Ferrite molding process, ferrite molding mold, and ferrite

Abstract

To provide a ferrite molding process, a ferrite molding die, and a ferrite, having a high yield.SOLUTION: A molding process includes the steps of: putting a powder material into a molding mold provided with a gap forming structure for forming a gap of ferrite; compressing the powder material to form a molded body; putting the molded body into a heating furnace, and sintering the molded body to form a sintered body; and performing molding on the sintered body to obtain the ferrite. The molding mold includes a main molding mold provided with a molding cavity and the gap forming structure for forming the gap of the ferrite, and has no need to perform gap molding after sintering, simplifies a process flow of the ferrite, reduces investment of a gap molding facility, prevents a situation in which the sintered body breaks in the gap molding step from occurring, strengthens a structure of the sintered body, and further reduces a risk that the ferrite breaks in an assembly stage, and thereby, improves a yield of the ferrite.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to the technical field of ferrite preparation, and particularly to a ferrite forming process, a ferrite forming mold, and a ferrite.

Background Art

[0002] With the development of wireless charging technology, wireless charging is rapidly spreading in intelligent electronic products. A wireless charging module usually employs a soft magnetic material to form a shield assembly, and the soft magnetic material is, by way of example, ferrite. Ferrite usually comprises a main body and a boss provided on the main body, and among them, a coil is wound around the boss and used to reinforce the magnetic flux concentration ability of the ferrite. A gap is provided in the main body to fix the end of the coil.

[0003] In the prior art, the manufacturing process of ferrite includes steps such as pressing, sintering, polishing, gap forming, barrel polishing, etc. Specifically, in the pressing process, powder of the material for forming ferrite is put into a mold, and high pressure is applied for pressing and forming. Commonly used forming methods include dry pressing forming and casting forming. In the sintering process, the formed parts are put into a high-temperature furnace for sintering treatment, and at high temperature, the powder particles are combined with each other to form a dense crystal structure. In the gap forming process, machining such as cutting is performed on the parts after sintering forming by mechanical equipment. In the barrel polishing process, the parts after gap forming processing are rotated slowly in a drum together with grinding media, and finishing treatment is performed by the relative movement between the parts and the abrasive. However, in the manufacturing process, the parts are broken during the gap forming process, and in the gap forming method, the parts become extremely brittle. After subsequent barrel polishing treatment, the overall yield of the ferrite preparation process is only about 60%. Moreover, some parts with potential microcracks enter the assembly stage. After coil assembly and pressure holding, an uneven yield loss within 5% is further caused, resulting in a low yield of the ferrite preparation process.

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a ferrite forming process, a ferrite forming mold, and ferrite in which the produced ferrite has a high yield.

Means for Solving the Problems

[0005] As conceived above, the technical solution adopted by the present invention is Step S1 of putting a powder material into a molding die provided with a gap forming structure for forming a gap of ferrite; Step S2 of pressing the powder material to form a molded body; Step S3 of putting the molded body into a heating furnace and sintering it to form a sintered body; And step S4 of performing a molding process on the sintered body to obtain ferrite, which is a ferrite forming process.

[0006] Preferably, the ferrite includes a main body structure and a boss structure integrally formed by one mold.

[0007] Preferably, the ferrite includes a main body structure and a boss structure separately formed by two molds.

[0008] Preferably, in step S1, the powder material is put into both the main body mold provided with the gap forming structure and the boss mold, In step S2, it is pressed by the main body mold to form a main body molded body, and pressed by the boss mold to form a boss molded body, In step S3, the main body molded body is put into a heating furnace and sintered to form a main body sintered body, and the boss molded body is put into a heating furnace and sintered to form a boss sintered body, The main body sintered body includes an integral first surplus body and a main body structure, the main body structure has a gap, the boss sintered body includes an integral second surplus body and a boss structure, Step S4 is Step S41 of removing the first surplus body of the main body sintered body to obtain the main body structure; Step S42 of removing the second surplus body of the boss sintered body to obtain the boss structure; Step S43 of connecting the boss structure and the main body structure to obtain ferrite, and the method includes the steps.

[0009] Preferably, in step S41, the first surplus body of the main body sintered body is polished and removed to obtain the main body structure, In step S42, the second surplus body of the boss sintered body is polished and removed to obtain the boss structure.

[0010] Preferably, step S43 Step S431 of applying an adhesive body to the main body structure; Step S432 of pressing the boss structure against the adhesive body to bond the boss structure and the main body structure with the adhesive body.

[0011] Preferably, the first surplus body is annular, the main body structures are all open annular, the inner annular surface of the first surplus body and the inner annular surface of the main body structure are flush, and the width of the first surplus body is larger than the width of the main body structure.

[0012] Preferably, before step S43, the ferrite forming process Performing barrel polishing treatment on the main body structure; Performing barrel polishing treatment on the boss structure.

[0013] Preferably, the sintered body includes an integral top surplus body, a main body structure, a boss structure, and a bottom surplus body. In step S4, the top surplus body and the bottom surplus body are polished and removed to obtain the ferrite.

[0014] The ferrite molding die is applied to the ferrite molding process as described above, and includes a main molding die provided with a molding cavity for molding a molded body and a gap forming structure for forming a gap of the ferrite.

[0015] Preferably, the sintered body includes an integral top surplus body, a main body structure, a boss structure, and a bottom surplus body. The main molding die includes a lower punch, a die core, and an upper punch. A first molding groove is provided on the end face of one end of the lower punch, a second molding groove is provided on the groove bottom of the first molding groove, and a core hole is provided on the groove bottom of the second molding groove. The die core is provided through the core hole, the first molding groove, and the second molding groove. The gap forming structure includes a first convex portion provided on the groove side wall of the first molding groove and a second convex portion provided on the groove bottom wall of the first molding groove. At the bottom end of the upper punch, a third convex portion capable of entering the first molding groove and facing the first convex portion is provided. The molding cavity includes a top molding cavity formed by the first convex portion, the second convex portion, the groove wall of the first molding groove, and the die core, and a bottom molding cavity formed by the groove wall of the second molding groove and the die core. The top molding cavity is used to mold the top surplus body and the main body structure, and the bottom molding cavity is used to mold the boss structure and the bottom surplus body.

[0016] Preferably, two fourth convex portions are provided at both ends of the top surface of the second convex portion, and the sum of the heights of the two fourth convex portions and the second convex portion is equal to the thickness of the main body structure.

[0017] Preferably, the main molding die includes a main body die and a boss die. The main body die includes a first lower punch tool, a first die core, and a first upper punch tool. A first concave groove is provided on the end face of one end of the first lower punch tool. A second concave groove is provided on the groove bottom of the first concave groove. A first through hole extending to the end face of the other end of the first lower punch tool is provided on the groove bottom of the second concave groove. The first die core is inserted into the first through hole, the first concave groove, and the second concave groove. The first die core and the groove wall of the first concave groove form a first molding cavity for molding the first surplus material body. The first die core and the groove wall of the second concave groove form a second molding cavity for molding the main body structure. The gap molding structure is a convex block provided in the second molding cavity. The first upper punch tool applies pressure to the powder material in the first molding cavity and the second molding cavity and presses it, and is used to mold the main body molded body. The boss die includes a second lower punch tool, a second die core, and a second upper punch tool. A third concave groove is provided on the end face of one end of the second lower punch tool. A fourth concave groove is provided on the groove bottom of the third concave groove. A second through hole extending to the end face of the other end of the second lower punch tool is provided on the groove bottom of the fourth concave groove. The second die core is inserted into the second through hole, the third concave groove, and the fourth concave groove. The second die core and the groove wall of the third concave groove form a third molding cavity for molding the second surplus material body. The second die core and the groove wall of the fourth concave groove form a fourth molding cavity for molding the boss structure. The second upper punch tool applies pressure to the powder material in the third molding cavity and the fourth molding cavity and presses it, and is used to mold the boss molded body.

[0018] The ferrite is manufactured by the ferrite forming process as described above.

Advantages of the Invention

[0019] The beneficial effects of the present invention are as follows. The ferrite forming process, ferrite forming mold, and ferrite according to the present invention can form a sintered body by first putting a powder material into the forming mold, pressing the powder material to form a formed body, and then putting the formed body into a heating furnace for sintering. The ferrite can be obtained by directly performing a forming process on the sintered body. Since the forming mold in this embodiment is provided with a gap forming structure, the gap can be directly obtained during the process of pressing the powder material, eliminating the need to perform the gap forming step after sintering. This simplifies the process flow of ferrite, reduces the investment in gap forming equipment, and further prevents the situation where the sintered body breaks during the gap forming step, strengthens the structure of the sintered body, and reduces the risk of the ferrite breaking during the assembly stage, thereby improving the yield of ferrite.

Brief Description of the Drawings

[0020]

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Mode for Carrying Out the Invention

[0021] In order to more clearly clarify the technical problems to be solved, the technical solutions adopted, and the technical effects to be achieved by the present invention, the technical solutions of the present invention will be further described below by specific embodiments with reference to the drawings. It should be understood that the specific embodiments described herein are only for interpreting the present invention and do not limit the present invention. For the sake of easy explanation, only the parts related to the present invention are shown in the drawings, and the whole is not shown.

[0022] It should be noted that similar reference numerals and letters represent similar items in the following drawings. Therefore, once an item is defined in one drawing, further definition and interpretation thereof in subsequent drawings are not required.

[0023] In the description of the present invention, unless otherwise clearly defined and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense. For example, it may be a fixed connection, a removable connection, or integrated, a mechanical connection, an electrical connection, directly connected, or indirectly connected through an intermediate medium, or the internal communication of two elements or the interaction relationship of two elements. A person skilled in the art can understand the specific meaning of the above terms in the present invention according to specific situations.

[0024] In the present invention, unless otherwise clearly defined and limited, the fact that the first feature is "above" or "below" the second feature may include direct contact between the first feature and the second feature, or may include the case where the first feature and the second feature do not directly contact each other and contact through other features therebetween. Further, the fact that the first feature is "above", "upper" and "upper surface" of the second feature includes the case where the first feature is directly above and obliquely above the second feature, or simply indicates that the horizontal height of the first feature is higher than that of the second feature. The fact that the first feature is "below", "lower" and "lower surface" of the second feature includes the case where the first feature is directly below and obliquely below the second feature, or simply indicates that the horizontal height of the first feature is lower than that of the second feature. In the description of this embodiment, unless otherwise specified, "a plurality" specifically means two or more.

[0025] In the description of this embodiment, the orientation and positional relationships such as the terms "above", "below", "right", etc. are based on the orientation and positional relationships shown in the drawings, and are merely for facilitating the description and simplifying the operation, and do not indicate or imply that such a device or element must have a specific orientation and be configured and operated in a specific orientation. Therefore, it cannot be understood as limiting the present invention. Further, the terms "first" and "second" are merely for distinction in the description and do not include any special meaning.

[0026] Example 1 This embodiment provides a ferrite forming process that is used for forming ferrite and the obtained ferrite has a high yield.

[0027] As shown in FIG. 12, the ferrite 100 in this embodiment includes a main body structure 110 and a boss structure 120. Among them, both the main body structure 110 and the boss structure 120 are annular, and the boss structure 120 is provided on the surface of the main body structure 110 and is coaxial with the main body structure 110. The boss structure 120 is used for winding a coil, and a gap is provided in the main body structure 110 so that the end of the coil can be provided. In some embodiments, the gap is obtained by opening in the main body structure 110, that is, the main body structure 110 is an annular shape having an opening.

[0028] As shown in FIG. 1, the ferrite forming process includes the following steps.

[0029] In S1, powder material is put into a mold provided with a gap forming structure for forming a gap of the ferrite 100. In this embodiment, there is no need to create a gap in subsequent secondary processing, and the mold is directly provided with a gap forming structure for forming a gap. The mold in this embodiment may have the structure shown in FIGS. 4 to 8. In some preferred embodiments, the gap forming structure may be a protruding structure or other structures as long as the formation of the gap is possible, and this embodiment is not limited thereto. The method of putting the powder material into the mold can refer to the prior art and will not be described in detail here.

[0030] In S2, the powder material is pressed to form a formed body. After putting the powder material into the mold, it is pressed to form the powder material. FIGS. 2 and 3 are schematic views of the formed body or sintered body 200 according to this embodiment. It should be noted that the shape and size of the formed body are different from both the shape and size of the ferrite 100 to be obtained, that is, there is excess material on the formed body. The method of pressing the powder material can refer to the prior art and will not be described in detail here.

[0031] In S3, the formed body is put into a heating furnace and sintered to form a sintered body 200. The method of heating the formed body in step S3 in a heating furnace can refer to the prior art and will not be described in detail here.

[0032] It should be noted that the shape and size of the sintered body 200 and the formed body are the same.

[0033] In S4, a forming process is performed on the sintered body 200 to obtain the ferrite 100.

[0034] In this embodiment, since the molded body is an object including flash, when attempting to obtain the ferrite 100, it is necessary to perform a molding process on the molded body. Exemplarily, the molding process may include a polishing process or other flash removal methods, and this embodiment is not limited thereto.

[0035] The ferrite molding process according to this embodiment can form the sintered body 200 by first putting the powder material into the molding die, pressing the powder material to form a molded body, and then putting the molded body into a heating furnace for sintering. By directly performing a molding process on the sintered body 200, the ferrite 100 can be obtained. Since the molding die in this embodiment is provided with a clearance molding structure, the clearance can be directly obtained during the process of pressing the powder material, eliminating the need to perform the clearance molding step after sintering, simplifying the process flow of the ferrite 100, reducing the investment in clearance molding equipment, and further preventing the situation where the sintered body 200 breaks during the clearance molding step, strengthening the structure of the sintered body 200, and further reducing the risk of the ferrite 100 breaking during the assembly stage, thereby improving the yield of the ferrite 100.

[0036] In some preferred embodiments, the main body structure 110 and the boss structure 120 are integrally formed in one die.

[0037] Preferably, as shown in FIGS. 2 and 3, the sintered body 200 includes an integral top flash body 210, a main body structure 110, a boss structure 120, and a bottom flash body. In step S4, the top flash body 210 and the bottom flash body are polished and removed to obtain the ferrite 100 as shown in FIG. 12.

[0038] This embodiment further provides a ferrite molding die applied to the above ferrite molding process. Specifically, the ferrite molding die includes a molding cavity for molding the molded body and a main molding die provided with a clearance molding structure for forming the clearance of the ferrite 100.

[0039] More preferably, as shown in FIGS. 4 to 8, the main molding die includes a lower punch 510, a die core 520, and an upper punch 530. Among them, a first forming groove 511 is provided on the end surface of one end of the lower punch 510, a second forming groove 512 is provided on the groove bottom of the first forming groove 511, and a core hole 513 is provided on the groove bottom of the second forming groove 512. The die core 520 is provided through the core hole 513, the first forming groove 511, and the second forming groove 512. Specifically, the bottom end of the die core 520 is located outside the core hole 513 and inside the first forming groove 511.

[0040] As shown in FIGS. 5 and 6, the gap forming structure in this embodiment includes a first convex portion 514 provided on the groove side wall of the first forming groove 511 and a second convex portion 515 provided on the groove bottom wall of the first forming groove 511. That is, the first convex portion 514 and the second convex portion 515 can cooperate to form a gap. In this embodiment, the first convex portion 514 and the second convex portion 515 are connected. In some preferred embodiments, the length of the second convex portion 515 is the same as the length of the first convex portion 514. The second convex portion 515 is used to form an interval 220 (as shown in FIG. 2) between the top surplus body 210 and the boss structure 120, and the interval 220 is a part of the gap. By setting the interval 220, the top surplus body 210 is not directly connected to the boss structure 120, and the top surplus body 210 can be smoothly removed without affecting the boss structure 120.

[0041] Preferably, as shown in FIG. 8, a third convex portion 516 that can enter the first forming groove 511 and face the first convex portion 514 is provided at the bottom end (one end facing the lower punch 510) of the upper punch 530. The forming cavity includes a top forming cavity surrounded by the first convex portion 514, the second convex portion 515, the groove wall of the first forming groove 511, and the mold core 520, and a bottom forming cavity surrounded by the groove wall of the second forming groove 512 and the mold core 520. Among them, the top forming cavity is used to form the top surplus body 210 and the main body structure 110, and the bottom forming cavity is used to form the boss structure 120 and the bottom surplus body. The top surplus body 210 is annular, and the thickness of the portion facing the gap of the top surplus body 210 is smaller than the thickness of other positions. Specifically, the first convex portion 514 and the third convex portion 516 cooperate to form a portion facing the gap of the top surplus body 210, and by thinning this portion, it is easy to remove the top surplus body 210, while facilitating the third convex portion 516 to directly contact and press the boss structure 120 to ensure the molding quality of the boss structure 120.

[0042] More preferably, as shown in FIG. 6, two fourth convex portions 517 are respectively provided at both ends of the top surface of the second convex portion 515, and the first convex portion 514 is used to form the material hole 230 shown in FIG. 2. The sum of the heights of the fourth convex portion 517 and the second convex portion 515 is equal to the thickness of the main body structure 110. Thus, during polishing, if the portion of the top surplus body 210 located above the material hole 230 is polished and removed, the main body structure 110 can be obtained. By installing the material hole 230, the thickness of the main body structure 110 can meet the requirements.

[0043] In some preferred embodiments, the top surface of the top surplus body 210 and the top surface of the upper punch 530 are flush, or the top surface of the top surplus body 210 is lower than the top surface of the upper punch 530, and the upper punch 530 can enter the first forming groove 511 so as to press the powder material better.

[0044] The ferrite forming process according to this embodiment integrally forms the main body structure 110 and the boss structure 120. As shown in FIGS. 2 and 3, at the same time, a top surplus body 210 located on one side of the boss structure 120 far from the main body structure 110 and a bottom surplus body located on one side of the boss structure 120 far from the main body structure 110 are also formed. Then, by polishing and removing the top surplus body 210 and the bottom surplus body, a ferrite 100 having a gap as shown in FIG. 11 is obtained.

[0045] Preferably, in this embodiment, after grinding and removing the top surplus body 210 and the bottom surplus body, a barrel polishing process can be performed on the main body structure 110 and the boss structure 120. Since the main body structure 110 and the boss structure 120 are not machined by cutting or drilling with a machine, they both have high structural strength. Therefore, they are not easily broken during the barrel polishing process and have a high yield.

[0046] Example 2 The ferrite forming process according to this embodiment is distinguished from Example 1 in that the main body structure 110 and the boss structure 120 are separately formed by two molds, and the main forming mold in this embodiment is also different from the main forming mold in Example 1.

[0047] The ferrite forming process includes Step S1 of putting a powder material into a forming mold provided with a gap forming structure for forming a gap of the ferrite 100, Step S2 of pressing the powder material to form a formed body, Step S3 of putting the formed body into a heating furnace for sintering to form a sintered body 200, and Step S4 of performing a forming process on the sintered body 200 to obtain the ferrite 100.

[0048] In Step S1, the powder material is put into both the main body mold 600 and the boss mold 700 provided with the gap forming structure. In Step S2, the main body formed body is formed by pressing with the main body mold 600, and the boss formed body is formed by pressing with the boss mold 700.

[0049] In step S3, the main body sintered compact is formed by putting the main body formed body into a heating furnace and sintering it, and the boss sintered compact is formed by putting the boss formed body into a heating furnace and sintering it. Among them, the structure of the boss sintered compact is as shown in FIG. 9, and the structure of the main body sintered compact is as shown in FIG. 10.

[0050] The main body sintered compact includes an integral first surplus body 300 and a main body structure 110, and the main body structure 110 has a gap. The boss sintered compact includes an integral second surplus body 400 and a boss structure 120. Step S4 includes the following.

[0051] In S41, the first surplus body 300 of the main body sintered compact is removed to obtain the main body structure 110. The main body structure 110 obtained after the first surplus body 300 of the main body sintered compact is removed is as shown in FIG. 11. As can be seen from FIG. 11, the main body structure 110 already has a gap.

[0052] In S42, the second surplus body 400 of the boss sintered compact is removed to obtain the boss structure 120. The boss structure 120 obtained after the second surplus body 400 of the boss sintered compact is removed is as shown in FIG. 11. As can be seen from FIG. 11, the boss structure 120 has an annular shape.

[0053] In S43, the boss structure 120 and the main body structure 110 are connected to obtain the ferrite 100.

[0054] Preferably, in step S41, the first surplus body 300 of the main body sintered compact is polished and removed to obtain the main body structure 110. In step S42, the second surplus body 400 of the boss sintered compact is polished and removed to obtain the boss structure 120.

[0055] More preferably, S43 includes the following steps.

[0056] In S431, an adhesive body is applied to the main body structure 110. In step S431, an adhesive body is applied to a region close to the inner annular surface of the main body structure 110.

[0057] In S432, the boss structure 120 is pressed against the adhesive body to bond the boss structure 120 and the main body structure 110 with the adhesive body.

[0058] In this embodiment, by bonding the boss structure 120 and the main body structure 110 with the adhesive body, the integrity of the ferrite 100 is improved.

[0059] In some preferred embodiments, as shown in FIG. 10, the first surplus body 300 is annular, the main body structures 110 are all open annular, and the inner annular surface of the first surplus body 300 and the inner annular surface of the main body structure 110 are flush. The width of the first surplus body 300 is larger than the width of the main body structure 110, whereby it is easy to form the main body structure 110 with a complete structure and a neat surface. Similarly, as shown in FIG. 9, the second surplus body 400 and the boss structure 120 are both annular, and the width of the second surplus body 400 is larger than the width of the boss structure 120, whereby it is easy to form the boss structure 120 with a complete structure and a neat surface.

[0060] Preferably, before connecting the boss structure 120 and the main body structure 110, that is, before step S43, the ferrite forming process further includes performing a barrel polishing process on the main body structure 110, and performing a barrel polishing process on the boss structure 120.

[0061] In this embodiment, the main body structure 110 and the boss structure 120 may be subjected to barrel polishing treatment in one drum, or may be subjected to barrel polishing treatment separately. Since the barrel polishing treatment is performed before connecting the boss structure 120 and the main body structure 110, it does not affect the connection effect between the boss structure 120 and the main body structure 110, and improves the certainty of the connection between the main body structure 110 and the boss structure 120.

[0062] For the ferrite forming process according to this embodiment, a ferrite forming mold is provided. The ferrite forming mold includes a main forming mold provided with a forming cavity for forming a formed body and a gap forming structure for forming a gap of the ferrite 100.

[0063] Furthermore, as shown in FIGS. 13 to 15, the main forming mold includes a body mold 600 and a boss mold 700.

[0064] Among them, as shown in FIGS. 13 and 14, the body mold 600 includes a first lower punch tool 610, a first mold core 620, and a first upper punch tool 630. A first concave groove 611 is provided on an end face of one end of the first lower punch tool 610. Specifically, there is a first concave groove 611 on the end face of the first lower punch tool 610 facing the first upper punch tool 630. A second concave groove 612 is provided at the groove bottom of the first concave groove 611. A first through hole 613 extending to the end face of the other end of the first lower punch tool 610 is provided at the groove bottom of the second concave groove 612. The first mold core 620 is inserted into the first through hole 613, the first concave groove 611, and the second concave groove 612. The groove walls of the first mold core 620 and the first concave groove 611 form a first forming cavity for forming the first surplus body 300. The groove walls of the first mold core 620 and the second concave groove 612 form a second forming cavity for forming the body structure 110. The gap forming structure is a convex block 614 provided in the second forming cavity. Specifically, the convex block 614 is provided on the groove bottom wall of the second concave groove 612. The first upper punch tool 630 is used to apply pressure to the powder material in the first forming cavity and the second forming cavity and press it to form a body formed body.

[0065] As shown in FIG. 15, the boss mold 700 includes a second lower punch 710, a second mold core 720, and a second upper punch 730. Among them, a third concave groove 711 is provided on the end face of one end of the second lower punch 710. Specifically, there is a third concave groove 711 on the end face of the second lower punch 710 facing the second upper punch 730. A fourth concave groove 712 is provided at the groove bottom of the third concave groove 711, and a second through hole extending to the end face of the other end of the second lower punch 710 is provided at the groove bottom of the fourth concave groove 712. The second mold core 720 is inserted into the second through hole, the third concave groove 711, and the fourth concave groove 712. Moreover, the groove walls of the second mold core 720 and the third concave groove 711 form a third molding cavity for forming the second surplus body 400, and the groove walls of the second mold core 720 and the fourth concave groove 712 form a fourth molding cavity for forming the boss structure 120. The second upper punch 730 is used to apply pressure to the powder material in the third molding cavity and the fourth molding cavity and press it to form a boss molded body.

[0066] The ferrite forming process and the ferrite forming mold according to this embodiment first press with the main body mold 600 to form a main body molded body, press with the boss mold 700 to form a boss molded body, and then sinter the main body molded body and the boss molded body respectively to obtain a main body sintered body and a boss sintered body. After that, the main body sintered body and the boss sintered body are polished to grind and remove both the first surplus body 300 and the second surplus body 400, obtaining the main body structure 110 and the boss structure 120, and directly assembling the main body structure 110 and the boss structure 120. Thereby, it avoids the defect of a large amount of breakage in the gap forming step, improves the yield of the ferrite 100, is applicable to the manufacture of ferrites 100 with different shapes, and reduces the investment in gap forming equipment.

[0067] Example 3 This embodiment provides a ferrite 100 manufactured by the ferrite forming process and the ferrite forming mold in Embodiment 1 and Embodiment 2.

[0068] Preferably, the ferrite 100 in this embodiment includes a main body structure 110 and a boss structure 120, and the main body structure 110 has a gap. In some embodiments, the main body structure 110 and the boss structure 120 are an integrally formed structure. In this case, the ferrite 100 is manufactured by the ferrite forming process according to Embodiment 1. In some other embodiments, the main body structure 110 and the boss structure 120 are connected by a connection method such as adhesion. In this case, the ferrite 100 is manufactured by the ferrite forming process according to Embodiment 2.

[0069] It should be noted that the above are only preferred embodiments of the present invention and the technical principles used. Those skilled in the art should understand that the present invention is not limited to the specific embodiments described herein, and as those skilled in the art, various obvious changes, readjustments and substitutions can be made without departing from the protection scope of the present invention. Therefore, although the present invention has been described in detail by the above embodiments, the present invention is not limited to the above embodiments, and more other equivalent embodiments may be included as long as they do not deviate from the concept of the present invention. The protection scope of the present invention is determined by the appended claims.

Explanation of Reference Numerals

[0070] 100... Ferrite, 110... Main body structure, 120... Boss structure, 200... Sintered body, 210... Top surplus body, 220... Interval, 230... Material hole, 300... First surplus body, 400... Second surplus body, 510... Lower punch, 511... First forming groove, 512... Second forming groove, 513... Core hole, 514... First convex part, 515... Second convex part, 516... Third convex part, 517... Fourth convex part, 520... Mold core, 530... Upper punch, 600... Main body mold, 610... First lower punch tool, 611... First concave groove, 612... Second concave groove, 613... First through hole, 614... Convex block, 620... First mold core, 630... First upper punch tool, 700...boss mold, 710...second lower punch tool, 711...third concave groove, 712...fourth concave groove, 720...second mold core, 730...second upper punch tool.

Claims

1. Step S1 of putting a powder material into a molding die provided with a gap forming structure for forming a gap of a ferrite (100); Step S2 of pressing the powder material to form a molded body; Step S3 of putting the molded body into a heating furnace and sintering it to form a sintered body (200); Step S4 of performing a molding process on the sintered body (200) to obtain a ferrite (100), characterizing a ferrite molding process.

2. The ferrite (100) includes a main body structure (110) and a boss structure (120) integrally formed by one die, characterizing the ferrite molding process according to Claim 1.

3. The ferrite (100) includes a main body structure (110) and a boss structure (120) separately formed by two dies, characterizing the ferrite molding process according to Claim 1.

4. In step S1, put the powder material into both the main body die (600) provided with the gap forming structure and the boss die (700), In step S2, press with the main body die (600) to form a main body molded body, and press with the boss die (700) to form a boss molded body, In step S3, put the main body molded body into a heating furnace and sinter it to form a main body sintered body, and put the boss molded body into a heating furnace and sinter it to form a boss sintered body, The main body sintered body includes an integral first surplus body (300) and a main body structure (110), the main body structure (110) has a gap, the boss sintered body includes an integral second surplus body (400) and a boss structure (120), Step S4 includes Step S41 of removing the first surplus body (300) of the main body sintered body to obtain the main body structure (110); Step S42 of removing the second surplus body (400) of the boss sintered body to obtain the boss structure (120); Step S43 of connecting the boss structure (120) and the main body structure (110) to obtain a ferrite (100), characterizing the ferrite molding process according to Claim 3.

5. In step S41, polish and remove the first surplus body (300) of the main body sintered body to obtain the main body structure (110), In step S42, polish and remove the second surplus body (400) of the boss sintered body to obtain the boss structure (120), characterizing the ferrite molding process according to Claim 4.

6. Step S43 is step S431 of applying an adhesive body to the main body structure (110), and step S432 of pressing the boss structure (120) against the adhesive body to bond the boss structure (120) and the main body structure (110) with the adhesive body, The ferrite forming process according to claim 4, characterized in that.

7. The first surplus body (300) has an annular shape, the main body structures (110) all have an open annular shape, and the inner annular surface of the first surplus body (300) and the inner annular surface of the main body structure (110) are flush, and the width of the first surplus body (300) is larger than the width of the main body structure (110). The ferrite forming process according to claim 4, characterized in that.

8. Before step S43, performing barrel polishing treatment on the main body structure (110), and performing barrel polishing treatment on the boss structure (120), further including The ferrite forming process according to claim 4, characterized in that.

9. The sintered body (200) includes an integral top surplus body (210), a main body structure (110), a boss structure (120), and a bottom surplus body. In step S4, the top surplus body (210) and the bottom surplus body are polished and removed to obtain the ferrite (100). The ferrite forming process according to claim 1, characterized in that.

10. A ferrite forming die applied to the ferrite forming process according to any one of claims 1 to 9, comprising a main forming die provided with a forming cavity for forming a formed body and a gap forming structure for forming a gap of the ferrite (100). The ferrite forming die, characterized in that.

11. The sintered body (200) includes an integral top surplus body (210), a main body structure (110), a boss structure (120), and a bottom surplus body. The main forming die includes a lower punch (510), a die core (520), and an upper punch (530). A first forming groove (511) is provided on an end surface of one end of the lower punch (510), a second forming groove (512) is provided at the groove bottom of the first forming groove (511), and a core hole (513) is provided at the groove bottom of the second forming groove (512). The die core (520) is provided through the core hole (513), the first forming groove (511), and the second forming groove (512). The gap forming structure includes a first convex portion (514) provided on the groove side wall of the first forming groove (511) and a second convex portion (515) provided on the groove bottom wall of the first forming groove (511). A third convex portion (516) that can enter the first forming groove (511) and is provided opposite to the first convex portion (514) is provided at the bottom end of the upper punch (530). The forming cavity includes a top forming cavity formed by the first convex portion (514), the second convex portion (515), the groove wall of the first forming groove (511), and the mold core (520), and a bottom forming cavity formed by the groove wall of the second forming groove (512) and the mold core (520). The top forming cavity is used to form the top surplus material body (210) and the main body structure (110), and the bottom forming cavity is used to form the boss structure (120) and the bottom surplus material body. The ferrite forming mold according to claim 10, characterized in that.

12. At both ends of the top surface of the second convex portion (515), two fourth convex portions (517) are provided, the sum of whose heights with the second convex portion (515) is equal to the thickness of the main body structure (110). The ferrite forming mold according to claim 11, characterized in that.

13. The main forming mold includes a main body mold (600) and a boss mold (700). The main body die (600) includes a first lower punch tool (610), a first die core (620), and a first upper punch tool (630). A first concave groove (611) is provided on the end face of one end of the first lower punch tool (610). A second concave groove (612) is provided on the groove bottom of the first concave groove (611). A first through hole (613) extending to the end face of the other end of the first lower punch tool (610) is provided on the groove bottom of the second concave groove (612). The first die core (620) is inserted into the first through hole (613), the first concave groove (611), and the second concave groove (612). The groove walls of the first die core (620) and the first concave groove (611) form a first molding cavity for molding the first surplus material body (300). The groove walls of the first die core (620) and the second concave groove (612) form a second molding cavity for molding the main body structure (110). The gap forming structure is a convex block (614) provided in the second molding cavity. The first upper punch tool (630) applies pressure to the powder material in the first molding cavity and the second molding cavity and presses it to be used for molding a main body molded body. The boss die (700) includes a second lower punch tool (710), a second die core (720), and a second upper punch tool (730). A third concave groove (711) is provided on the end face of one end of the second lower punch tool (710). A fourth concave groove (712) is provided on the groove bottom of the third concave groove (711). A second through hole extending to the end face of the other end of the second lower punch tool (710) is provided on the groove bottom of the fourth concave groove (712). The second die core (720) is inserted into the second through hole, the third concave groove (711), and the fourth concave groove (712). The groove walls of the second die core (720) and the third concave groove (711) form a third molding cavity for molding the second surplus material body (400). The groove walls of the second die core (720) and the fourth concave groove (712) form a fourth molding cavity for molding the boss structure (120). The second upper punch tool (730) applies pressure to the powder material in the third molding cavity and the fourth molding cavity and presses it to be used for molding a boss molded body. The ferrite molding die according to claim 11, characterized in that.

14. A ferrite manufactured by the ferrite forming process according to any one of claims 1 to 9, characterized by the above.

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