CN114005666A - Manufacturing method of LTCC planar transformer - Google Patents
Manufacturing method of LTCC planar transformer Download PDFInfo
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- CN114005666A CN114005666A CN202111651313.XA CN202111651313A CN114005666A CN 114005666 A CN114005666 A CN 114005666A CN 202111651313 A CN202111651313 A CN 202111651313A CN 114005666 A CN114005666 A CN 114005666A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/041—Printed circuit coils
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Abstract
The invention discloses a manufacturing method of an LTCC planar transformer, which comprises the following steps: s1, selecting a substrate, and processing a through hole on the substrate; s2, placing a layer of substrate, pressing the LTCC material on the substrate through a mould pressing machine to form a coil, wherein the substrate and the coil form a transformer base layer; s3, a layer of substrate is further superposed on the pressed transformer base layer, the pressing procedure of S2 is repeated to manufacture coils, and the LTCC material is filled and pressed in the through holes to form the next transformer base layer; and S4, repeating the step S3 until the coil with the preset number of layers is manufactured, and forming the LTCC planar transformer. According to the invention, the LTCC material is pressed into the coil on the substrate in a mould pressing mode, the multilayer transformer base layers can be stacked according to the product requirements, and the LTCC material is filled in the through hole to realize the electric connection of the coils of each layer, so that the integration level of the transformer is improved, the leakage inductance is reduced, the reliability of the transformer is improved, the pressing mode is simple, the rejection rate is reduced, and the processing difficulty and cost are reduced.
Description
Technical Field
The invention relates to the technical field of transformers, in particular to a manufacturing method of an LTCC planar transformer.
Background
With the rapid development of power electronic technology, the power electronic equipment has increasingly close relationship with the work and life of people, the electronic equipment cannot be powered by a reliable power supply, and the transformer can convert input voltage into used voltage for output so as to be used by the electronic equipment. Conventional transformers are typically constructed with ferrite cores and copper coils, are bulky and are prone to electromagnetic interference. The planar transformer can effectively solve the problems of volume and high frequency, and therefore, the planar transformer has the characteristics of high frequency, low shape, very low height and very high working frequency. The LTCC transformer is one of planar transformers, and an LTCC transformer material system comprises dielectric slurry and conductor materials which are physically and chemically compatible, can be co-fired with a ferrite LTCC substrate, and has the characteristics of excellent magnetic coupling, high magnetic conductivity, high resistivity and good saturation.
The existing LTCC transformer forms a coil on a substrate by pressing, but the existing manufacturing method is complex, and the processing difficulty and cost are high, so that in order to solve the above problems, it is necessary to design a manufacturing method of an LTCC planar transformer.
Disclosure of Invention
In order to solve the technical problems, the invention discloses a manufacturing method of an LTCC planar transformer, wherein a coil is formed by pressing an LTCC material on a substrate in a mould pressing mode, a plurality of layers of transformer base layers can be stacked according to the product requirements, and the LTCC material is filled in a through hole to realize the electric connection of each layer of coil, so that the integration level of the transformer is improved, the leakage inductance is reduced, the reliability of the transformer is improved, the pressing mode is simple, the rejection rate is reduced, and the processing difficulty and the cost are reduced; it includes:
s1, selecting a substrate, and processing a through hole on the substrate through a punching machine;
s2, manufacturing a corresponding die according to the shape and the size of the coil, installing the die on a molding press, placing a layer of the substrate, pressing the LTCC material on the substrate through the molding press to form the coil, wherein the substrate and the coil form a transformer base layer;
s3, overlapping a layer of the substrate on the pressed transformer base layer, repeating the pressing procedure of S2 to manufacture the coil, and filling and pressing the LTCC material into the through hole to form a next layer of the transformer base layer;
and S4, repeating the step S3 until the coil with the preset number of layers is manufactured, and forming the LTCC planar transformer.
Preferably, the substrate comprises a dielectric layer plate and a ferrite base layer plate, the dielectric layer plate is connected in the ferrite base layer plate in an embedded mode, the shape and the size of the dielectric layer plate are matched with those of the coil, and the dielectric layer plate is made of low-permeability materials.
Preferably, the upper surface and the lower surface of the transformer base layer are respectively covered with a ferrite cover plate, and the ferrite cover plates and the transformer base layer are sintered through hot pressing.
Preferably, the coil is provided in any one of a circular shape and a rectangular shape.
Preferably, the LTCC material in the through hole is connected to the LTCC material in the same layer of the coil and the adjacent layer of the coil.
Preferably, the mold comprises: the coil forming die comprises an upper die and a lower die which are matched with each other, wherein the upper die is a male die, the lower die is a female die, the upper die and the lower die are arranged in a surrounding mode to form a die pressing space, and the shape and the size of the die pressing space are consistent with those of the coil.
Preferably, the LTCC material is pressed into the coil using a press, the press comprising:
a body;
the first lifting mechanism is mounted at the top end of the machine body, the bottom end of the first lifting mechanism is connected with a fixed plate, and the fixed plate is connected with the upper die;
the second lifting mechanism is arranged on the machine body table board, the top end of the second lifting mechanism is connected with the lower die, and the substrate is placed on the table board below the lower die;
the third lifting mechanism is arranged at the side end of the machine body;
the feeding mechanism is connected with the third lifting mechanism and is arranged on the rear side of the machine body;
and the controller is electrically connected with the first lifting mechanism, the second lifting mechanism, the third lifting mechanism and the feeding mechanism.
Preferably, the feeding mechanism includes:
the transverse plate is connected to the output end of the third lifting mechanism;
the sliding groove is horizontally arranged in the transverse plate;
the rack is fixedly connected to the top end of the transverse plate;
the gear is connected above the rack in a meshed manner;
the output end of the motor is connected to the center of the gear through a rotating shaft, and the motor is electrically connected with the controller;
the vertical plate is fixedly connected to the bottom end of the motor, and vertically penetrates through the transverse plate to extend downwards;
the sliding block is fixedly connected to the side end of the vertical plate and is connected in the sliding groove in a sliding manner;
the electric push rod is connected to the bottom end of the vertical plate, one side of the electric push rod, which is close to the lower die, is connected with a feeder, the feed end of the feeder is communicated with the storage barrel through an inlet pipe, and the electric push rod is electrically connected with the controller.
Preferably, the die press further comprises a vent assembly, the vent assembly comprising:
the limiting rod is fixedly connected to the top end of the upper die, penetrates through the fixing plate and extends vertically and upwards, and a plurality of threads are uniformly arranged on the limiting rod;
the limiting nut is arranged on the upper surface of the fixing plate and is in threaded connection with the limiting rod;
the clamping groove is formed in the bottom end of the fixing plate;
the clamping block is fixedly connected to the top end of the upper die and is clamped and connected in the clamping groove;
the first spring is connected between the clamping groove and the top end of the clamping block in an abutting mode;
the airtight holes are uniformly formed in the bottom end of the upper die, the top ends of the airtight holes penetrate through the upper die and are communicated with the clamping grooves, and the aperture of each airtight hole is smaller than the diameter of LTCC material particles;
blast pipe, a plurality of the blast pipe even connect in the fixed plate top, blast pipe and draw-in groove top intercommunication, the blast pipe includes:
the tube bodies are uniformly connected to the top end of the fixing plate, the bottom ends of the tube bodies are communicated with the clamping grooves through air inlet holes, and air outlet holes are formed in the top ends of the tube bodies;
the buffer tube is connected inside the tube body, the buffer tube is arranged in a spiral shape, and two ends of the buffer tube are respectively connected with the air inlet hole and the air outlet hole of the tube body;
the spherical plate is communicated with the top end of the pipe body, and a plurality of air holes are uniformly formed in the spherical plate;
the arc-shaped guide plates are arranged in a concave manner, and the two arc-shaped guide plates are symmetrically connected to two ends of the spherical plate;
the baffle is fixedly connected to the top end of the spherical plate, and the baffle is arranged above the arc-shaped guide plate.
Preferably, be provided with calibrating device in the fixed plate, calibrating device sets up is worn to establish by the gag lever post, calibrating device includes:
the shell is fixedly connected inside the fixing plate, and the limiting rod penetrates through a central hole of the shell;
the ball blocking ring is fixedly connected to the inner wall of the central hole of the shell, the limiting rod penetrates through the central hole of the ball blocking ring, and a plurality of ball blocking grooves are symmetrically formed in the side wall of the ball blocking ring;
the limiting balls are symmetrically arranged in the shell and are clamped with the ball blocking grooves, the side ends of the limiting balls extend into the central holes of the ball blocking rings through the ball blocking grooves, and the limiting balls are connected with the limiting rods;
the push plate is connected to the inner wall of the shell in a sliding mode, and one side of the push plate is in contact with the limiting ball;
one end of the screw rod is rotatably connected to the other side of the push plate, the other end of the screw rod penetrates through the shell and the fixing plate to extend outwards, and the extending end of the screw rod is connected with a knob;
the fixing nut is fixedly connected to the side wall of the shell, and the screw is in threaded connection with the fixing nut;
the angle sensor is connected to the machine body and used for detecting the angle deviation between the upper die and the lower die, and the angle sensor is electrically connected with the controller.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a schematic diagram of the basic structure of a transformer according to the present invention;
FIG. 2 is a schematic diagram of a transformer stacking structure according to the present invention;
FIG. 3 is a schematic view of a substrate structure according to the present invention;
FIG. 4 is a schematic view showing the structure of the molding press of the present invention;
FIG. 5 is a schematic view of the structure of the feeding mechanism of the present invention;
FIG. 6 is a schematic view of the exhaust assembly of the present invention;
FIG. 7 is a schematic view of an exhaust pipe according to the present invention;
FIG. 8 is a schematic view of a calibration device according to the present invention;
FIG. 9 is a schematic view of a retaining ring structure according to the present invention.
In the figure: 1. a substrate; 2. a through hole; 4. a coil; 5. a transformer base layer; 6. a dielectric laminate; 7. a ferrite base layer plate; 8. a ferrite cover plate; 10. a calibration device; 21. an upper die; 22. a lower die; 80. a fixing plate; 81. a body; 82. a first lifting mechanism; 83. a second lifting mechanism; 84. a feeding mechanism; 85. a transverse plate; 86. a chute; 87. a rack; 88. a gear; 89. a motor; 810. a vertical plate; 811. a slider; 812. an electric push rod; 91. a limiting rod; 92. a limit nut; 93. a card slot; 94. a clamping block; 95. a first spring; 96. a gas-tight hole; 97. a pipe body; 98. a buffer tube; 99. a spherical plate; 910. an arc-shaped guide plate; 911. a baffle plate; 912. a housing; 913. a ball blocking ring; 914. a ball blocking groove; 915. a limiting ball; 916. pushing the plate; 917. a screw; 918. a knob; 919. and (5) fixing the nut.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Examples
The invention will be further described with reference to the accompanying drawings.
As shown in fig. 1 to 9, the method for manufacturing an LTCC planar transformer provided in this embodiment includes:
s1, selecting a substrate 1, and processing a through hole 2 on the substrate 1 through a punching machine;
s2, manufacturing a corresponding die according to the shape and the size of the coil 4, installing the die on a molding press, placing a layer of the substrate 1, pressing LTCC material on the substrate 1 through the molding press to form the coil 4, and forming the transformer base layer 5 by the substrate 1 and the coil 4;
s3, overlapping a layer of the substrate 1 on the pressed transformer base layer 5, repeating the pressing procedure of S2 to manufacture the coil 4, filling and pressing the LTCC material in the through hole 2 to form a next layer of the transformer base layer 5;
and S4, repeating the step S3 until the coil 4 with the preset number of layers is manufactured, and forming the LTCC planar transformer.
The working principle of the invention is as follows:
the invention provides a method for manufacturing an LTCC planar transformer, which comprises the steps of selecting a combined substrate 1 of a dielectric layer plate 6 and a ferrite base layer plate 7 according to the manufacturing requirements of a coil 4, processing a through hole 2 on the substrate 1, manufacturing a corresponding die according to the shape and the size of the coil 4, installing an upper die 21 on a die press, fixing a lower die 22 above the substrate 1, filling an LTCC material in the lower die 22, pressing the LTCC material on the substrate 1 through the upper die 21 to form the coil 4 to form a transformer base layer 5, then overlapping one layer of substrate 1 on the pressed transformer base layer 5, performing pressing operation again to form the next layer of transformer base layer 5, pressing the LTCC material in the through hole 2, connecting the coils 4 of the upper layer and the lower layer, repeating the pressing process, and completing the manufacturing after the coils 4 reach a preset number.
The invention has the beneficial effects that:
according to the manufacturing method of the LTCC planar transformer, the LTCC materials are pressed into the coils 4 on the substrate 1 in a mould pressing mode, the multilayer transformer base layers 5 can be stacked according to product requirements, the LTCC materials are filled in the through holes 2 to realize the electric connection of the coils 4 of each layer, the integration level of the transformer is improved, the leakage inductance is reduced, the reliability of the transformer is improved, the pressing mode is simple, the rejection rate is reduced, and the processing difficulty and the cost are reduced.
As shown in fig. 3, in one embodiment, the substrate 1 includes a dielectric layer plate 6 and a ferrite substrate plate 7, the dielectric layer plate 6 is embedded and connected in the ferrite substrate plate 7, the shape and size of the dielectric layer plate 6 are adapted to the shape and size of the coil 4, and the dielectric layer plate 6 is made of a low-permeability material.
The working principle and the beneficial effects of the technical scheme are as follows:
when the LTCC transformer is used, compared with a traditional planar transformer, the LTCC transformer is not provided with a closed iron core, the dielectric material is arranged on the ferrite base plate 7 through the ferrite base plate 7, the LTCC material is pressed on the ferrite base plate 7 to form a primary winding and a secondary winding of the coil 4, the initial voltage is converted into the required voltage after the coil 4 is electrified, the transformation function is realized, in addition, the dielectric layer plate 6 with low magnetic permeability is adopted to bear the coil 4, the isolation can be carried out between all rings of the coil 4, and the leakage inductance is reduced.
Through the structural design, the base plate 1 is combined and designed, and the dielectric layer plate 6 is embedded in the ferrite base layer plate 7, so that the base plate 1 has a low magnetic permeability in the installation area of the coil 4 while realizing a voltage transformation function, the interference between adjacent coils of the coil 4 is reduced, the leakage inductance is reduced, and the reliability of the transformer is improved.
As shown in fig. 2, in one embodiment, the upper and lower surfaces of the transformer base 5 are covered with ferrite covers 8, and the ferrite covers 8 and the transformer base 5 are sintered by hot pressing.
The working principle and the beneficial effects of the technical scheme are as follows:
the upper and lower surface of transformer basic unit 5 has covered ferrite apron 8 respectively, and ferrite apron 8 and ferrite basic unit 7 combined use replace the ferrite core that traditional transformer used, and 4 windings of coil constitute the magnetic circuit of transformer on ferrite apron 8 and ferrite basic unit 7 to realize the vary voltage function, cover ferrite apron 8 on transformer basic unit 5 upper and lower surface simultaneously, can protect coil 4, avoid coil 4 to produce the damage.
In one embodiment, the coil 4 is provided in any one of a circular shape and a rectangular shape.
The working principle and the beneficial effects of the technical scheme are as follows:
according to different use requirements, the coil 4 is set to be any one of a circular shape and a rectangular shape, the coil 4 is in a spiral winding form to form a coil 4 winding, current flows in the coil 4, different use requirements of the transformer are effectively met, the transformer can be made into any one of a circular shape and a rectangular shape, and the application range of the transformer is enlarged.
In one embodiment, the LTCC material in the via 2 is connected to the LTCC material in the same layer of the coil 4 and an adjacent layer of the coil 4.
The working principle and the beneficial effects of the technical scheme are as follows:
through-hole 2 wears to establish base plate 1 setting, and suppress after filling the LTCC material in through-hole 2, the LTCC material in through-hole 2 is connected with the LTCC material in same layer coil 4 and adjacent layer coil 4, thereby realize the electricity connection of adjacent layer coil 4, guarantee that electric current can pass through the elementary and secondary winding of coil 4 smoothly, need not extra wire and connect, reduce the even electric phenomenon that uses the wire to produce, the integrated level of transformer has been improved, the wire risk of droing has been avoided, the leakage inductance has been reduced, make the reliability of transformer higher.
As shown in fig. 4, in one embodiment, the mold comprises: the coil forming device comprises an upper die 21 and a lower die 22 which are matched with each other, wherein the upper die 21 is set as a male die, the lower die 22 is set as a female die, the upper die 21 and the lower die 22 are surrounded to form a die pressing space, and the shape and the size of the die pressing space are consistent with those of the coil 4.
The working principle and the beneficial effects of the technical scheme are as follows:
the mould comprises last mould 21 and lower mould 22 of accurate complex, and during the mould used, with lower mould 22 fixed connection on base plate 1, evenly fill the LTCC material in the recess of lower mould 22, the recess spiral form of lower mould 22 is the same with the spiral form of coil 4, then will go up mould 21 through the moulding press and fall down to the recess of lower mould 22 in, exert pressure to the LTCC material, with forming coil 4 on the LTCC material suppression base plate 1. Through the accurate cooperation of last mould 21 and lower mould 22, realize the even suppression of coil 4 fast, avoid the LTCC material to spill, make coil 4 can satisfy the use intensity requirement, compare in coil 4 that screen printing and coating process formed, need not the binder, reduced manufacturing cost, realize the shaping of coil 4 through the suppression, connect more closely between the LTCC material granule, the homogeneity is better, and electric conductivity is superior.
As shown in fig. 4, in one embodiment, the LTCC material is pressed into the coil 4 using a press comprising:
a body 81;
the first lifting mechanism 82 is installed at the top end of the machine body 81, the bottom end of the first lifting mechanism 82 is connected with a fixing plate 80, and the fixing plate 80 is connected with the upper die 21;
the second lifting mechanism 83 is installed on the table top of the machine body 81, the top end of the second lifting mechanism 83 is connected with the lower die 22, and the substrate 1 is placed on the table top below the lower die 22;
a third lifting mechanism, which is mounted at the side end of the machine body 81;
a feeding mechanism 84, wherein the feeding mechanism 84 is connected with a third lifting mechanism, and the feeding mechanism 84 is arranged at the rear side of the machine body 81;
and a controller electrically connected to the first lifting mechanism 82, the second lifting mechanism 83, the third lifting mechanism, and the feed mechanism 84.
The working principle and the beneficial effects of the technical scheme are as follows:
a first lifting mechanism 82, a second lifting mechanism 83, a third lifting mechanism and a feeding mechanism 84 are arranged on the die press, the first lifting mechanism 82 is connected with the upper die 21, the height of the upper die 21 is adjusted through the first lifting mechanism 82, and the upper die 21 is driven to be pressed downwards; the second lifting mechanism 83 is connected with the lower die 22, the height of the lower die 22 is adjusted through the second lifting mechanism 83, the lower die 22 can use the layer number of the lower transformer base layer 5, and the lower die 22 is tightly attached to the surface of the substrate 1 during pressing operation, so that the LTCC material is prevented from leaking out of the lower die 22; connecting the third lifting mechanism with the feeding mechanism 84, and adjusting the height of the feeding mechanism 84 to enable the feeding mechanism 84 to adapt to the height of the lower die 22 for adjustment; the LTCC material can be filled in the lower mold 22 by the feed mechanism 84. Through the design of film pressing machine, can carry out the pressfitting with last mould 21 and lower mould 22, suppress the LTCC material fast and form coil 4 on base plate 1, effectively adapt to the coil 4 of the different number of piles, device control is simple, need not to frequently dismantle the mould, and the operation of being convenient for has reduced manufacturing cost, has improved the yield of transformer.
As shown in fig. 5, in one embodiment, the feed mechanism 84 includes:
the transverse plate 85, the transverse plate 85 is connected to the output end of the third lifting mechanism;
the sliding groove 86 is horizontally arranged in the transverse plate 85;
the rack 87 is fixedly connected to the top end of the transverse plate 85;
a gear 88, wherein the gear 88 is connected above the rack 87 in a meshing manner;
the output end of the motor 89 is connected to the center of the gear 88 through a rotating shaft, and the motor is electrically connected with the controller;
the vertical plate 810 is fixedly connected to the bottom end of the motor 89, and the vertical plate 810 vertically penetrates through the transverse plate 85 and extends downwards;
the sliding block 811 is fixedly connected to the side end of the vertical plate 810, and the sliding block 811 is slidably connected in the sliding groove 86;
the electric push rod 812 is connected to the bottom end of the vertical plate 810, one side of the electric push rod 812, which is close to the lower die 22, is connected with a feeder, the feed end of the feeder is communicated with a storage bin through a feed pipe, and the electric push rod 812 is electrically connected with a controller.
The working principle and the beneficial effects of the technical scheme are as follows:
when feed mechanism 84 used, starter motor 89, motor 89 drives gear 88 and rotates, through the meshing transmission of gear 88 and rack 87, drive motor 89 and remove along the horizontal direction, motor 89 is connected with slider 811 through riser 810, slider 811 slides along spout 86 horizontal slip, lead to riser 810, thereby realize the removal of feeder in the horizontal direction, start electric putter 812, drive the feeder through electric putter 812, make the feeder be close to and keep away from lower mould 22 according to the material loading needs. Through above-mentioned structural design, through the drive of motor 89 and electric putter 812, realize the regulation of feeder position in the horizontal plane, make the discharge gate of feeder can adapt to the extending direction of lower mould 22 recess, with the even packing of LTCC material in lower mould 22, avoid producing the circumstances that local material is piled up, can continuously carry out the material loading according to predetermineeing the route, the control of being convenient for has improved the material loading stability of device.
As shown in fig. 6 and 7, in one embodiment, the die press further comprises a vent assembly comprising:
the limiting rod 91 is fixedly connected to the top end of the upper die 21, the limiting rod 91 penetrates through the fixing plate 80 to vertically extend upwards, and a plurality of threads are uniformly arranged on the limiting rod 91;
the limiting nut 92 is arranged on the upper surface of the fixing plate 80, and the limiting nut 92 is in threaded connection with the limiting rod 91;
the clamping groove 93 is formed in the bottom end of the fixing plate 80;
the fixture block 94 is fixedly connected to the top end of the upper die 21, and the fixture block 94 is clamped and connected in the clamping groove 93;
the first spring 95 is connected between the clamping groove 93 and the top end of the clamping block 94 in an abutting mode;
the airtight holes 96 are uniformly formed in the bottom end of the upper die 21, the top ends of the airtight holes 96 penetrate through the upper die 21 and are communicated with the clamping grooves 93, and the aperture of each airtight hole 96 is smaller than the diameter of LTCC material particles;
blast pipe, a plurality of blast pipe evenly connect in the fixed plate 80 top, blast pipe and draw-in groove 93 top intercommunication, the blast pipe includes:
the tube bodies 97 are uniformly connected to the top end of the fixing plate 80, the bottom ends of the tube bodies 97 are communicated with the clamping grooves 93 through air inlet holes, and the top ends of the tube bodies 97 are provided with air outlet holes;
a buffer tube 98, wherein the buffer tube 98 is connected inside the tube body 97, the buffer tube 98 is arranged in a spiral shape, and two ends of the buffer tube 98 are respectively connected with an air inlet hole and an air outlet hole of the tube body 97;
the spherical plate 99, the spherical plate 99 is communicated with the top end of the pipe body 97, and a plurality of air holes are uniformly formed on the spherical plate 99;
the arc-shaped guide plates 910 are concavely arranged, and the two arc-shaped guide plates 910 are symmetrically connected to two ends of the spherical plate 99;
a baffle 911, wherein the baffle 911 is fixedly connected to the top end of the spherical plate 99, and the baffle 911 is arranged above the arc-shaped guide plate 910.
The working principle and the beneficial effects of the technical scheme are as follows:
when going up mould 21 and lower mould 22 and carrying out the pressfitting, go up the recess precision fit of mould 21 and lower mould 22 and consolidate the LTCC material, at the pressfitting in-process, there is the air between mould 21 and the lower mould 22, need in time discharge the air and just can suppress smoothly, consequently set up the exhaust subassembly on the moulding press. When the exhaust assembly is used, when the upper die 21 is connected with the fixed plate 80, the limiting rod 91 extends into the fixed plate 80, then the limiting nut 92 is rotated to tightly press the limiting nut 92 and the upper part of the fixed plate 80, and therefore the upper die 21 and the fixed plate 80 are fixed; during the exhaust operation, as the fixing plate 80 is pushed downwards by the first lifting mechanism 82, the upper die 21 enters the groove of the lower die 22, air between the upper die 21 and the lower die 22 enters the airtight hole 96 of the upper die 21, because the aperture of the airtight hole 96 is smaller than the diameter of LTCC material particles, the LTCC material can be prevented from entering the airtight hole 96, then the air enters the clamping groove 93 between the fixing plate 80 and the upper die 21 through the airtight hole 96, the air enters the buffer tube 98 through the air inlet hole of the tube body 97 through the clamping groove 93, the buffer tube 98 buffers the air, then the air enters the spherical plate 99 through the air outlet hole of the tube body 97, the air diffuses outwards from the air holes of the spherical plate 99, and then the air flows out of the fixing plate 80 from two sides of the spherical plate 99 under the combined action of the arc-shaped guide plate 910 and the baffle 911. During the pressing operation, the first spring 95 damps and cushions the upper die 21, thereby reducing the impact on the fixing plate 80 during the pressing operation.
Through the structural design, the exhaust assembly is arranged on the die press, so that when the upper die 21 and the fixing plate 80 are stably connected, the air between the upper die 21 and the lower die 22 can be discharged, the influence on the pressing operation is avoided, the phenomenon that the LTCC material particles are loose due to the fact that the air is accumulated in the die is prevented, the pressing forming quality is improved, when the air is discharged through the exhaust assembly, under the combined action of the buffer tube 98, the arc-shaped guide plate 910 and the baffle 911, the air discharge speed can be effectively delayed, the stability of air discharge is improved, and when air is prevented from being rapidly discharged from the airtight hole 96, the material depression phenomenon caused by higher air pressure at the part where the air is not contacted with the airtight hole 96 is caused, the flatness of the material is improved, the uniformity of the distribution of the coil 4 material is further improved, and compared with the existing pressing method, the performance of the planar transformer is optimized, and the yield of the transformer is improved.
As shown in fig. 8 and 9, in an embodiment, a calibration device 10 is disposed in the fixing plate 80, the limiting rod 91 is disposed through the calibration device 10, and the calibration device 10 includes:
the shell 912 is fixedly connected to the inside of the fixing plate 80, and the limiting rod 91 penetrates through a central hole of the shell 912;
the ball blocking ring 913 is fixedly connected to the inner wall of the central hole of the housing 912, the limiting rod 91 penetrates through the central hole of the ball blocking ring 913, and a plurality of ball blocking grooves 914 are symmetrically formed in the side wall of the ball blocking ring 913;
a plurality of limiting balls 915 which are symmetrically arranged in the housing 912, wherein the limiting balls 915 are clamped with the ball blocking grooves 914, the side ends of the limiting balls 915 extend into the central holes of the ball blocking rings 913 through the ball blocking grooves 914, and the limiting balls 915 are connected with the limiting rod 91;
the push plate 916, the push plate 916 is slidably connected to the inner wall of the housing 912, and one side of the push plate 916 is in contact with the limiting ball 915;
one end of the screw 917 is rotatably connected to the other side of the push plate 916, the other end of the screw 917 penetrates through the housing 912 and the fixing plate 80 to extend outwards, and the extending end of the screw 917 is connected with a knob 918;
the fixing nut 919 is fixedly connected to the side wall of the shell 912, and the screw 917 is in threaded connection with the fixing nut 919;
and the angle sensor is connected to the machine body 81 and used for detecting the angle deviation between the upper die 21 and the lower die 22, and the angle sensor is electrically connected with the controller.
The working principle and the beneficial effects of the technical scheme are as follows:
after the upper die 21 and the lower die 22 are installed, a small angular deviation is generated, which affects the press fit of the upper die 21 and the lower die 22, therefore, a calibration device 10 is arranged in the fixing plate 80, after the upper die 21 and the lower die 22 are installed, the angular deviation between the upper die 21 and the lower die 22 is detected by an angle sensor, and the detected data is transmitted to a controller, the deviation data is displayed to a worker, the worker adjusts the calibration device 10 according to the measured value, when the calibration device 10 is used, in an initial state, the knob 918 is far away from the shell, the push plate 916 is far away from the ball blocking ring 913, so that a gap exists between the limiting ball 915 and the ball blocking ring 913, the limit rod 91 can freely slide in the central hole of the ball blocking ring 913, when the top end of the limit rod 91 is fixed, the knob 918 is rotated, the knob 918 drives the screw rod 917 to rotate, the push plate 916 to move towards the direction of the limit rod 91, and press the limit ball 915 to be tightly clamped with the ball blocking groove 914 on the ball blocking ring 913, make spacing ball 915 and gag lever post 91 contact, lock gag lever post 91, when angular deviation exceeded preset range, the staff rotated different angles to the knob 918 of casing 912 both sides, made the removal distance adaptation adjustment of push pedal 916, under spacing ball 915's conflict effect, finely tuned gag lever post 91 angle to finely tune the angle of going up mould 21, satisfied processing condition until going up the angular deviation between mould 21 and the lower mould 22.
Through the structure design, set up calibrating device 10 in fixed plate 80, carry out real-time detection through angle sensor to the angle deviation between last mould 21 after the installation and the lower mould 22, the staff adjusts calibrating device 10 according to the testing result, press from both sides the gag lever post 91 through spacing ball 915 and press from both sides tightly, it takes place to shift to avoid going up mould 21 in the use, the steadiness of going up mould 21 has been improved, and adjust through the difference of gag lever post 91 both sides spacing ball 915, the realization is to the fine setting of last mould 21 installation angle, make the adaptability between last mould 21 and the lower mould 22 better, reduce the unable pressfitting of mould or the great condition of pressfitting process friction because of the angle deviation produces, thereby improve the reliability of transformer manufacture process, reduce the wearing and tearing of mould, and reduce production cost.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications therefrom are within the scope of the invention.
Claims (10)
1. A manufacturing method of an LTCC planar transformer is characterized by comprising the following steps:
s1, selecting a substrate (1), and processing a through hole (2) on the substrate (1) through a punching machine;
s2, manufacturing a corresponding die according to the shape and the size of the coil (4), installing the die on a molding press, placing a layer of the substrate (1), pressing LTCC materials on the substrate (1) through the molding press to form the coil (4), and forming the transformer base layer (5) by the substrate (1) and the coil (4);
s3, overlapping a layer of the substrate (1) on the pressed transformer base layer (5), repeating the pressing procedure of S2 to manufacture the coil (4), and filling and pressing the LTCC material in the through hole (2) to form the next layer of the transformer base layer (5);
and S4, repeating the step S3 until the coils (4) with the preset number of layers are manufactured, and forming the LTCC planar transformer.
2. The method for manufacturing the LTCC planar transformer according to claim 1, wherein the substrate (1) comprises a dielectric layer plate (6) and a ferrite base layer plate (7), the dielectric layer plate (6) is connected in the ferrite base layer plate (7) in an embedded mode, the shape and the size of the dielectric layer plate (6) are matched with the shape and the size of the coil (4), and the dielectric layer plate (6) is made of low-permeability materials.
3. The method for manufacturing the LTCC planar transformer according to claim 1, wherein the upper and lower surfaces of the plurality of transformer base layers (5) are covered with ferrite cover plates (8), and the ferrite cover plates (8) and the transformer base layers (5) are sintered by hot pressing.
4. A method of making an LTCC planar transformer as claimed in claim 1, wherein said coil (4) is arranged in any one of a circular and rectangular configuration.
5. A method of making an LTCC planar transformer as claimed in claim 1 wherein LTCC material in said through hole (2) is connected to LTCC material in the same layer of said coil (4) and adjacent layers of said coil (4).
6. The method of claim 1, wherein the mold comprises: the coil forming die comprises an upper die (21) and a lower die (22) which are matched with each other, wherein the upper die (21) is arranged into a male die, the lower die (22) is arranged into a female die, the upper die (21) and the lower die (22) are arranged in a surrounding mode to form a die pressing space, and the shape and the size of the die pressing space are consistent with those of the coil (4).
7. A method of manufacturing an LTCC planar transformer according to claim 6, wherein LTCC material is pressed into said coil (4) using a press comprising:
a body (81);
the first lifting mechanism (82) is installed at the top end of the machine body (81), the bottom end of the first lifting mechanism (82) is connected with a fixing plate (80), and the fixing plate (80) is connected with the upper die (21);
the second lifting mechanism (83) is installed on the table top of the machine body (81), the top end of the second lifting mechanism (83) is connected with the lower die (22), and the substrate (1) is placed on the table top below the lower die (22);
the third lifting mechanism is arranged at the side end of the machine body (81);
the feeding mechanism (84) is connected with the third lifting mechanism, and the feeding mechanism (84) is arranged on the rear side of the machine body (81);
the controller is electrically connected with the first lifting mechanism (82), the second lifting mechanism (83), the third lifting mechanism and the feeding mechanism (84).
8. The method for manufacturing an LTCC planar transformer, as claimed in claim 7, wherein said feeding mechanism (84) comprises:
the transverse plate (85), the transverse plate (85) is connected to the output end of the third lifting mechanism;
the sliding chute (86), the said sliding chute (86) is opened in the said horizontal plate (85) horizontally;
the rack (87), the rack (87) is fixedly connected to the top end of the transverse plate (85);
a gear (88), wherein the gear (88) is connected above the rack (87) in a meshed manner;
the output end of the motor (89) is connected to the center of the gear (88) through a rotating shaft, and the motor is electrically connected with the controller;
the vertical plate (810) is fixedly connected to the bottom end of the motor (89), and the vertical plate (810) vertically penetrates through the transverse plate (85) to extend downwards;
the sliding block (811) is fixedly connected to the side end of the vertical plate (810), and the sliding block (811) is slidably connected into the sliding groove (86);
electric putter (812), electric putter (812) connect in riser (810) bottom, one side that electric putter (812) are close to lower mould (22) is connected with the feeder, the feeder feed end passes through inlet pipe and storage vat intercommunication, electric putter (812) are connected with the controller electricity.
9. The method of claim 7, wherein the molding press further comprises a vent assembly, the vent assembly comprising:
the limiting rod (91) is fixedly connected to the top end of the upper die (21), the limiting rod (91) penetrates through the fixing plate (80) to vertically extend upwards, and a plurality of threads are uniformly arranged on the limiting rod (91);
the limiting nut (92), the limiting nut (92) is arranged on the upper surface of the fixing plate (80), and the limiting nut (92) is in threaded connection with the limiting rod (91);
the clamping groove (93), the clamping groove (93) is arranged at the bottom end of the fixing plate (80);
the fixture block (94), the fixture block (94) is fixedly connected to the top end of the upper die (21), and the fixture block (94) is clamped and connected in the clamping groove (93);
the first spring (95) is connected between the clamping groove (93) and the top end of the clamping block (94) in an abutting mode;
the air-tight holes (96) are uniformly formed in the bottom end of the upper die (21), the top ends of the air-tight holes (96) penetrate through the upper die (21) and are communicated with the clamping groove (93), and the aperture of each air-tight hole (96) is smaller than the diameter of LTCC material particles;
blast pipe, a plurality of blast pipe evenly connect in fixed plate (80) top, blast pipe and draw-in groove (93) top intercommunication, the blast pipe includes:
the tube bodies (97) are uniformly connected to the top end of the fixing plate (80), the bottom ends of the tube bodies (97) are communicated with the clamping grooves (93) through air inlet holes, and air outlet holes are formed in the top ends of the tube bodies (97);
the buffer tube (98) is connected to the inside of the tube body (97), the buffer tube (98) is arranged in a spiral shape, and two ends of the buffer tube (98) are respectively connected with an air inlet hole and an air outlet hole of the tube body (97);
the spherical plate (99), the spherical plate (99) is communicated with the top end of the pipe body (97), and a plurality of air holes are uniformly formed in the spherical plate (99);
the arc-shaped guide plates (910) are arranged in a concave manner, and the two arc-shaped guide plates (910) are symmetrically connected to two ends of the spherical plate (99);
a baffle plate (911), wherein the baffle plate (911) is fixedly connected to the top end of the spherical plate (99), and the baffle plate (911) is arranged above the arc-shaped guide plate (910).
10. The method for manufacturing an LTCC planar transformer according to claim 9, wherein the fixing plate (80) is internally provided with a calibration device (10), the limiting rod (91) is disposed through the calibration device (10), and the calibration device (10) comprises:
the shell (912), the shell (912) is fixedly connected inside the fixing plate (80), and the limiting rod (91) penetrates through a central hole of the shell (912);
the ball blocking ring (913) is fixedly connected to the inner wall of the central hole of the shell (912), the limiting rod (91) penetrates through the central hole of the ball blocking ring (913), and a plurality of ball blocking grooves (914) are symmetrically formed in the side wall of the ball blocking ring (913);
the limiting balls (915), a plurality of the limiting balls (915) are symmetrically arranged in the shell (912), the limiting balls (915) are clamped with the ball blocking grooves (914), the side ends of the limiting balls (915) extend into the central holes of the ball blocking rings (913) through the ball blocking grooves (914), and the limiting balls (915) are connected with the limiting rod (91);
the push plate (916), the push plate (916) is connected to the inner wall of the shell (912) in a sliding mode, and one side of the push plate (916) is in contact with the limiting ball (915);
one end of the screw rod (917) is rotatably connected to the other side of the push plate (916), the other end of the screw rod (917) penetrates through the shell (912) and the fixing plate (80) to extend outwards, and the extending end of the screw rod (917) is connected with a knob (918);
the fixing nut (919), the fixing nut (919) is fixedly connected to the side wall of the shell (912), and the screw rod (917) is in threaded connection with the fixing nut (919);
the angle sensor is connected to the machine body (81) and used for detecting the angle deviation between the upper die (21) and the lower die (22), and the angle sensor is electrically connected with the controller.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114743787A (en) * | 2022-03-29 | 2022-07-12 | 中国电子科技集团公司第四十三研究所 | Manufacturing method of detachable LTCC planar transformer |
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