A chip inductor cold pressing molding apparatus and molding method thereof

Abstract

This invention discloses a chip inductor cold pressing forming apparatus and its forming method. The chip inductor cold pressing forming apparatus includes a frame, a fixed middle template, a movable middle template assembly, an upper stamping structure, a lower stamping structure, a powder feeding mechanism, and a driving unit. The upper stamping structure includes an upper first stamp and an upper second stamp, the upper second stamp being hollow, with the upper first stamp passing through the inner cavity of the upper second stamp. The lower stamping structure includes a lower first stamp and a lower second stamp, the lower second stamp being hollow, with the lower first stamp passing through the inner cavity of the lower second stamp, and an adjustable-depth powder-containing space being formed between the lower first stamp and the lower second stamp. A first driving mechanism is used to drive the upper first stamp and the upper second stamp to perform synchronous or asynchronous lifting, and a second driving mechanism is used to drive the lower first stamp and the lower second stamp to perform synchronous or asynchronous lifting. The technical solution of this invention aims to solve the problems of poor controllability, poor consistency, and low preparation efficiency of existing equipment.

Description

Technical Field

[0001] This invention relates to the field of chip inductor cold pressing molding apparatus, and particularly to a chip inductor cold pressing molding apparatus and molding method thereof. Background Technology

[0002] In the production of chip inductors, cold pressing is a crucial preliminary process. Its core task is to precisely fill and pre-press magnetic powder into a blank (i.e., a preform) of a specific shape for subsequent hot pressing and curing. Currently, the industry commonly uses a fixed-volume powder-filling cold pressing mold. This technology typically includes a powder-filling plate, a powder-filling plate cover, a powder-filling plate bottom cover, and a matching positioning and lifting mechanism. Its basic working principle is: under the action of gravity and external vibration, the powder falls into the cavity of the mold below through the pre-set fixed-volume holes on the powder-filling plate, and then forms a blank through stamping. However, in practical applications, it has been found that this traditional fixed-volume powder-filling technology has significant drawbacks and can no longer meet the demands of high-precision and high-efficiency modern production. Specifically, these drawbacks are as follows:

[0003] Poor controllability: Existing technology uses powder filling holes with fixed volume for powder filling, and the amount of powder filled is determined by the physical dimensions of the powder filling plate itself. Once the processing is completed, it cannot be adjusted.

[0004] Poor consistency: The original cold pressing process leaves powder residue in the powder filling device, resulting in poor consistency in the weight and density of the product.

[0005] Low setup efficiency: When adjusting the powder filling amount is required to produce products of different specifications, existing technology requires stopping the machine and manually replacing key components such as powder filling plates and master mold plates with different apertures or thicknesses. This process is time-consuming and labor-intensive, which not only increases the time and labor costs of production, but also reduces the overall utilization rate of equipment and production flexibility, making it unable to adapt to the needs of rapid changeover for small batches and multiple varieties. Summary of the Invention

[0006] The main objective of this invention is to provide a chip inductor cold pressing molding apparatus and molding method, which aims to solve the problems of poor controllability, poor consistency and low preparation efficiency of existing equipment.

[0007] To achieve the above objectives, the present invention provides a chip inductor cold pressing forming apparatus, comprising:

[0008] frame;

[0009] A fixed template is fixedly mounted on the frame. The fixed template has powder filling holes that run vertically through it. The top area of ​​the powder filling holes forms a powder filling area for receiving powder.

[0010] A movable template assembly is movably mounted on the frame. The movable template assembly has through-holes at the top and bottom. The movable template assembly can move relative to the fixed template. When it moves to the powder filling area, the forming holes and the powder filling holes are aligned one by one.

[0011] The upper stamping structure includes an upper first stamp and an upper second stamp, wherein the upper second stamp is a hollow structure and the upper first stamp is inserted into the inner cavity of the upper second stamp;

[0012] The lower stamping structure is vertically opposite to the upper stamping structure and includes a lower stamp and a lower second stamp. The lower second stamp is a hollow structure. The lower stamp passes through the inner cavity of the lower second stamp, and an adjustable powder-containing space can be formed between the lower stamp and the lower second stamp.

[0013] A powder feeding mechanism is connected to one side of the fixed template and is used to feed powder into the powder filling area of ​​the fixed template.

[0014] The drive structure includes a first drive mechanism and a second drive mechanism. The first drive mechanism is connected to the upper first stroke and the upper second stroke drive mechanism and is used to drive the upper first stroke and the upper second stroke to perform synchronous or asynchronous lifting and lowering. The second drive mechanism is connected to the lower next stroke and the lower second stroke drive mechanism and is used to drive the lower next stroke and the lower second stroke to perform synchronous or asynchronous lifting and lowering.

[0015] The control unit is electrically connected to the drive structure and the powder feeding mechanism.

[0016] In one possible implementation, the movable template assembly includes a movable template and a template base, the movable template being slidably disposed on the template base and having a first working position and a second working position.

[0017] In the first working position, the forming holes of the moving template are aligned with the corresponding holes of the template base;

[0018] In the second working position, the forming holes of the moving template are misaligned with the corresponding holes of the template base, and the template base covers the bottom of the forming holes.

[0019] In one possible implementation, the powder feeding mechanism includes:

[0020] A powder feeding box, which is used to contain powder materials;

[0021] A powder feeding motor module is mounted on the frame and is driven by the powder feeding box.

[0022] A vibrator is attached to the outer wall of the powder feeding box to cause the powder in the powder feeding box to fall into the powder holding space.

[0023] In one possible implementation, the powder feeding box is provided with a cleaning air hole, which is connected to an external air source.

[0024] In one possible implementation, both the first driving mechanism and the second driving mechanism include a slider assembly and a first driving part and a second driving part that can be controlled independently. The slider assembly includes an outer layer and an inner layer that can move relative to each other.

[0025] Specifically, for the first driving mechanism, its outer layer is connected to the upper first punch, its inner layer is connected to the upper second punch, the first driving part drives the outer layer, and the second driving part drives the inner layer;

[0026] For the second drive mechanism, its outer layer is connected to the next stroke, and its inner layer is connected to the next second stroke. The first drive unit drives the outer layer, and the second drive unit drives the inner layer.

[0027] In one possible implementation, the upper and lower ends of the forming cavity of the moving template are provided with a chamfered structure.

[0028] In one possible implementation, a gravity balancing mechanism is also included, which is connected to the upper stamping structure for shock reduction and vibration damping.

[0029] In one possible implementation, the drive structure further includes a handling robot electrically connected to the control unit, the handling robot being driven to move the moving template assembly between the powder filling station and an adjacent processing station.

[0030] To achieve the above objectives, the present invention also provides a forming method for a chip inductor cold pressing forming apparatus, applicable to the chip inductor cold pressing forming apparatus described in any of the above possible embodiments, comprising the following steps:

[0031] The control unit controls the second drive mechanism to drive the next punch and the second punch to rise synchronously and extend into the powder filling cavity of the fixed template;

[0032] The second drive mechanism adjusts the position of the next punch relative to the second punch, forming a powder-containing space with adjustable depth between the inner cavity of the second punch and the next punch.

[0033] The powder feeding box moves to the powder filling area via the powder feeding motor module, and the powder in the powder box is transported into the powder holding space by the vibration of the vibrator and the gravity of the powder. The next stroke repeats the relative displacement along the next two strokes to shake the powder.

[0034] After the powder filling is completed, the powder feeding motor module drives the powder feeding box to return to the initial position;

[0035] The control unit controls the handling robot to move the moving template assembly to the powder filling area, and the forming cavity is aligned with the powder filling cavity;

[0036] The second drive mechanism drives the first punch and the second punch to rise asynchronously into the forming cavity, with the first punch protruding out of the second punch.

[0037] The first drive mechanism drives the upper punch and the upper second punch to descend synchronously into the forming cavity, and the second drive mechanism drives the lower punch to gradually descend and become flush with the lower second punch.

[0038] The first drive mechanism drives the upper punch to protrude from the upper second punch, forming an inductor blank;

[0039] The first drive mechanism drives the first and second upper strokes to descend synchronously, pressing the powder material together.

[0040] This invention achieves precise control of powder filling volume by utilizing an adjustable powder-capacity space formed by the relative displacement of the lower punch and the second lower punch in the lower punch structure. This allows for flexible adaptation to the powder quantity requirements of different products without the need to change mold parts. Secondly, the powder remains within a closed or semi-closed space enclosed by the punches throughout the entire filling and transfer process. The active pushing action of the punches completes all steps, virtually eliminating powder residue and adhesion on the mold wall, ensuring consistent product weight and density. Finally, the combination of powder feeding vibration and punch shaking, along with the precise movement of the upper and lower punches within the forming cavity, ensures uniform powder distribution within complex cavities (such as inductor blank structures), thereby improving the performance consistency and reliability of the final inductor element. Attached Figure Description

[0041] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0042] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present invention;

[0043] Figure 2 This is a schematic diagram of the driving structure according to an embodiment of the present invention;

[0044] Figure 3 This is a schematic diagram of the powder feeding mechanism according to an embodiment of the present invention;

[0045] Figure 4 This is a schematic diagram of the powder delivery box according to an embodiment of the present invention;

[0046] Figure 5 This is a schematic diagram illustrating the cooperation between the upper and lower stamping parts in one embodiment of the present invention;

[0047] Figure 6 This is a schematic diagram of the structure before powder filling in an embodiment of the present invention;

[0048] Figure 7 This is a schematic diagram of the structure in the powder filling process according to an embodiment of the present invention;

[0049] Figure 8 This is a schematic diagram of the structure after powder filling according to an embodiment of the present invention;

[0050] Figure 9 This is a schematic diagram of the structure of a handling robot according to an embodiment of the present invention;

[0051] Figure 10 This is a schematic diagram of the punch structure extending into the powder filling cavity according to an embodiment of the present invention.

[0052] Explanation of icon numbers:

[0053] 1. Frame; 2. Fixed template; 21. Powder filling holes; 22. Powder filling area;

[0054] 31. Moving template; 32. Template base; 33. Molding cavity; 331. Chamfered structure; 34. Handling robot;

[0055] 4. Upper stamping structure; 41. First upper stamp; 42. Second upper stamp;

[0056] 5. Lower stamping structure; 51. First lower stamp; 52. Second lower stamp; 53. Powder-containing space;

[0057] 6. Powder feeding mechanism; 61. Powder feeding box; 62. Powder feeding motor module; 63. Vibrator; 64. Cleaning air blowing hole;

[0058] 7. First drive mechanism; 71. Slider assembly; 711. Inner layer; 712. Outer layer; 72. First drive unit; 73. Second drive unit; 8. Second drive mechanism;

[0059] 9; Gravity balancing mechanism.

[0060] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0061] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0062] To address the problems in the background technology, this invention proposes a chip inductor cold pressing molding apparatus and its molding method, comprising:

[0063] Rack 1;

[0064] The fixed template 2 is fixedly mounted on the frame 1. The fixed template 2 is provided with powder filling holes 21 that are vertically connected. The top area of ​​the powder filling holes 21 constitutes a powder filling area 22 for receiving powder.

[0065] The movable template 31 assembly is movably mounted on the frame 1. The movable template 31 assembly is provided with a vertically penetrating forming cavity 33. The movable template 31 assembly can move relative to the fixed template 2. When it moves to the powder filling area 22, the forming cavity 33 is aligned with the powder filling cavity 21.

[0066] The upper stamping structure 4 includes an upper first stamp 41 and an upper second stamp 42. The upper second stamp 42 is a hollow structure, and the upper first stamp 41 passes through the inner cavity of the upper second stamp 42.

[0067] The lower stamping structure 5 is vertically opposite to the upper stamping structure 4 and includes a lower stamp 51 and a lower second stamp 52. The lower second stamp 52 is a hollow structure. The lower stamp 51 passes through the inner cavity of the lower second stamp 52, and an adjustable powder-containing space 53 can be formed between the lower stamp 51 and the lower second stamp 52.

[0068] The powder feeding mechanism 6 is connected to one side of the fixed template 2 and is used to feed powder to the powder filling area 22 of the fixed template 2.

[0069] The drive structure includes a first drive mechanism 7 and a second drive mechanism 8. The first drive mechanism 7 is driven and connected to the upper first stroke 41 and the upper second stroke 42, and is used to drive the upper first stroke 41 and the upper second stroke 42 to perform synchronous or asynchronous lifting and lowering. The second drive mechanism 8 is driven and connected to the lower next stroke 51 and the lower second stroke 52, and is used to drive the lower next stroke 51 and the lower second stroke 52 to perform synchronous or asynchronous lifting and lowering.

[0070] The control unit is electrically connected to the drive structure and the powder feeding mechanism 6.

[0071] Combined with reference Figures 1 to 9As shown, in this embodiment, the frame 1 is preferably made of cast iron and has leveling feet at the bottom to ensure overall installation stability and structural rigidity, providing a stable support foundation for each functional component. The fixed template 2 is fastened to the frame 1 with high-strength bolts. Its material is preferably mold steel and has been quenched. The fixed template 2 has multiple vertically penetrating powder filling holes 21 arranged in an array along its length. The diameter of the powder filling holes 21 is adapted to the bottom size of the part to be formed, and the center spacing of adjacent holes is consistent. Its top area forms a flat powder filling area 22. This powder filling area 22 is precisely matched with the moving path of the powder feeding mechanism 6 to ensure full coverage of powder material conveying. The movable template 31 assembly includes a template base 32 and a movable template 31. The template base 32 can be slidably connected to the frame 1 via a linear guide rail. The movable template 31 is also preferably made of mold steel and can be slidably mounted on top of the template base 32 via a cross roller guide rail. The movable template 31 assembly is provided with forming holes 33 that correspond one-to-one with the number and diameter of the powder filling holes 21. When the movable template 31 assembly moves to the powder filling area 22, the forming holes 33 are coaxially aligned with the powder filling holes 21.

[0072] The upper stamping structure 4 and the lower stamping structure 5 are arranged vertically opposite each other. The upper stamping structure 4 is located directly above the powder-filling area 22, and the lower stamping structure 5 is located directly below the powder-filling area 22. Both can be made of cemented carbide. Specifically, the upper second stamp 42 is designed as a hollow cylindrical or square cylindrical structure, and its inner cavity is used to accommodate the upper first stamp 41. The upper first stamp 41 is a solid rod-shaped structure that can move axially along the inner cavity of the upper second stamp 42. The two can be connected by a guide key or spline to ensure concentricity of movement. The lower stamping structure 5 is arranged vertically opposite to the upper stamping structure 4, including a lower first stamp 51 and a lower second stamp 52, whose structure corresponds to and is arranged in a mirror image of the upper stamping structure 4. The lower second stamp 52 is also a hollow structure, and the lower first stamp 51 passes through its inner cavity. By controlling the axial position of the first punch 51 relative to the second punch 52, a powder-containing space 53 with continuously adjustable depth can be formed between the two. This space is the metering chamber for each powder filling. The powder filling volume can be precisely adjusted by changing the relative displacement. The powder filling amount can be accurately matched according to the molding requirements of different parts, thereby fundamentally solving the problem of inconvenient adjustment of the traditional fixed volume powder filling method.

[0073] The powder feeding mechanism 6 is located on one side of the fixed template 2 and is used to quantitatively supply powder to the powder filling area 22. Specifically, it may include a powder storage bin, a powder feeding box 61, a linear drive module, and a vibrator 63. The powder feeding box 61 is driven by a linear drive module (such as a cylinder, electric push rod, or servo slide) and can reciprocate between the powder storage bin and the powder filling area 22 of the fixed template 2. The vibrator 63 is installed on the outside of the powder feeding box 61 and generates high-frequency micro-amplitude vibrations during operation to promote powder flow, prevent bridging or blockage, and ensure that the powder is uniformly and completely filled into the powder-containing space 53.

[0074] The drive structure includes a first drive mechanism 7 and a second drive mechanism 8, which independently control the movement of the upper stamping structure 4 and the lower stamping structure 5, respectively. The first drive mechanism 7 is connected to the upper first stamp 41 and upper second stamp 42, and the second drive mechanism 8 is connected to the lower first stamp 51 and lower second stamp 52. Each drive mechanism can achieve high-precision position control using a combination of servo motor, ball screw, and linear guide, or it can use a hydraulic cylinder or pneumatic cylinder in conjunction with a position sensor. Each drive mechanism should have the ability to independently control the outer layer 712 punches (i.e., upper first stamp 41 and upper second stamp 42, lower first stamp 51 and lower second stamp 52), enabling both synchronous lifting and lowering of the inner and outer punches for overall transfer, and asynchronous lifting and lowering of the inner and outer punches for actions such as adjusting the powder space 53, compacting the powder, and molding and demolding.

[0075] The control unit can be a PLC-based or industrial computer-based system, electrically connected to the servo drives, linear drive modules of the powder feeding mechanism 6, and vibrator 63 in the drive structure. The control unit stores preset programs that can coordinate and command all action sequences of powder feeding, mold moving, punch alignment, powder filling, powder shaking, transfer, pressing, and demolding to achieve fully automated operation.

[0076] In one possible implementation, the movable template 31 assembly includes a movable template 31 and a template base 32. The movable template 31 is slidably disposed on the template base 32 and has a first working position and a second working position.

[0077] In the first working position, the forming holes 33 of the moving template 31 are aligned with the corresponding holes of the template base 32;

[0078] In the second working position, the forming hole 33 of the moving template 31 is offset from the corresponding hole of the template base 32, and the template base 32 covers the bottom of the forming hole 33.

[0079] Combined with reference Figure 5 and Figure 9As shown, in this embodiment, the movable template 31 assembly specifically includes a template base 32 and a movable template 31. The template base 32 is a plate-like structure with through holes corresponding to the number and position of the forming cavities 33 of the movable template 31, referred to as base cavities. The movable template 31 is slidably mounted on the upper surface of the template base 32 via a linear guide mechanism. This linear guide mechanism can be specifically a combination of a linear guide rail mounted on the base and a slider mounted on the bottom of the movable template 31, or a sliding pair consisting of a precision-machined boss and a groove. The movable template 31 can be driven by an independent drive component, such as a cylinder, an electric push rod, or a servo module, enabling it to slide back and forth in a direction parallel to the upper surface of the base. Through the above sliding design, the movable template 31 has two precisely positioned working positions. In the first working position (usually the powder filling and pressing molding station), the moving template 31 is driven until its forming cavity 33 is completely aligned with the base cavity of the template base 32, thus forming a vertically connected channel, facilitating the lower punch to carry the powder material upwards and the upper punch to press down and form the preform. After pressing and molding, when the moving template 31 carrying the formed preform needs to be moved out of the station, the drive component is controlled to slide the moving template 31 to the second working position. In this position, the forming cavity 33 of the moving template 31 is horizontally misaligned with the base cavity of the template base 32, so that the bottom of the forming cavity 33 is completely blocked by the solid part of the template base 32 (i.e., the bridging area between two adjacent base cavities). This prevents the formed, not yet fully solidified powder preform from falling from the bottom of the forming cavity 33 due to its own weight or inertia during the process of the moving template 31 being transferred to the next station (such as the hot pressing station or the demolding station).

[0080] In one possible implementation, the powder feeding mechanism 6 includes:

[0081] Powder feeding box 61, the powder feeding box 61 is used to contain powder materials;

[0082] A powder feeding motor module 62 is mounted on the frame 1 and is driven by the powder feeding box 61.

[0083] Vibrator 63, which abuts against the outer wall of the powder feeding box 61, is used to cause the powder in the powder feeding box 61 to fall into the powder holding space 53.

[0084] Combined with reference Figure 3 and Figure 4As shown, in this embodiment, the powder feeding box 61, as a container for holding powder, can be made of smooth and wear-resistant materials such as stainless steel. It has a storage chamber inside and one or more discharge ports at the bottom. The shape and size of the discharge ports match the powder filling holes 21 of the fixed template 2 or the top opening of the lower stamping structure 5. The powder feeding box 61 is connected to the moving parts of the powder feeding motor module 62 via a mounting plate or connector. The powder feeding motor module 62, as a drive unit, is fixedly mounted on the frame 1. Its core includes a servo motor or stepper motor, and precision transmission components driven by the motor, such as a ball screw pair or a synchronous belt linear module. This module can precisely control the reciprocating linear motion of the powder feeding box 61 in the horizontal direction (perpendicular to the stamping direction), and the motion trajectory allows its discharge port to precisely switch between the receiving position below the storage bin and the unloading position above the powder filling area 22 of the fixed template 2.

[0085] The vibrator 63 is fixed to the outer wall (usually the side wall or bottom) of the powder feeding box 61 by means of a mounting bracket or direct bolt connection. The vibrator 63 is preferably a pneumatic piston vibrator 63 or a high-frequency micro-electric vibrator 63. Its function is to start when the powder feeding box 61 moves to the unloading position and pauses, transmitting high-frequency micro-amplitude mechanical vibrations to the powder feeding box 61. Under the action of gravity and vibration, the powder flows out evenly, smoothly, and completely from the discharge port and falls into the powder-containing space 53 formed by the lower punch 51 and the lower second punch 52 until it is full. After filling, the vibrator 63 stops working, and the powder feeding motor module 62 drives the powder feeding box 61 to reverse and reset. The entire process achieves quantitative and uniform powder feeding.

[0086] In one possible implementation, the powder feeding box is provided with a cleaning air hole 64, which is connected to an external air source.

[0087] Combined with reference Figure 3 and Figure 4 As shown, in this embodiment, specifically, the cleaning air hole 64 is opened on the inner wall of the powder feeding box 61, preferably near or above the discharge port. This hole is inclined towards the discharge port or a corner of the inner cavity where powder easily accumulates, and its external port is connected to an external air source (such as a factory compressed air pipeline) via a quick-connect air hose connector. When a powder filling operation is completed, during or after the powder feeding box 61 is driven back to its initial (or receiving) position by the powder feeding motor module 62, the control unit can control a solenoid valve to open instantaneously, allowing a short burst of clean compressed air to be sprayed into the powder feeding box 61 through the cleaning air hole 64. This airflow effectively sweeps away any residual powder that may adhere to the box wall or the edge of the discharge port, causing it to fall into the powder filling hole 21 of the fixed template 2 below or a dedicated collection device, thereby avoiding cross-contamination caused by residue from different batches of powder and preventing powder accumulation and hardening that could clog the discharge port.

[0088] Meanwhile, to achieve automatic and continuous replenishment of powder, a feeding connector is provided at the top of the powder feeding box 61. This connector is sealed to the discharge port of the storage hopper (or feed bin) above the initial position of the powder feeding box 61 via a flexible corrugated pipe or plastic hose. Thus, when the powder feeding box 61 returns to the receiving position, the powder in the upper hopper can automatically flow into the storage chamber of the powder feeding box 61 through the hose under gravity, promptly replenishing the consumed powder and ensuring that the powder feeding box 61 always has sufficient material.

[0089] In one possible implementation, both the first driving mechanism 7 and the second driving mechanism 8 include a slider assembly 71 and a first driving part 72 and a second driving part 73 that can be controlled independently. The slider assembly 71 includes an outer layer 712 and an inner layer 711 that can move relative to each other.

[0090] Specifically, for the first driving mechanism 7, its outer layer 712 is connected to the upper punch 41, its inner layer 711 is connected to the upper punch 42, the first driving part 72 drives the outer layer 712, and the second driving part 73 drives the inner layer 711.

[0091] For the second drive mechanism 8, its outer layer 712 is connected to the next punch 51, and its inner layer 711 is connected to the next second punch 52. The first drive unit 72 drives the outer layer 712, and the second drive unit 73 drives the inner layer 711.

[0092] Combined with reference Figure 1 and Figure 2As shown, in this embodiment, each drive mechanism includes a slider assembly 71 and two independently controllable drive units (i.e., the first drive unit 72 and the second drive unit 73). The slider assembly 71, as a motion carrier, has a structure comprising a basic outer frame 712 and a nested inner movable block 711. The outer and inner layers 712 are connected by high-precision linear guide components, such as side-by-side ball linear guide pairs or guide post guide sleeve pairs, to ensure independent, smooth, and coaxial relative linear motion in the vertical direction (Z-axis). For the first drive mechanism 7 controlling the upper stamping structure 4, the outer layer 712 of its slider assembly 71 is rigidly connected to the top of the upper stamp 41 via a connecting plate, while its inner layer 711 is rigidly connected to the top of the upper stamp 42 via another connecting plate. The first drive unit 72 drives the entire outer layer 712 to perform lifting and lowering movements; specifically, it can be a module consisting of a servo motor and a ball screw, with the screw nut fixed to the outer layer 712 of the slider assembly 71. The second drive unit 73 is used to independently drive the inner layer 711 to move up and down relative to the outer layer 712. It can use the same servo motor and lead screw module, but its lead screw nut is fixed to the inner layer 711, and the mounting base of the lead screw or motor is associated with the outer layer 712. In this way, by controlling the rotation of the two servo motors, synchronous lifting and lowering of the upper punch 41 and the upper second punch 42 (two motors rotate at the same speed and in the same direction), asynchronous lifting and lowering (different speeds or directions), or a combination of static and dynamic movements can be achieved. The second drive mechanism 8 that controls the lower punch structure 5 has the same structure as the first drive mechanism 7 and is symmetrically arranged. Its outer layer 712 is connected to the lower punch 51, and its inner layer 711 is connected to the lower second punch 52. It is controlled by two other independent drive units. The relative displacement of the first punch 51 and the second punch 52 can be precisely controlled to form a powder-containing space 53 with adjustable depth, so as to achieve stepless adjustment of the powder filling amount; and it can drive the first punch 51 to move up and down repeatedly along the inner cavity of the second punch 52 to achieve a shaking effect, which can effectively break the powder agglomeration and make it fill more evenly and densely in the powder-containing space 53.

[0093] In one possible implementation, the upper and lower ends of the forming holes 33 of the moving template 31 are provided with chamfered structures 331.

[0094] Combined with reference Figure 5As shown, in this embodiment, the forming cavity 33 of the moving template 31 is provided with a chamfer structure 331 at both its upper and lower ends. Specifically, the chamfer structure 331 refers to an inclined transition surface or a rounded transition surface formed by machining at the inlet and outlet edges of the forming cavity 33. For example, it can be machined into a common 45° chamfer or a rounded chamfer with a specific radius, which can be designed according to the powder particle size, punch size and product requirements. The chamfer can be formed on the upper and lower surfaces of the moving template 31 by CNC milling, EDM or die grinding. When the lower punching structure 5 carries the powder upward into the forming cavity 33, and when the upper punching structure 4 descends for pressing, the chamfers at the upper and lower ends can play a good guiding role, guiding the punch to smoothly and accurately enter the cavity.

[0095] In one possible implementation, a gravity balancing mechanism is also included, which is connected to the upper stamping structure 4 for shock reduction and vibration damping.

[0096] Combined with reference Figure 1 As shown, in this embodiment, gravity balancing mechanisms are also provided on both sides of the frame 1. These mechanisms are connected to the upper stamping structure 4, and their function is to actively balance the weight of the upper stamping structure 4 (mainly including the upper punch 41, the upper second punch 42, and their connecting components) and buffer the inertial force generated during its reversal. It consists of an upper top seat, a lower top seat, a spring guide post, a compression spring, and a height-adjustable screw. The upper top seat is bolted to the slider assembly 71 of the upper stamping structure 4 (or the upper crossbeam of the frame 1), and the lower top seat is fixed to the support column of the frame 1 by positioning pins and bolts. When the upper stamping structure 4 moves downwards (e.g., during the pressing process), the slider assembly 71 drives the upper top seat to move downwards synchronously, and the compression spring is compressed and deformed, converting the weight and inertial force of the punch into the elastic potential energy of the spring, reducing impact vibration. When resetting upwards, the spring releases its elastic potential energy, assisting the drive mechanism in lifting the slider and reducing the motor load.

[0097] In one possible implementation, the drive structure further includes a handling robot 34 electrically connected to the control unit. The handling robot 34 is drivenly connected to the moving template 31 assembly and is used to drive the moving template 31 assembly to move between the powder filling station and the adjacent processing station.

[0098] Specifically, the handling robot 34 can be a linear handling mechanism, such as a precision linear module driven by a servo motor or stepper motor (including ball screw or synchronous belt drive), or a pushing mechanism composed of a cylinder and a guide rail slider. Its mounting base is fixed to the frame 1 or an independent ground support. Its motion execution end (such as a slide table or push rod) is connected to the moving template 31 assembly (typically the template base 32) via a coupling mechanism (such as a gripper, positioning pin, or electromagnetic chuck) that allows for quick connection / separation from the moving template 31 assembly. This coupling mechanism ensures that the moving template 31 assembly is reliably gripped during handling and can be precisely released and positioned upon reaching the target station. After the chip inductor cold pressing molding device completes the powder filling and pressing operation on the moving template 31 currently located at the powder filling station, the control unit issues a command. The handling robot 34 moves its actuator to the powder filling station, docks with and locks the moving template 31 assembly, and then smoothly and quickly moves it to the next adjacent processing station along a preset straight trajectory. Afterward, the handling robot 34 can move another empty moving template 31 assembly from the previous station to the powder filling station, thereby realizing the cyclical flow between stations.

[0099] The present invention also provides a forming method for a chip inductor cold pressing forming apparatus, applicable to the chip inductor cold pressing forming apparatus described in any of the above possible embodiments, comprising the following steps:

[0100] The control unit controls the second drive mechanism to drive the next punch and the second punch to rise synchronously and extend into the powder filling cavity of the fixed template;

[0101] The second drive mechanism adjusts the position of the next punch relative to the second punch, forming a powder-containing space with adjustable depth between the inner cavity of the second punch and the next punch.

[0102] The powder feeding box moves to the powder filling area via the powder feeding motor module, and the powder in the powder box is transported into the powder holding space by the vibration of the vibrator and the gravity of the powder. The next stroke repeats the relative displacement along the next two strokes to shake the powder.

[0103] After the powder filling is completed, the powder feeding motor module drives the powder feeding box to return to the initial position;

[0104] The control unit controls the handling robot to move the moving template assembly to the powder filling area, and the forming cavity is aligned with the powder filling cavity;

[0105] The second drive mechanism drives the first punch and the second punch to rise asynchronously into the forming cavity, with the first punch protruding out of the second punch.

[0106] The first drive mechanism drives the upper punch and the upper second punch to descend synchronously into the forming cavity, and the second drive mechanism drives the lower punch to gradually descend and become flush with the lower second punch.

[0107] The first drive mechanism drives the upper punch to protrude from the upper second punch, forming an inductor blank;

[0108] The first drive mechanism drives the first and second upper strokes to descend synchronously, pressing the powder material together.

[0109] In this embodiment, firstly, the control unit commands the second drive mechanism to operate, driving the first and second punches to rise synchronously, so that their tips extend into the powder-filling holes of the fixed template and stop at a preset height. Next, the second drive mechanism adjusts the axial position of the first punch relative to the second punch. Since the solid rod of the first punch passes through the hollow cavity of the second punch, their relative movement creates a columnar cavity with adjustable depth and precise volume between the bottom of the second punch cavity and the top of the first punch—the powder-filling space. The actual depth of this space is set by the control unit according to the required powder quantity for the product. After setting the powder-filling space, the filling process begins. The control unit starts the powder feeding motor module, driving the powder feeding box to move horizontally to directly above the powder-filling area of ​​the fixed template, aligning its outlet with the powder-filling holes. Simultaneously, the vibrator installed on the powder feeding box is activated. Under the action of high-frequency micro-vibration and the powder's own gravity, the powder falls evenly and smoothly from the powder feeding box into the powder-filling space. To eliminate voids between powder particles and ensure tight and uniform filling, the control unit controls the second drive mechanism to perform several short-stroke, high-frequency axial reciprocating movements ("vibration") while maintaining a relatively constant overall position with the second and third strokes. This vibration effectively breaks up powder agglomeration and bridging, promoting a denser arrangement of the powder within the powder-containing space. After the preset filling amount is reached, the powder feeding motor module drives the powder feeding box back to its initial (receiving) position. Simultaneously, the cleaning air vent briefly sprays air to clean the box walls, ensuring no residue remains.

[0110] After the powder material is precisely filled at the fixed intermediate template, it needs to be transferred to the moving intermediate template for forming. The control unit instructs the transport robot to move, transporting the moving intermediate template assembly carrying the moving intermediate template to the powder filling station and precisely positioning it so that the forming holes on the moving intermediate template are strictly aligned vertically with the powder filling holes on the fixed intermediate template. Subsequently, the second drive mechanism drives the first and second lower punches carrying the powder material to rise synchronously, passing through the powder filling holes of the fixed intermediate template and entering the forming holes of the moving intermediate template. At the end of this rising process, the second drive mechanism is controlled to make the first lower punch have a slight forward displacement relative to the second lower punch, so that the top of the first lower punch "protrudes" from the second lower punch, so that the powder material presents a preliminary distribution pattern in the forming holes. Next is the pressing and forming stage. The first drive mechanism drives the first and second upper punches to descend synchronously. The lower end face of the second upper punch first contacts and seals the upper surface of the moving intermediate template, while the first upper punch extends into the inner cavity of the second upper punch and the forming hole below it. Simultaneously, the second drive mechanism begins to drive the next punch to slowly descend, gradually retracting its tip until it is "flush" with the tip of the second punch. This relative movement of the upper and lower punches redistributes and initially shapes the powder material within the forming cavity. Subsequently, the first drive mechanism further moves, causing the solid upper punch to protrude downwards relative to the hollow upper second punch. Its specifically shaped punch end face works in conjunction with the pre-adjusted powder material contour below to "form" the basic shape of the target product—the inductor blank—within the cavity. Finally, the first drive mechanism drives the upper and upper second punches to press down synchronously at a set pressure, while the lower punch of the second drive mechanism provides necessary support or reverse pressure, jointly completing the final "pressing" of the powder material to obtain a high-density, highly consistent inductor blank. After pressing, each punch resets, and the transport robot moves the moving template assembly carrying the formed blank to the next station (such as the hot pressing station), thus completing one work cycle.

[0111] In the accompanying drawings of this embodiment, the same or similar reference numerals correspond to the same or similar components. In the description of this application, it should be understood that if terms such as "upper," "lower," "left," and "right" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, they are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the accompanying drawings are only for illustrative purposes and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0112] The above are merely preferred embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A chip inductor cold pressing molding apparatus, characterized in that, include: frame; A fixed template is fixedly mounted on the frame. The fixed template has powder filling holes that run vertically through it. The top area of ​​the powder filling holes forms a powder filling area for receiving powder. A movable template assembly is movably mounted on the frame. The movable template assembly has through-holes at the top and bottom. The movable template assembly can move relative to the fixed template. When it moves to the powder filling area, the forming holes and the powder filling holes are aligned one by one. The upper stamping structure includes an upper first stamp and an upper second stamp, wherein the upper second stamp is a hollow structure and the upper first stamp is inserted into the inner cavity of the upper second stamp; The lower stamping structure is vertically opposite to the upper stamping structure and includes a lower stamp and a lower second stamp. The lower second stamp is a hollow structure. The lower stamp passes through the inner cavity of the lower second stamp, and an adjustable powder-containing space can be formed between the lower stamp and the lower second stamp. A powder feeding mechanism is connected to one side of the fixed template and is used to feed powder into the powder filling area of ​​the fixed template. The drive structure includes a first drive mechanism and a second drive mechanism. The first drive mechanism is connected to the upper first stroke and the upper second stroke drive mechanism and is used to drive the upper first stroke and the upper second stroke to perform synchronous or asynchronous lifting and lowering. The second drive mechanism is connected to the lower next stroke and the lower second stroke drive mechanism and is used to drive the lower next stroke and the lower second stroke to perform synchronous or asynchronous lifting and lowering. The control unit is electrically connected to the drive structure and the powder feeding mechanism.

2. The chip inductor cold pressing forming apparatus according to claim 1, characterized in that, The movable template assembly includes a movable template and a template base. The movable template is slidably mounted on the template base and has a first working position and a second working position. In the first working position, the forming holes of the moving template are aligned with the corresponding holes of the template base; In the second working position, the forming holes of the moving template are misaligned with the corresponding holes of the template base, and the template base covers the bottom of the forming holes.

3. The chip inductor cold pressing forming apparatus according to claim 1, characterized in that, The powder feeding mechanism includes: A powder feeding box, which is used to contain powder materials; A powder feeding motor module is mounted on the frame and is driven by the powder feeding box. A vibrator is attached to the outer wall of the powder feeding box to cause the powder in the powder feeding box to fall into the powder holding space.

4. The chip inductor cold pressing forming apparatus according to claim 3, characterized in that, The powder feeding box is equipped with a cleaning air blowing hole, which is connected to an external air source.

5. The chip inductor cold pressing forming apparatus according to claim 1, characterized in that, Both the first driving mechanism and the second driving mechanism include a slider assembly and a first driving part and a second driving part that can be controlled independently. The slider assembly includes an outer layer and an inner layer that can move relative to each other. Specifically, for the first driving mechanism, its outer layer is connected to the upper first punch, its inner layer is connected to the upper second punch, the first driving part drives the outer layer, and the second driving part drives the inner layer; For the second drive mechanism, its outer layer is connected to the next stroke, and its inner layer is connected to the next second stroke. The first drive unit drives the outer layer, and the second drive unit drives the inner layer.

6. The chip inductor cold pressing forming apparatus according to claim 1, characterized in that, The upper and lower ends of the forming holes of the moving template are provided with chamfered structures.

7. The chip inductor cold pressing forming apparatus according to claim 1, characterized in that, It also includes a gravity balancing mechanism, which is connected to the upper stamping structure and is used to reduce impact and vibration.

8. The chip inductor cold pressing forming apparatus according to claim 1, characterized in that, The drive structure also includes a handling robot that is electrically connected to the control unit. The handling robot is driven to connect to the moving template assembly and is used to drive the moving template assembly to move between the powder filling station and the adjacent processing station.

9. A molding method for a chip inductor cold pressing molding apparatus, applied to the chip inductor cold pressing molding apparatus as described in any one of claims 1 to 8, characterized in that, Includes the following steps: The control unit controls the second drive mechanism to drive the next punch and the second punch to rise synchronously and extend into the powder filling cavity of the fixed template; The second drive mechanism adjusts the position of the next punch relative to the second punch, forming a powder-containing space with adjustable depth between the inner cavity of the second punch and the next punch. The powder feeding box moves to the powder filling area via the powder feeding motor module, and the powder in the powder box is transported into the powder holding space by the vibration of the vibrator and the gravity of the powder. The next stroke repeats the relative displacement along the next two strokes to shake the powder. After the powder filling is completed, the powder feeding motor module drives the powder feeding box to return to the initial position; The control unit controls the handling robot to move the moving template assembly to the powder filling area, and the forming cavity is aligned with the powder filling cavity; The second drive mechanism drives the first punch and the second punch to rise asynchronously into the forming cavity, with the first punch protruding out of the second punch. The first drive mechanism drives the upper punch and the upper second punch to descend synchronously into the forming cavity, and the second drive mechanism drives the lower punch to gradually descend and become flush with the lower second punch. The first drive mechanism drives the upper punch to protrude from the upper second punch, forming an inductor blank; The first drive mechanism drives the first and second upper strokes to descend synchronously, pressing the powder material together.

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