Ferrite molding process, ferrite molding die 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 ferrite.

Background Art

[0002] With the development of wireless charging technology, wireless charging is rapidly popularizing in intelligent electronic products. A wireless charging module usually adopts a soft magnetic material to form a shield assembly, and the soft magnetic material is, for example, ferrite. Ferrite usually includes a main body and a boss provided on the main body. Among them, a coil is wound around the boss and used to reinforce the magnetic collection 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, and barrel polishing. Specifically, in the pressing process, the powder of the material for forming ferrite is put into a mold, and high pressure is applied to press and form it. The 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 are rotated at a low speed in a drum together with grinding media, and finishing treatment is performed by the relative movement between the parts and the grinding material. 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%. And some parts with potential microcracks enter the assembly stage. After passing through the 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

[0004] The present invention aims to provide a ferrite molding process, a ferrite molding die, and ferrite that produce ferrite with a high yield. [Means for solving the problem]

[0005] As outlined above, the technical solution implemented by this invention is Step S1 involves placing powder material into a molding die equipped with a gap-forming structure for forming gaps in ferrite, Step S2 involves pressing the powder material to form a molded body, Step S3 involves placing the molded body in a heating furnace and sintering it to form a sintered body, The ferrite molding process includes step S4, which involves performing a molding process on the sintered body to obtain ferrite.

[0006] Preferably, the ferrite comprises a body structure and a boss structure integrally formed in a single mold.

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

[0008] Preferably, in step S1, powder material is placed in both the main mold and the boss mold, which are equipped with the gap molding structure. In step S2, the main body is formed by pressing with the main body mold, and the boss is formed by pressing with the boss mold. In step S3, the main body molded body is placed in a heating furnace and sintered to form a sintered main body, and the boss molded body is placed in a heating furnace and sintered to form a sintered boss. The main body sintered body comprises an integral first excess body and main body structure, the main body structure having a gap, and the boss sintered body comprises an integral second excess body and boss structure. Step S4 is Step S41 involves removing the first excess material from the sintered body to obtain the main body structure, Step S42 involves removing the second excess material from the boss sintered body to obtain the boss structure, The process includes step S43, which involves connecting the boss structure and the main body structure to obtain ferrite.

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

[0010] Preferably, step S43 is Step S431 involves applying an adhesive to the main body structure, The process includes step S432, which involves pressing the boss structure against the adhesive body to bond the boss structure and the main body structure together with the adhesive body.

[0011] Preferably, the first extra body is annular, the main body structure is an open annular, the inner ring surface of the first extra body and the inner ring surface of the main body structure are flush, and the width of the first extra body is greater than the width of the main body structure.

[0012] Preferably, before step S43, the ferrite molding process is performed The main body structure is subjected to barrel polishing, The process further includes performing barrel polishing on the boss structure.

[0013] Preferably, the sintered body comprises an integral top excess material, a main body structure, a boss structure, and a bottom excess material, and in step S4, the top excess material and the bottom excess material are polished and removed to obtain the ferrite.

[0014] The ferrite molding die is applied to the ferrite molding process described above and comprises a main molding die equipped with a molding cavity for forming a molded body and a gap molding structure for forming gaps in the ferrite.

[0015] Preferably, the sintered body comprises an integral top excess body, a main body structure, a boss structure, and a bottom excess body, the main molding die comprises a lower punch, a mold 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 at the bottom of the first molding groove, a core hole is provided at the bottom of the second molding groove, and the mold core is provided passing through the core hole, the first molding groove, and the second molding groove. The gap forming structure comprises a first protrusion provided on the groove side wall of the first forming groove and a second protrusion provided on the groove bottom wall of the first forming groove, and the bottom end of the upper punch is provided with a third protrusion that can enter the first forming groove and be provided opposite to the first protrusion, and the forming cavity comprises a top forming cavity formed by the first protrusion, the second protrusion, the groove wall of the first forming groove and the mold core and a bottom forming cavity formed by the groove wall of the second forming groove and the mold core, the top forming cavity is used to form the top excess material and the main body structure and the bottom forming cavity is used to form the boss structure and the bottom excess material.

[0016] Preferably, two fourth protrusions are provided at both ends of the top surface of the second protrusion, the sum of their heights with the second protrusion being equal to the thickness of the main body structure.

[0017] Preferably, the main molding die comprises a main body die and a boss die. The main body mold comprises a first lower punch, a first mold core, and a first upper punch, wherein a first recess is provided on the end face of one end of the first lower punch, a second recess is provided at the bottom of the first recess, and a first through hole is provided at the bottom of the second recess, extending to the end face of the other end of the first lower punch, the first mold core is inserted into the first through hole, the first recess and the second recess, and the groove walls of the first mold core and the first recess form a first molding cavity for forming the first excess body, the groove walls of the first mold core and the second recess form a second molding cavity for forming the main body structure, the gap molding structure is a convex block provided in the second molding cavity, and the first upper punch is used to apply pressure to the powder material in the first molding cavity and the second molding cavity to press and form the main body molded body. The boss mold comprises a second lower punch, a second mold core, and a second upper punch, wherein a third groove is provided on the end face of one end of the second lower punch, a fourth groove is provided at the bottom of the third groove, and a second through hole is provided at the bottom of the fourth groove, extending to the end face of the other end of the second lower punch, the second mold core is inserted into the second through hole, the third groove, and the fourth groove, the groove walls of the second mold core and the third groove form a third molding cavity for forming the second excess body, the groove walls of the second mold core and the fourth groove form a fourth molding cavity for forming the boss structure, and the second upper punch is used to apply pressure to the powder material in the third molding cavity and the fourth molding cavity and press it to form the boss molded body.

[0018] Ferrite is manufactured by the ferrite molding process described above. [Effects of the Invention]

[0019] The beneficial effects of the present invention are as follows: The ferrite forming process, ferrite forming die, and ferrite according to the present invention can form a sintered body by first putting a powder material into a forming die, pressing the powder material to form a formed body, and 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 die in this embodiment is provided with a gap forming structure, the gap can be directly obtained in the process of pressing the powder material, and there is no need to perform the step of gap forming after sintering, which simplifies the process flow of ferrite, reduces the investment in gap forming equipment, and further prevents the situation where the sintered body breaks in the step of gap forming, strengthens the structure of the sintered body, and further reduces the risk that the ferrite breaks in the assembly stage. Thereby, the yield of ferrite can be improved.

Brief Description of the Drawings

[0020] [Figure 1] It is a flowchart of the ferrite forming process according to an embodiment of the present invention. [Figure 2] It is one of the structural schematic diagrams of the formed body according to an embodiment of the present invention. [Figure 3] It is two of the structural schematic diagrams of the formed body according to an embodiment of the present invention. [Figure 4] It is one of the structural schematic diagrams of the main forming die according to an embodiment of the present invention. [Figure 5] It is two of the structural schematic diagrams of the main forming die according to an embodiment of the present invention. [Figure 6] It is an enlarged view at location A shown in FIG. 5 of the present invention. [Figure 7] It is a reference view of the use state of the main forming die according to an embodiment of the present invention. [Figure 8] It is a structural schematic diagram of the upper punch according to an embodiment of the present invention. [Figure 9] It is a structural schematic diagram of the boss structure and the second surplus body according to an embodiment of the present invention. [Figure 10] It is a structural schematic diagram of the main body structure and the first surplus body according to an embodiment of the present invention. [Figure 11]This is an exploded schematic diagram of the main body structure and boss structure according to an embodiment of the present invention. [Figure 12] This is a schematic diagram of the structure of ferrite according to an embodiment of the present invention. [Figure 13] This is an exploded schematic diagram of the main mold according to an embodiment of the present invention. [Figure 14] This is a schematic diagram of the structure of the first lower punching tool according to an embodiment of the present invention. [Figure 15] This is an exploded schematic diagram of a boss mold according to an embodiment of the present invention. [Modes for carrying out the invention]

[0021] To further clarify the technical problems to be solved, the technical solutions adopted, and the technical effects to be achieved by this invention, the technical solutions of this invention will be further described below with reference to the drawings, using specific embodiments. It should be understood that the specific embodiments described herein are merely for interpretation purposes and do not limit the invention. Furthermore, for the sake of ease of explanation, only the parts relevant to the invention are shown in the drawings, and not the entirety.

[0022] Similar symbols and letters in the following drawings represent similar terms, and it should be noted that once a term is defined in one drawing, no further definition or interpretation of it is required in subsequent drawings.

[0023] In the description of this invention, unless otherwise explicitly stated and limited, the terms “connected,” “connection,” and “fixed” should be understood in a broad sense. For example, they may be fixed connections, detachable connections, or integrated, mechanical connections, electrical connections, direct connections, indirect connections via an intermediate mediator, or internal communication between two elements or an interaction relationship between two elements. Those skilled in the art will understand the specific meaning of these terms in this invention depending on the specific circumstances.

[0024] In the present invention, unless otherwise explicitly stated and limited, the presence of a first feature "above" or "below" a second feature may include direct contact between the first and second features, or it may include contact between the first and second features without direct contact, but through other features between them. Furthermore, the presence of a first feature "above," "above," and "on the top surface" of a second feature may include the first feature being directly above and diagonally above the second feature, or simply indicating that the horizontal height of the first feature is greater than that of the second feature. The presence of a first feature "below," "below," and "on the bottom surface" of a second feature may include the first feature being directly below and diagonally below the second feature, or simply indicating that the horizontal height of the first feature is lower than that of the second feature. In the description of these embodiments, unless otherwise specifically stated, "multiple" specifically means two or more.

[0025] In the description of this embodiment, terms such as "up," "down," and "right," which refer to directions and positional relationships, are based on the directions and positional relationships shown in the drawings and are merely for the purpose of facilitating explanation and simplifying operation. They do not indicate or imply that such devices or elements have a specific direction, or must be configured and operated in a specific direction, and therefore should not be understood as limiting the present invention. Furthermore, the terms "first" and "second" are merely for the purpose of distinction in the description and do not carry any special meaning.

[0026] Example 1 This embodiment provides a ferrite molding process used for ferrite molding, which yields a high yield of ferrite.

[0027] As shown in Figure 12, the ferrite 100 in this embodiment comprises a main body structure 110 and a boss structure 120. Both the main body structure 110 and the boss structure 120 are annular in shape, 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 coils, and the main body structure 110 has a gap to accommodate the ends of the coils. In some embodiments, the gap is obtained by opening in the main body structure 110; that is, the main body structure 110 is annular with an opening.

[0028] As shown in Figure 1, the ferrite molding process includes the following steps:

[0029] In S1, powder material is placed into a molding die provided with a gap forming structure for forming gaps in the ferrite 100. In this embodiment, there is no need to create a gap in subsequent secondary processing, and the molding die is directly provided with a gap-forming structure for forming the gap. The molding die in this embodiment may have the structure shown in Figures 4 to 8. In some preferred embodiments, the gap-forming structure may be a protruding structure or other structure that enables the formation of a gap, and this embodiment is not limited thereto. The method of introducing powder material into the molding die can be found in the prior art and will not be described in detail here.

[0030] In S2, the powder material is pressed to form a molded body. After placing the powder material into a molding die, the powder material is pressed to form it. Figures 2 and 3 are schematic diagrams of the molded or sintered body 200 according to this embodiment. Note that the shape and size of the molded body differ from the shape and size of the ferrite 100 to be obtained; in other words, the molded body has excess material. The method of pressing the powder material can be found in the prior art, and this embodiment will not be described in detail here.

[0031] In S3, the molded body is placed in a heating furnace and sintered to form a sintered body 200. The method for heating the molded body in a heating furnace in step S3 is based on prior art and will not be described in detail here.

[0032] Furthermore, the shape and size of the sintered body 200 and the molded body are identical.

[0033] In step S4, the sintered body 200 is subjected to a molding process to obtain ferrite 100.

[0034] In this embodiment, since the molded body is an object that includes excess material, a molding process is required for the molded body in order to obtain ferrite 100. Exemplarily, the molding process may include polishing or other methods of removing excess material, and this embodiment is not limited thereto.

[0035] In this embodiment, the ferrite molding process involves first placing powder material into a molding die, then pressing the powder material to form a molded body, and finally placing the molded body in a heating furnace for sintering to form a sintered body 200. Ferrite 100 can then be obtained by directly performing a molding process on the sintered body 200. Since the molding die in this embodiment is provided with a gap molding structure, gaps are directly created during the pressing process of the powder material, eliminating the need for a gap molding step after sintering. This simplifies the process flow for ferrite 100, reduces investment in gap molding equipment, prevents the sintered body 200 from fracturing during the gap molding step, strengthens the structure of the sintered body 200, and reduces the risk of ferrite 100 fracturing during the assembly stage, thereby improving the yield of ferrite 100.

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

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

[0038] This embodiment further provides a ferrite molding die for application to the above-described ferrite molding process, specifically comprising a main molding die provided with a molding cavity for molding a molded body and a gap molding structure for forming gaps in the ferrite 100.

[0039] More preferably, as shown in Figures 4 to 8, the main molding die comprises a lower punch 510, a mold core 520, and an upper punch 530. Of these, a first molding groove 511 is provided on one end face of the lower punch 510, a second molding groove 512 is provided at the bottom of the first molding groove 511, and a core hole 513 is provided at the bottom of the second molding groove 512. The mold core 520 is provided passing through the core hole 513, the first molding groove 511, and the second molding groove 512. Specifically, the bottom end of the mold core 520 is located outside the core hole 513 and inside the first molding groove 511.

[0040] As shown in Figures 5 and 6, the gap forming structure in this embodiment comprises a first protrusion 514 provided on the groove side wall of the first forming groove 511, and a second protrusion 515 provided on the groove bottom wall of the first forming groove 511, that is, the first protrusion 514 and the second protrusion 515 can work together to form a gap. In this embodiment, the first protrusion 514 and the second protrusion 515 are connected. In some preferred embodiments, the length of the second protrusion 515 is the same as the length of the first protrusion 514. The second protrusion 515 is used to form a gap 220 (as shown in Figure 2) between the top excess material 210 and the boss structure 120, and this gap 220 is part of the gap. The setting of the gap 220 prevents the top excess material 210 from being directly connected to the boss structure 120, allowing the top excess material 210 to be removed smoothly without affecting the boss structure 120.

[0041] Preferably, as shown in Figure 8, the bottom end of the upper punch 530 (one end facing the lower punch 510) is provided with a third protrusion 516 that can enter the first molding groove 511 and be positioned opposite the first protrusion 514. The molding cavity comprises a top molding cavity surrounded by the first protrusion 514, the second protrusion 515, the groove wall of the first molding groove 511, and the mold core 520, and a bottom molding cavity surrounded by the groove wall of the second molding groove 512 and the mold core 520. Of these, the top molding cavity is used to mold the top excess material 210 and the main body structure 110, and the bottom molding cavity is used to mold the boss structure 120 and the bottom excess material. Furthermore, the top excess material 210 is ring-shaped, and the thickness of the portion of the top excess material 210 that directly faces the gap is smaller than the thickness of other portions. Specifically, the first protrusion 514 and the third protrusion 516 work together to form a portion that directly faces the gap in the top excess material 210, and by making this portion thin, the removal of the top excess material 210 is facilitated, while the third protrusion 516 is made to directly contact and press the boss structure 120, thereby ensuring the molding quality of the boss structure 120.

[0042] More preferably, as shown in Figure 6, two fourth protrusions 517 are provided at each end of the top surface of the second protrusion 515, and the first protrusion 514 is used to form the material hole 230 shown in Figure 2. The sum of the heights of the fourth protrusion 517 and the second protrusion 515 is equal to the thickness of the main body structure 110, so that the main body structure 110 can be obtained by polishing away the portion of the top excess material 210 located above the material hole 230. The thickness of the main body structure 110 can be met by providing the material hole 230.

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

[0044] In this embodiment, the ferrite molding process integrally molds the main body structure 110 and the boss structure 120, and as shown in Figures 2 and 3, simultaneously forms a top excess material 210 located on one side of the main body structure 110 that is far from the boss structure 120, and a bottom excess material located on one side of the boss structure 120 that is far from the main body structure 110. Then, by polishing and removing the top excess material 210 and the bottom excess material, a ferrite 100 having a gap as shown in Figure 11 is obtained.

[0045] Preferably, in this embodiment, after polishing away the excess material at the top 210 and the excess material at the bottom, the main body structure 110 and the boss structure 120 can be subjected to barrel polishing. Since the main body structure 110 and the boss structure 120 are not machined or drilled, they both have high structural strength, and therefore are less likely to break during barrel polishing, resulting in a high yield.

[0046] Example 2 The ferrite molding process in this embodiment is distinguished from Embodiment 1 by the fact that the main body structure 110 and the boss structure 120 are formed separately using two molds, and the main molding die in this embodiment is also different from the main molding die in Embodiment 1.

[0047] The ferrite molding process is Step S1 involves placing powder material into a molding die provided with a gap-forming structure for forming gaps in ferrite 100, Step S2 involves pressing the powder material to form a molded body, Step S3 involves placing the molded body in a heating furnace and sintering it to form a sintered body 200, The process includes step S4, in which a molding process is performed on the sintered body 200 to obtain ferrite 100.

[0048] In step S1, powder material is placed in both the main mold 600 and the boss mold 700, which are equipped with a gap molding structure. In step S2, the main body is formed by pressing with the main body mold 600, and the boss is formed by pressing with the boss mold 700.

[0049] In step S3, the main body molded body is placed in a heating furnace and sintered to form the main body sintered body, and the boss molded body is placed in a heating furnace and sintered to form the boss sintered body. The structure of the boss sintered body is as shown in Figure 9, and the structure of the main body sintered body is as shown in Figure 10.

[0050] The main sintered body comprises an integral first excess body 300 and a main body structure 110, the main body structure 110 having a gap, and the boss sintered body comprises an integral second excess body 400 and a boss structure 120, and step S4 includes the following:

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

[0052] In S42, the second excess body 400 of the boss sintered body is removed to obtain the boss structure 120. The boss structure 120 obtained after the removal of the second excess body 400 of the boss sintered body is as shown in Figure 11, and as can be seen from Figure 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 excess material 300 of the main sintered body is polished and removed to obtain the main body structure 110. In step S42, the second excess material 400 of the boss sintered body is polished and removed to obtain the boss structure 120.

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

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

[0057] In step S432, the boss structure 120 is pressed against the adhesive body, and the boss structure 120 and the main body structure 110 are bonded together by the adhesive body.

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

[0059] In some preferred embodiments, as shown in Figure 10, the first extra body 300 is annular, the main body structure 110 is an open annular, and the inner annular surface of the first extra body 300 and the inner annular surface of the main body structure 110 are flush, and the width of the first extra body 300 is greater than the width of the main body structure 110, thereby facilitating the formation of a main body structure 110 with a complete structure and an orderly surface. Similarly, as shown in Figure 9, the second extra body 400 and the boss structure 120 are both annular, and the width of the second extra body 400 is greater than the width of the boss structure 120, thereby facilitating the formation of a boss structure 120 with a complete structure and an orderly surface.

[0060] Preferably, before connecting the boss structure 120 and the main body structure 110, that is, before step S43, the ferrite molding process is performed. The main body structure 110 is subjected to barrel polishing, The method further includes performing barrel polishing on the boss structure 120.

[0061] In this embodiment, the main body structure 110 and the boss structure 120 may be barrel polished within a single drum, or they may be barrel polished separately. Since the barrel polishing 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 reliability of the connection between the main body structure 110 and the boss structure 120.

[0062] For the ferrite molding process according to this embodiment, a ferrite molding die is provided, which comprises a main molding die equipped with a molding cavity for molding a molded body and a gap molding structure for forming gaps in the ferrite 100.

[0063] Furthermore, as shown in Figures 13 to 15, the main molding die comprises a main body die 600 and a boss die 700.

[0064] As shown in Figures 13 and 14, the main mold 600 comprises a first lower punch 610, a first mold core 620, and a first upper punch 630. A first groove 611 is provided on the end face of one end of the first lower punch 610. Specifically, the end face of the first lower punch 610 facing the first upper punch 630 has a first groove 611, and a second groove 612 is provided at the bottom of the first groove 611. A first through hole 613 is provided at the bottom of the second groove 612, extending to the end face of the other end of the first lower punch 610. The first mold core 620 comprises the first through hole 613, the first groove 611, and the second The first mold core 620 and the groove walls of the first groove 611 are inserted into the groove 612, and the groove walls of the first mold core 620 and the first groove 611 form a first molding cavity for forming the first excess body 300, and the groove walls of the first mold core 620 and the second groove 612 form a second molding cavity for forming the main body structure 110, and the gap molding structure is a convex block 614 provided in the second molding cavity, specifically the convex block 614 provided in the groove bottom wall of the second groove 612. The first upper punch tool 630 is used to press and press the powder material in the first molding cavity and the second molding cavity to form the main body molded body.

[0065] As shown in Figure 15, the boss die 700 comprises a second lower punch 710, a second die core 720, and a second upper punch 730. Of these, a third groove 711 is provided on the end face of one end of the second lower punch 710; specifically, the end face of the second lower punch 710 facing the second upper punch 730 has a third groove 711. A fourth groove 712 is provided at the bottom of the third groove 711, and a second through hole is provided at the bottom of the fourth groove 712, extending to the end face of the other end of the second lower punch tool 710. The second mold core 720 is inserted into the second through hole, the third groove 711, and the fourth groove 712. The groove walls of the second mold core 720 and the third groove 711 form a third molding cavity for forming the second excess material 400, and the groove walls of the second mold core 720 and the fourth groove 712 form a fourth molding cavity for forming the boss structure 120. The second upper punch tool 730 is used to apply pressure to the powder material in the third and fourth molding cavities and press it to form the boss molded body.

[0066] The ferrite molding process and ferrite molding die according to this embodiment first press a main body molded body with a main body mold 600, then press a boss molded body with a boss mold 700, and then sinter the main body molded body and boss molded body respectively to obtain a sintered main body body and a sintered boss body. Subsequently, the sintered main body body and the sintered boss body are polished to remove the first excess material 300 and the second excess material 400, obtaining the main body structure 110 and the boss structure 120. The main body structure 110 and the boss structure 120 are then directly assembled. This avoids defects such as a large amount of breakage caused by the gap molding step, improves the yield of ferrite 100, can be applied to the manufacture of ferrite 100 of different shapes, and reduces investment in gap molding equipment.

[0067] Example 3 This embodiment provides ferrite 100 manufactured using the ferrite molding process and ferrite molding die described in Examples 1 and 2.

[0068] Preferably, the ferrite 100 in this embodiment comprises a main body structure 110 and a boss structure 120, the main body structure 110 having a gap. In some embodiments, the main body structure 110 and the boss structure 120 are integrally molded structures, in which case the ferrite 100 is manufactured by the ferrite molding 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 adhesive bonding, in which case the ferrite 100 is manufactured by the ferrite molding process according to Embodiment 2.

[0069] The above describes only preferred embodiments and technical principles of the present invention. Those skilled in the art should understand that the present invention is not limited to the specific embodiments described herein and that various obvious modifications, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Accordingly, although the present invention has been described in detail by the above embodiments, the present invention is not limited to the above embodiments and may include more other equivalent embodiments as long as they do not depart from the concept of the present invention, and the scope of protection of the present invention is determined by the appended claims. [Explanation of Symbols]

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

Claims

1. Step S1 involves placing powder material into a molding die provided with a gap-forming structure for forming gaps in ferrite (100), Step S2 involves pressing the powder material to form a molded body, Step S3 involves placing the molded body in a heating furnace and sintering it to form a sintered body (200), The process includes step S4, in which a molding process is performed on the sintered body (200) to obtain ferrite (100), The ferrite (100) comprises a main body structure (110) and a boss structure (120) formed separately by two molds. In step S1, powder material is placed into both the main mold (600) and the boss mold (700) equipped with the gap molding structure. In step S2, the main body molded body is formed by pressing with the main body mold (600), and the boss molded body is formed by pressing with the boss mold (700). In step S3, the main body molded body is placed in a heating furnace and sintered to form a sintered main body, and the boss molded body is placed in a heating furnace and sintered to form a sintered boss. The main body sintered body comprises an integral first excess body (300) and a main body structure (110), the main body structure (110) having a gap, and the boss sintered body comprises an integral second excess body (400) and a boss structure (120). Step S4 is, Step S41 involves removing the first excess material (300) of the sintered body to obtain the main body structure (110), Step S42 involves removing the second excess material (400) of the boss sintered body to obtain the boss structure (120), The step S43 involves connecting the boss structure (120) and the main body structure (110) to obtain ferrite (100), The first extra body (300) is annular, the main body structure (110) is an open annular, and the inner annular surface of the first extra body (300) and the inner annular surface of the main body structure (110) are flush, and the width of the first extra body (300) is greater than the width of the main body structure (110). A ferrite molding process characterized by the following:

2. In step S41, the first excess material (300) of the sintered body is polished and removed to obtain the main body structure (110). In step S42, the second excess material (400) of the boss sintered body is polished and removed to obtain the boss structure (120). The ferrite molding process according to feature 1.

3. Step S43 is, Step S431 involves applying an adhesive to the main body structure (110), The method includes step S432, which involves pressing the boss structure (120) against the adhesive body to bond the boss structure (120) and the main body structure (110) together with the adhesive body. The ferrite molding process according to feature 1.

4. Before step S43, The main body structure (110) is subjected to barrel polishing, The process further includes performing barrel polishing on the boss structure (120), The ferrite molding process according to feature 1.

5. A ferrite molding die applied to the ferrite molding process described in claim 1, The main molding die is provided with a molding cavity for forming a molded body and a gap molding structure for forming a gap in the ferrite (100). The main molding die comprises a main body die (600) and a boss die (700). The main mold (600) comprises a first lower punch (610), a first mold core (620), and a first upper punch (630), wherein a first recessed groove (611) is provided on the end face of one end of the first lower punch (610), a second recessed groove (612) is provided at the bottom of the first recessed groove (611), and a first through hole (613) is provided at the bottom of the second recessed groove (612) extending to the end face of the other end of the first lower punch (610), the first mold core (620) is inserted into the first through hole (613), the first recessed groove (611), and the second recessed groove (612), and the first mold The mold core (620) and the groove walls of the first recess (611) form a first molding cavity for forming a first excess body (300), the first mold core (620) and the groove walls of the second recess (612) form a second molding cavity for forming the main body structure (110), the gap molding structure is a convex block (614) provided in the second molding cavity, and the first upper punch (630) is used to apply pressure to the powder material in the first molding cavity and the second molding cavity to press and form the main body molded body. The boss die (700) comprises a second lower punch (710), a second die core (720), and a second upper punch (730), wherein a third groove (711) is provided on the end face of one end of the second lower punch (710), a fourth groove (712) is provided at the bottom of the third groove (711), and a second through hole is provided at the bottom of the fourth groove (712) that extends to the end face of the other end of the second lower punch (710), and the second die core (720) comprises the second through hole, the third groove (711), and the fourth groove (7 12) is inserted into the above, and the groove walls of the second mold core (720) and the third recess (711) form a third molding cavity for forming a second excess body (400), and the groove walls of the second mold core (720) and the fourth recess (712) form a fourth molding cavity for forming the boss structure (120), and 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 the boss molded body. A ferrite molding die characterized by the following features.

6. A ferrite molding die used in the ferrite molding process, The ferrite molding process described above is Step S1 involves placing powder material into a molding die provided with a gap-forming structure for forming gaps in ferrite (100), Step S2 involves pressing the powder material to form a molded body, Step S3 involves placing the molded body in a heating furnace and sintering it to form a sintered body (200), The process includes step S4, in which a molding process is performed on the sintered body (200) to obtain ferrite (100), The ferrite (100) comprises a main body structure (110) and a boss structure (120) integrally formed in a single mold. The ferrite molding die comprises a main molding die provided with a molding cavity for molding a molded body and a gap molding structure for forming gaps in the ferrite (100). The sintered body (200) comprises an integral top excess material (210), a main body structure (110), a boss structure (120), and a bottom excess material, and the main molding die comprises a lower punch (510), a mold core (520), and an upper punch (530), with a first molding groove (511) provided on the end face of one end of the lower punch (510), a second molding groove (512) provided at the bottom of the first molding groove (511), and a core hole (513) provided at the bottom of the second molding groove (512), and the mold core (520) is provided passing through the core hole (513), the first molding groove (511), and the second molding groove (512). The gap forming structure comprises a first protrusion (514) provided on the groove side wall of the first forming groove (511), and a second protrusion (515) provided on the groove bottom wall of the first forming groove (511), and a third protrusion (516) is provided at the bottom end of the upper punch (530) that can enter the first forming groove (511) and be provided opposite to the first protrusion (514), and the forming cavity comprises the first protrusion (514), the second protrusion (515), and the front The mold comprises a top molding cavity formed by the groove wall of the first molding groove (511) and the mold core (520), and a bottom molding cavity formed by the groove wall of the second molding groove (512) and the mold core (520), wherein the top molding cavity is used to mold the top excess material (210) and the main body structure (110), and the bottom molding cavity is used to mold the boss structure (120) and the bottom excess material. A ferrite molding die characterized by the following features.

7. At both ends of the top surface of the second protrusion (515), there are two fourth protrusions (517) whose combined height with that of the second protrusion (515) is equal to the thickness of the main body structure (110). The ferrite molding die according to feature 6.

8. Manufactured by the ferrite molding process described in any one of claims 1 to 4, A ferrite characterized by the following features.

Images