Iron core having novel structure, and manufacturing process and injection mold therefor

Abstract

The present invention relates to the field of iron core processing, and in particular to an iron core having a novel structure, and a manufacturing process and an injection mold therefor. The iron core having a novel structure comprises a large end part formed by turning and a small end part formed by drawing or turning; a first channel is arranged inside the large end part, a second channel is arranged inside the small end part, a connecting part is connected between the large end part and the small end part by means of injection molding, a third channel is arranged inside the connecting part, and the third channel, the second channel, and the first channel are in communication; and obround holes in communication with the third channel are symmetrically formed on the side wall of the connecting part. The processing process combining turning and injection molding greatly shortens the production cycle and improves the production efficiency. The small end part can be pre-formed by using a suitable bar stock or tube stock, thereby saving materials and time that may be wasted in a traditional process.

Description

A novel structural iron core, its manufacturing process and injection mold Technical Field

[0001] This invention relates to the field of iron core processing, specifically to a novel structural iron core, its manufacturing process, and its injection mold. Background Technology

[0002] Currently, the manufacturing of electromagnetic pump cores typically involves turning a single bar into a small end, a connecting section, and a large end. The main steps include: first, machining the large end; then, finely turning the small end; and finally, machining the connecting section. For example, in one instance, if the large end diameter is φ14.3 mm and the small end diameter is φ4.3 mm, using a φ14.5 mm diameter bar as raw material, machining the large end is relatively simple and quick, requiring only about 10 seconds. However, machining the small end is much more complex; due to the limitation on feeding too much material at once, the entire process may take close to 50 seconds. Furthermore, machining the connecting section takes approximately 15 seconds. Therefore, completing the entire outer shape takes approximately 75 seconds. This traditional manufacturing process is not only time-consuming but also results in significant material waste during the machining of the small end and the connecting section.

[0003] Existing injection mold designs present inconveniences in terms of core pulling and ejection pin operation.

[0004] Therefore, we propose a novel structural iron core, manufacturing process, and injection mold to solve the above problems. Technical issues

[0005] To solve the above-mentioned technical problems, the present invention provides a novel structural iron core, manufacturing process and injection mold. Technical solutions

[0006] This invention provides a novel structural iron core, comprising a large end formed by turning and a small end formed by drawing or turning. The large end and the small end are independent of each other. The inner side of the large end is provided with a first channel, and the interior of the small end is provided with a second channel. The large end and the small end are connected by injection molding with a connecting part. The interior of the connecting part is provided with a third channel, and the third channel, the second channel and the first channel are connected. The sidewall of the connecting part is symmetrically provided with waist-shaped holes that communicate with the third channel.

[0007] Preferably, the outer side wall of the small end is integrally provided with a fixing structure, and the fixing structure is located inside the connecting part.

[0008] Preferably, the end of the connecting portion furthest from the small end is embedded and fixed within the large end.

[0009] Preferably, the outer diameter of the larger end is greater than the outer diameter of the connecting portion, and the outer diameter of the connecting portion is greater than the outer diameter of the smaller end.

[0010] Preferably, the inner diameter of the larger end is larger than the inner diameter of the connecting portion, and the inner diameter of the connecting portion is larger than the inner diameter of the smaller end.

[0011] This invention provides a novel manufacturing process for structural iron cores, comprising the following steps:

[0012] S1. Turning of the large end:

[0013] The large end is machined using a suitable soft magnetic rod material on a lathe.

[0014] S2. Turning of the small end:

[0015] The small end is shaped by turning a suitable bar on a lathe, and the turning of the small end and the turning of the large end are carried out simultaneously and separately.

[0016] S3. The large end, small end, and connecting part are injection molded into a single unit:

[0017] The small end and the large end are placed in the mold. After the mold is closed, injection molding is performed to connect the large end and the small end into a whole. The injection-molded part between the large end and the small end is the connecting part.

[0018] This invention provides a novel injection mold for manufacturing structural iron cores, comprising an upper mold and a lower mold. Both the upper and lower molds are provided with a large end receiving groove, a small end receiving groove, a connecting portion forming groove, and a sprue groove. The sprue groove communicates with the connecting portion forming groove. The connecting portion forming groove contains a waist-shaped protrusion for forming a waist-shaped hole. The upper mold has an injection port communicating with the sprue groove. The lower mold contains a stepped mold core for engaging with the inner wall of the novel structural iron core. The lower mold contains a driving component for moving the stepped mold core. The upper mold contains an actuating structure for moving the driving component.

[0019] Preferably, the driving assembly includes a trapezoidal plate slidably connected within the upper mold, the trapezoidal plate being fixedly connected to the stepped mold core, a first inclined portion being provided at the top of the trapezoidal plate, an ear plate being fixed at the bottom of the trapezoidal plate, a telescopic rod being installed between the ear plate and the lower mold, a first return spring being sleeved on the outside of the telescopic rod, the two ends of the first return spring contacting the ear plate and the lower mold respectively, and the actuating structure includes a vertical plate fixed to the bottom of the upper mold, a triangular portion being symmetrically fixed on the vertical plate, and a second inclined portion being provided on the triangular portion that contacts the first inclined portion.

[0020] Preferably, each of the four corners of the bottom of the lower mold is fixed with a column, the bottom end of the column is fixedly connected to a base plate, a fixing plate is fixedly connected to the four columns, a plurality of ejector pins are slidably connected inside the lower mold, a blocking part is fixed to the outside of the ejector pin, the blocking part contacts the top of the fixing plate, a second return spring is sleeved on the outside of the ejector pin, the two ends of the second return spring contact the blocking part and the bottom of the lower mold respectively, a push plate is fixed to the bottom of the vertical plate, the push plate is slidably connected to the column, and the bottom end of the ejector pin is provided with a pressing part that cooperates with the push plate.

[0021] Preferably, the ejector pin is positioned directly opposite the large end receiving groove, the small end receiving groove, and the sprue groove, and the vertical plate is slidably connected to the fixed plate. Beneficial effects

[0022] Beneficial effects:

[0023] Processing efficiency and cost control:

[0024] The combination of turning and injection molding significantly shortens the production cycle and improves production efficiency.

[0025] The smaller end can be pre-processed using suitable bar or tube material, saving materials and time that might be wasted in traditional processes.

[0026] The stepped mold core design allows for the sealing of the inner sides of the large and small ends, as well as the molding of the connecting parts, to be completed in a single injection molding process, further reducing processing costs.

[0027] Ease of use and product removal:

[0028] The mold closing and opening process is designed to be very simple. The movement of the stepped mold core can be easily achieved through the movement of the mold and the action of the first return spring.

[0029] The design of the ejector pin and push plate allows the molded product to be easily removed from the mold, avoiding the removal difficulties that may be encountered in traditional methods. Attached Figure Description

[0030] Figure 1 is a schematic diagram of the overall structure of the novel structural iron core of the present invention;

[0031] Figure 2 is a schematic diagram of the explosion of the novel iron core structure of the present invention;

[0032] Figure 3 is a schematic diagram of the overall structure of the injection mold of the present invention;

[0033] Figure 4 is a schematic diagram of the upper mold structure of the present invention;

[0034] Figure 5 is a schematic diagram of the lower mold structure of the present invention;

[0035] Figure 6 is a schematic diagram of the trapezoidal plate structure of the present invention;

[0036] Figure 7 is a schematic diagram of the vertical plate structure of the present invention;

[0037] Figure 8 is a front view of the injection mold of the present invention;

[0038] Figure 9 is a schematic diagram showing the position of the novel structural iron core after injection molding of the present invention;

[0039] Figure 10 is a schematic diagram of the stepped mold core structure of the present invention.

[0040] The diagram is labeled as follows: 1. Large end; 2. Small end; 3. First channel; 4. Second channel; 5. Connecting part; 6. Third channel; 7. Waist-shaped hole; 8. Fixing structure; 9. Upper mold; 10. Lower mold; 11. Large end receiving groove; 12. Small end receiving groove; 13. Connecting part forming groove; 14. Sprue groove; 15. Waist-shaped protrusion; 16. Injection port; 17. Stepped mold core; 18. Trapezoidal plate; 19. First inclined part; 20. Ear plate; 21. Telescopic rod; 22. First return spring; 23. Vertical plate; 24. Triangular part; 25. Second inclined part; 26. Column; 27. Base plate; 28. Fixing plate; 29. ​​Ejector pin; 30. Blocking part; 31. Second return spring; 32. Push plate; 33. Extrusion part. Embodiments of the present invention

[0041] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0042] Referring to Figures 1 and 2, a novel structural iron core includes a large end 1 formed by turning and a small end 2 formed by drawing or turning. The large end 1 and the small end 2 are independent of each other. The inner side of the large end 1 is cleverly designed with a first channel 3, while the interior of the small end 2 has a second channel 4. These two parts are connected by an injection molding process with a connecting part 5. The interior of the connecting part 5 has a third channel 6. This design ensures smooth communication between the third channel 6, the second channel 4, and the first channel 3. On the side wall of the connecting part 5, symmetrically formed oblong holes 7 are opened, communicating with the third channel 6. This step usually requires a machining center in traditional processing methods, but it is achieved more streamlined and efficiently in this novel structure.

[0043] Of particular note is that a fixing structure 8 extends integrally from one end of the outer wall of the small end 2. This design not only enhances the connection stability between the small end 2 and the connecting part 5, but also increases the contact area between them. The fixing structure 8 is cleverly located inside the connecting part 5, providing additional stability to the overall structure.

[0044] The end of the connecting portion 5 furthest from the small end 2 is embedded within the large end 1, making the overall structure more compact and stable. In terms of dimensions, the outer diameter of the large end 1 is larger than that of the connecting portion 5, which in turn is larger than that of the small end 2. This stepped design not only facilitates precise positioning of the large end 1 and the small end 2 in the injection mold but also gives the core more diverse functions and forms.

[0045] Similarly, the inner diameter is also carefully designed: the inner diameter of the large end 1 is larger than the inner diameter of the connecting part 5, and the inner diameter of the connecting part 5 is larger than the inner diameter of the small end 2. This design allows a single stepped mold core 17 to simultaneously seal the inner sides of the large end 1 and the small end 2, as well as form the connecting part 5 during the injection molding process, greatly improving production efficiency and processing accuracy.

[0046] A novel structural iron core manufacturing process includes the following steps:

[0047] S1. Turning of the large end 1:

[0048] The large end 1 is shaped by turning a suitable (appropriate thickness, not too thick or too thin) soft magnetic rod material on a lathe.

[0049] S2. Turning of the small end 2:

[0050] The small end 2 is formed by turning a suitable bar stock (appropriate thickness, not too thick or too thin) on a lathe. The turning of the small end 2 and the turning of the large end 1 are carried out simultaneously and separately.

[0051] S3. The large end 1, the small end 2, and the connecting part 5 are injection molded into a single unit:

[0052] Place the small end 2 and the large end 1 into the mold. After the mold is closed, perform injection molding to connect the large end 1 and the small end 2 into a whole. The injection-molded part between the large end 1 and the small end 2 is the connecting part 5.

[0053] The technical solution of this invention is to divide the iron core into three parts: large end 1, small end 2 and connecting part 5. The processing technology is as follows: the small end 2 can be pre-processed using suitable rod or tube material, saving the materials and time wasted in traditional processes; the large end 1 is also pre-processed using suitable soft magnetic rod material, and the processing accuracy can be relaxed to reduce processing time; the connecting part 5 is more complex and is determined by the mold. This mold can be made by plastic injection molding. The small end 2 and the large end 1 are placed in the mold, and after the mold is closed, injection molding is performed to connect the two into a whole.

[0054] Referring to Figures 3 to 10, a novel injection mold for manufacturing a structural iron core includes an upper mold 9 and a lower mold 10. Both molds have a large end receiving groove 11, a small end receiving groove 12, a connecting portion forming groove 13, and a sprue groove 14. The sprue groove 14 is connected to the connecting portion forming groove 13 to ensure smooth flow of the injection molding liquid. The connecting portion forming groove 13 also has a waist-shaped protrusion 15 specifically designed for forming the waist-shaped hole 7. The upper mold 9 has an injection port 16 connected to the sprue groove 14 to facilitate the injection of the injection molding liquid.

[0055] Inside the lower mold 10, we installed a stepped mold core 17 to mate with the inner wall of the new structural iron core. To ensure the precise movement of the stepped mold core 17, we also designed a drive assembly and an actuation structure.

[0056] The driving assembly includes a trapezoidal plate 18 slidably connected within the upper mold 9, the trapezoidal plate 18 being fixedly connected to the stepped mold core 17, a first inclined portion 19 being provided at the top of the trapezoidal plate 18, an ear plate 20 being fixed at the bottom of the trapezoidal plate 18, a telescopic rod 21 being installed between the ear plate 20 and the lower mold 10, a first return spring 22 being sleeved on the outside of the telescopic rod 21, the two ends of the first return spring 22 being in contact with the ear plate 20 and the lower mold 10 respectively, and the actuating structure including a vertical plate 23 fixed at the bottom of the upper mold 9, a triangular portion 24 being symmetrically fixed on the vertical plate 23, and a second inclined portion 25 being provided on the triangular portion 24 in contact with the first inclined portion 19.

[0057] Each of the four corners of the lower mold 10 is fixed with a column 26 for stable installation; the bottom of each column 26 is fixedly connected to a base plate 27. A fixing plate 28 is also fixedly connected to the four columns 26 for further reinforcement and positioning of the mold. Inside the lower mold 10, several ejector pins 29 are slidably connected to eject the product from the mold after injection molding. A blocking part 30 is fixed to the outside of the ejector pin 29 to prevent excessive sliding; the blocking part 30 contacts the top of the fixing plate 28 to ensure its stable position. A second return spring 31 is also sleeved on the outside of the ejector pin 29 for reset; the two ends of the second return spring 31 contact the blocking part 30 and the bottom of the lower mold 10, respectively. A push plate 32 is fixed to the bottom of the vertical plate 23, and the push plate 32 is slidably connected to the column 26. The bottom of the ejector pin 29 is provided with a pressing part 33 that cooperates with the push plate 32.

[0058] The ejector pin 29 is positioned directly opposite the large end receiving groove 11, the small end receiving groove 12, and the sprue groove 14, and the vertical plate 23 is slidably connected to the fixed plate 28.

[0059] Injection molding process:

[0060] Mold Closing Process: First, the large end 1 and the small end 2 are placed into the large end receiving groove 11 and the small end receiving groove 12 in the lower mold 10. Then, the upper mold 9 moves down, causing the second inclined part 25 to press against the first inclined part 19. The first return spring 2 is compressed, and the stepped mold core 17 is inserted into the large end 1 and the small end 2 in sequence, sealing the inner walls of the large end 1 and the small end 2. After the upper mold 9 and the lower mold 10 are closed, the connecting part forming groove 13 of the upper mold 9, the connecting part forming groove 13 of the lower mold 10, and the stepped mold core 17 form a connecting part mold cavity. Injection is performed through the injection port 16. The injection liquid enters the connecting part mold cavity along the injection port 16 and the sprue groove 14, forming the connecting part 5, so that the connecting part 5, the large end 1, and the small end 2 form a whole.

[0061] Mold opening process: The upper mold 9 moves upward, and the second inclined part 25 also moves upward. Under the action of the first return spring 22, the stepped mold core 17 and the trapezoidal plate 18 move together. The stepped mold core 17 moves out of the new structure iron core. When the vertical plate 23 drives the push plate 32 to move upward together, when the push plate 32 contacts the extrusion part 33, the push plate 32 squeezes the ejector pin 29. The ejector pin 29 lifts the large end 1, the small end 2 and the sprue together, making it convenient to take the injection molded product out of the mold.

[0062] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A novel structural iron core, characterized in that, It includes a large end (1) formed by turning and a small end (2) formed by drawing or turning. The large end (1) and the small end (2) are independent of each other. The inner side of the large end (1) is provided with a first channel (3). The interior of the small end (2) is provided with a second channel (4). The large end (1) and the small end (2) are connected by injection molding with a connecting part (5). The interior of the connecting part (5) is provided with a third channel (6). The third channel (6), the second channel (4) and the first channel (3) are connected. The side wall of the connecting part (5) is symmetrically provided with waist-shaped holes (7) that communicate with the third channel (6).

2. The novel structural iron core according to claim 1, characterized in that, The outer wall of the small end (2) is integrally provided with a fixing structure (8), and the fixing structure (8) is located inside the connecting part (5).

3. The novel structural iron core according to claim 1, characterized in that, The end of the connecting part (5) away from the small end (2) is embedded and fixed in the large end (1).

4. A novel structural iron core according to claim 1, characterized in that, The outer diameter of the large end (1) is greater than the outer diameter of the connecting part (5), and the outer diameter of the connecting part (5) is greater than the outer diameter of the small end (2).

5. A novel structural iron core according to claim 1, characterized in that, The inner diameter of the large end (1) is greater than the inner diameter of the connecting part (5), and the inner diameter of the connecting part (5) is greater than the inner diameter of the small end (2).

6. A manufacturing process for a novel structural iron core according to any one of claims 1-5, characterized in that, Includes the following steps: S1. Turning of the large end (1): The large end (1) is formed by turning a suitable soft magnetic rod material on a lathe; S2. Turning of the small end (2): The small end (2) is formed by turning a suitable bar on a lathe. The turning of the small end (2) and the turning of the large end (1) are carried out simultaneously. S3. The large end (1), the small end (2), and the connecting part (5) are injection molded into a single unit: Place the small end (2) and the large end (1) in the mold. After the mold is closed, perform injection molding to connect the large end (1) and the small end (2) into a whole. The injection part between the large end (1) and the small end (2) is the connecting part (5).

7. An injection mold for use in the manufacturing process of the novel structural iron core as described in claim 6, comprising an upper mold (9) and a lower mold (10), characterized in that, The upper mold (9) and the lower mold (10) are each provided with a large end receiving groove (11), a small end receiving groove (12), a connecting part forming groove (13), and a sprue groove (14). The sprue groove (14) is connected to the connecting part forming groove (13). The connecting part forming groove (13) is provided with a waist-shaped protrusion (15) for forming a waist-shaped hole (7). The upper mold (9) is provided with an injection port (16) connected to the sprue groove (14). The lower mold (10) is provided with a stepped mold core (17) for cooperating with the inner wall of the new structure iron core. The lower mold (10) is provided with a driving component for driving the stepped mold core (17) to move. The upper mold (9) is provided with an execution structure for driving the driving component to move.

8. The novel structural iron core injection mold according to claim 7, characterized in that, The driving assembly includes a trapezoidal plate (18) slidably connected in the upper mold (9), the trapezoidal plate (18) being fixedly connected to the stepped mold core (17), the top of the trapezoidal plate (18) being provided with a first inclined portion (19), the bottom of the trapezoidal plate (18) being fixed with an ear plate (20), a telescopic rod (21) being installed between the ear plate (20) and the lower mold (10), a first return spring (22) being sleeved on the outside of the telescopic rod (21), the two ends of the first return spring (22) being in contact with the ear plate (20) and the lower mold (10) respectively, and the actuating structure including a vertical plate (23) fixed at the bottom of the upper mold (9), a triangular portion (24) being symmetrically fixed on the vertical plate (23), and a second inclined portion (25) being provided on the triangular portion (24) in contact with the first inclined portion (19).

9. A novel structural iron core injection mold according to claim 8, characterized in that, The lower mold (10) has four columns (26) fixed at its bottom corners. The bottom ends of the columns (26) are all fixedly connected to a base plate (27). The four columns (26) are all fixedly connected to a fixing plate (28). The lower mold (10) has several ejector pins (29) slidably connected inside. The ejector pins (29) have a blocking part (30) fixed on their outer side. The blocking part (30) contacts the top of the fixing plate (28). The ejector pins (29) are fitted with a second return spring (31). The two ends of the second return spring (31) contact the blocking part (30) and the bottom of the lower mold (10) respectively. The bottom of the vertical plate (23) is fixed with a push plate (32). The push plate (32) is slidably connected to the columns (26). The bottom end of the ejector pins (29) is provided with a pressing part (33) that cooperates with the push plate (32).

10. A novel structural iron core injection mold according to claim 8, characterized in that, The ejector pin (29) is positioned opposite the large end receiving groove (11), the small end receiving groove (12), and the sprue groove (14), and the vertical plate (23) is slidably connected to the fixed plate (28).

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