an enclosure component (12) assembled together; The cavity (111) is provided on a side of the cavity component (11), and the enclosure component (12) is fitted on one side of the cavity (111) of the cavity component (11); A boss (121) is disposed inside the enclosure component (12), and a positioning groove (122) is provided on the surface of the boss (121); A side wall (112) is provided on one side of the cavity component (11) that is in contact with the enclosure component (12), and a side groove (123) is provided on one side of the enclosure component (12) that is in contact with the cavity component (11) for accommodating the protruding side wall (112); The cavity component (11) and the enclosure component (12) are both equipped with heating devices (4).

9. A die-casting mold according to claim 8, characterized in that: include: The positioning groove (122) is used for positioning and assembling a coil with flattened ends.

10. A die-casting mold according to claim 9, characterized in that: include: The first pressing rod (2) and the second pressing rod (3) are used to synchronously run towards each other from both ends of the cavity (111) to perform die-casting on the powder contained in the cavity (111) and the coil covered by the powder, and the heating device (4) simultaneously performs heating treatment.

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