A filter and a method of forming the same

Abstract

The application discloses a filter and a forming method thereof, and comprises the following steps: preparing four copper bars, three of which are lower copper bars and one of which is an upper copper bar, and the two ends of the four copper bars are provided with terminals; firstly, three lower copper bars are embedded, the three lower copper bars are arranged according to a preset sequence, and then first injection molding is carried out, so that the three lower copper bars are fixed tightly, plastic cover plates for fixing are formed between the three lower copper bars, groove positions for placing the upper copper bar are formed on the plastic cover plates, and positioning protrusions are formed on the plastic cover plates; the upper copper bar is placed between two lower copper bars, the upper copper bar is clamped in the groove position of the plastic cover plate, and then second injection molding is carried out, so that a shell is formed, the four copper bars are accommodated in the shell, through holes are formed on the shell, and the positioning protrusions are embedded in the through holes. The application improves the forming quality, the structure is more reliable, and the yield is improved.

Description

Technical Field

[0001] This invention relates to the technical field of filters, specifically a filter and its molding method. Background Technology

[0002] Filters are widely used devices that remove signal interference in various types of electrical equipment. Some filters include metal busbars to facilitate the conduction of electrical signals.

[0003] Current filters are often manufactured using injection molding. Because filters consist of upper and lower copper busbars that need to be assembled overlappingly, they cannot be formed in a single process. Furthermore, the thinness of the material during the first and second injection molding stages can easily lead to material shortages. After molding, the filter housing surface can easily develop undercut structures at the terminal locations, increasing the difficulty of subsequent assembly. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a filter and its molding method.

[0005] A method for molding a filter, the method comprising the following steps: Prepare four copper busbars, three of which are lower copper busbars and one is upper copper busbar. Terminals are provided at both ends of the four copper busbars. First, three lower copper busbars are embedded. The three lower copper busbars are arranged in a preset order. Then, the first injection molding is performed to fix the three lower copper busbars. A plastic cover plate for fixing is formed between the three lower copper busbars. A groove for placing the upper copper busbar is formed on the plastic cover plate. A positioning protrusion is formed on the plastic cover plate. The upper copper busbar is placed between two of the lower copper busbars, and the upper copper busbar is fitted into the groove of the plastic cover plate. Then, a second injection molding is performed to form a shell that accommodates all four copper busbars. The shell has through holes, and positioning protrusions are embedded in the through holes.

[0006] As a further improvement, during the first injection molding, at least three plastic cover plates are formed, which are located in different areas of the three lower copper busbars and connect and secure the three lower copper busbars in the radial direction.

[0007] As a further improvement, the sidewall of the plastic cover is formed with a radially protruding support wall, through which a tight connection is formed with the housing during the second injection molding.

[0008] As a further improvement, the three lower copper busbars are formed inside the plastic cover plate, and the slots are formed on the upper part of the plastic cover plate and exposed to the outside, so that the upper copper busbars are embedded in the upper part of the plastic cover plate and then contained inside by the second injection-molded shell.

[0009] As a further improvement, the first injection-molded plastic cover plate incorporates three lower copper busbars, which are spaced apart, with a thickness of 1-2 mm between the lower copper busbars and the surface of the plastic cover plate. After the second injection molding, the thickness of the upper copper busbars between them and the surface of the plastic cover plate is 1-2 mm.

[0010] As a further improvement, the lower copper busbar is provided with a positioning notch and a positioning hole. During the second injection molding, a positioning block is formed in the positioning notch and a positioning post is formed in the positioning hole, so that the housing and the lower copper busbar are tightly assembled.

[0011] As a further improvement, during the second injection molding, a plurality of inwardly protruding top posts are formed on the shell, which abut against the lower copper busbar and the upper copper busbar.

[0012] As a further improvement, the housing is formed with terminal holes for assembling terminals, and a recessed adhesive position is provided on one side of the terminal hole, in which the lower copper busbar and the upper copper busbar are embedded for connection with the terminal.

[0013] As a further improvement, the housing is filled with adhesive at the position corresponding to the plastic cover to cover the plastic cover.

[0014] A filter includes a housing, three lower copper busbars and one upper copper busbar. The three lower copper busbars are connected by a plastic cover plate, which has slots on which the upper copper busbar is laid. The three lower copper busbars and the upper copper busbar are all installed inside the housing. The plastic cover plate has positioning protrusions, and the housing has through holes. The positioning protrusions are embedded in the through holes. The lower copper busbars have positioning notches and positioning holes. The housing has positioning blocks and positioning pins. The positioning blocks are installed in the positioning notches, and the positioning pins are inserted into the positioning holes.

[0015] Compared with the prior art, the present invention has the following beneficial technical effects: The process involves two injection molding processes, one for the upper copper busbar and one for the lower copper busbar. The lower copper busbar is first formed and then the upper copper busbar is formed, thus ensuring a stable assembly of the upper and lower copper busbars. By setting positioning notches and positioning holes on the lower copper busbar and matching them with the corresponding positions on the housing, the positioning accuracy is ensured, and the problem of displacement is prevented during the processing and forming process. Thickening the plastic cover plate can prevent the problem of insufficient material during injection. The connection between the copper busbar and the terminal, i.e. the bend, is embedded in the plastic part to avoid exposure and facilitate the sealing process. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the three-dimensional structure of the present invention after molding; Figure 2 This is a schematic diagram of the first injection molding state of the present invention; Figure 3 This is a schematic diagram of the assembly process before the second injection molding of the present invention; Figure 4 This is a three-dimensional structural diagram of the present invention from another perspective after molding; Figure 5 for Figure 4 Enlarged diagram of point A in the middle.

[0017] Figure label: 1. Housing; 2. Lower copper busbar; 21. First lower copper busbar; 22. Second lower copper busbar; 23. Third lower copper busbar; 3. Upper copper busbar; 4. Plastic cover plate; 5. Positioning protrusion; 6. Slot; 7. Terminal; 8. Bending part; 9. Positioning notch; 10. Positioning hole; 11. Supporting rubber wall; 12. Through hole. Detailed Implementation

[0018] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0019] In the description of this invention, it should be understood that if terms such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, they are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0020] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. They can refer to a mechanical connection or an electrical connection. They can refer to a direct connection or an indirect connection through an intermediate medium, and they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0021] Example 1 like Figure 1-4 As shown, a method for molding a filter includes the following steps: Prepare four copper busbars, three of which are lower copper busbars 2 and one is an upper copper busbar 3. Each end of the four copper busbars is equipped with a terminal 7. For ease of description, the three lower copper busbars can be defined from left to right as the first lower copper busbar 21, the second lower copper busbar 22, and the third lower copper busbar 23. The lower copper busbars 2 and the upper copper busbar 3 have bends 8 at the connection points with the terminals 7.

[0022] First, three lower copper busbars 2 are embedded and arranged in a preset order. Then, the first injection molding is performed to secure the three lower copper busbars 2. A plastic cover plate 4 is formed between the three lower copper busbars 2 for securing them. The three lower copper busbars 2 are assembled together through the plastic cover plate 4. The three lower copper busbars 2 are arranged at intervals to form a structure in which the lower copper busbars 2 pass through the middle of the plastic cover plate 4. The plastic cover plate has grooves for placing the upper copper busbars and positioning protrusions. These positioning protrusions help with positioning during the molding process.

[0023] The upper copper busbar 3 is placed between two of the lower copper busbars, namely between the second lower copper busbar 22 and the third lower copper busbar 23, and the upper copper busbar 3 is fitted into the groove 6 of the plastic cover plate 4. Then, a second injection molding is performed to form a shell, which covers the groove 6 of the plastic cover plate 4, so that the upper copper busbar 3 is also formed inside the plastic cover plate 4. Thus, the plastic cover plate accommodates all four copper busbars. The shell has through holes formed, and positioning protrusions are embedded in the through holes. Through the first and second injection molding, the three lower copper busbars and one upper copper busbar are fastened in the plastic cover plate. The plastic cover plate is block-shaped and located in local positions of the lower and upper copper busbars. By setting multiple plastic cover plates, the stable forming of longer lower and upper copper busbars can be achieved. During the first injection molding, at least three plastic cover plates are formed. These at least three plastic cover plates are located in different areas of the three lower copper busbars, connecting and fastening the three lower copper busbars radially.

[0024] By using two injection molding processes, the four copper busbars are divided into three lower copper busbars and one upper copper busbar, which ensures the stable assembly of the four copper busbars.

[0025] Example 2 refer to Figure 1-5 As shown, during the first injection molding, multiple plastic cover plates 4 are formed at various positions on the three lower copper busbars 2. The shapes of the plastic cover plates formed at different positions will vary because the thickness and size of the plastic cover plates are formed according to the curvature of the lower copper busbars to ensure that the three lower copper busbars 2 can be fixed at the same time. At the same time, grooves 6 for placing the upper copper busbars 3 are formed on the plastic cover plates 4. When there are multiple plastic cover plates, the grooves on the multiple plastic cover plates are connected to ensure the accurate and smooth placement of the upper copper busbars 3. The side wall of the plastic cover plate 4 is formed with a radially protruding support wall 11. Through this support wall 11, a tight connection is formed with the shell during the second injection molding. The support wall is located on the side wall of the plastic cover plate, while the positioning protrusion is positioned in the vertical direction, and the support wall is supported in the radial direction, forming a relatively strong assembly structure.

[0026] The first injection-molded plastic cover plate incorporates three lower copper busbars, which are spaced apart. The distance between the lower copper busbars and the surface of the plastic cover plate is 1-2 mm. After the second injection molding, the distance between the upper copper busbars and the surface of the plastic cover plate is 1-2 mm. This thickness helps to avoid the problem of insufficient material during injection.

[0027] The lower copper busbar 2 is provided with a positioning notch 9 and a positioning hole 10. During the second injection molding, a positioning block is formed in the positioning notch 9 and a positioning post is formed in the positioning hole 10, so that the shell and the lower copper busbar are tightly assembled, further improving the positioning performance.

[0028] During the second injection molding process, several inwardly protruding top posts are formed on the shell. These top posts abut against the lower and upper copper busbars, preventing them from moving vertically or horizontally and ensuring accurate positioning.

[0029] The housing 1 has terminal holes for assembling terminals 7. One side of the terminal hole has a recessed adhesive position. The lower copper busbar and the upper copper busbar are connected to the terminal, i.e., the bent part 8 is embedded in the recessed adhesive position, which is beneficial for subsequent sealing treatment.

[0030] In addition, the housing is filled with adhesive at the positions corresponding to the plastic cover to cover the plastic cover. This is mainly for some deeper grooves on the housing, filling and sealing the grooves with adhesive. In thinner areas of the housing, the adhesive filling can be appropriately thickened, that is, the overall thickness is increased by filling with adhesive material.

[0031] Example 3 In addition to the configuration of three lower copper busbars and one upper copper busbar mentioned in Example 1, three lower copper busbars and two upper copper busbars can also be configured for other usage requirements. In this case, the specific implementation steps are as follows: Prepare five copper busbars, three of which are lower busbars and two are upper busbars. Each end of the five busbars has a terminal. For ease of description, the three lower busbars can be designated from left to right as the first lower busbar, the second lower busbar, and the third lower busbar. The lower and upper busbars have bends at their connections to the terminals.

[0032] First, three lower copper busbars are embedded and arranged in a preset order. Then, the first injection molding is performed to secure the three lower copper busbars. A plastic cover plate is formed between the three lower copper busbars for securing them. The three lower copper busbars are assembled together through the plastic cover plate. The three lower copper busbars are arranged at intervals to form a structure in which the lower copper busbars pass through the middle of the plastic cover plate. The plastic cover plate has grooves for placing the upper copper busbars and positioning protrusions. These positioning protrusions help with positioning during the molding process.

[0033] Because the three lower copper busbars are spaced apart, two interval areas are formed. Two slots are formed on the plastic cover plate corresponding to these interval areas, and an interval is also formed between the two slots.

[0034] Two upper copper busbars are placed in two slots, with one upper copper busbar corresponding to each of the first and second lower copper busbars, and another upper copper busbar corresponding to each of the second and third lower copper busbars. A second injection molding process is then performed to form the housing, simultaneously covering the slots of the plastic cover plate. This allows the upper copper busbar 3 to also be molded within the plastic cover plate, thus accommodating all five copper busbars. The housing has through holes, and positioning protrusions are embedded in these holes. Through the first and second injection molding processes, the three lower copper busbars and two upper copper busbars are securely fixed within the plastic cover plate, forming a stable assembly and ensuring that the copper busbars do not easily loosen during use, thereby improving product quality.

[0035] Example 4 refer to Figure 1 , 4As shown in Figure 5, a filter includes a housing 1, three lower copper busbars 2, and one upper copper busbar 3. For ease of description, the three lower copper busbars can be defined from left to right as the first lower copper busbar 21, the second lower copper busbar 22, and the third lower copper busbar 23. Terminals 7 are connected to both the lower and upper copper busbars. Bending portions 8 are formed at the connections between the lower and upper copper busbars 2 and the terminals. The three lower copper busbars 2 have a certain length and form curved transitions at some points in the middle. They are connected by a plastic cover plate 4, which has grooves 6 on which the upper copper busbar 3 is laid. The three lower copper busbars 2 and the upper copper busbar 3 are all installed inside the housing 1. Positioning protrusions 5 are provided on the plastic cover plate 4. Through holes 12 are provided on the housing 1, and the positioning protrusions 5 are embedded in the through holes 12. Positioning notches 9 and positioning holes 10 are provided on the lower copper busbars 2. Positioning blocks and positioning pins are provided inside the housing 1. The positioning blocks are installed in the positioning notches, and the positioning pins are inserted into the positioning holes. The positioning protrusions can be round and inserted into the through holes of the housing. They can be observed from the outside of the housing and do not require a cover. The plastic cover does not need to completely cover the lower copper busbar. Instead, multiple plastic cover plates can be set at different positions on the lower copper busbar. The lower copper busbar is embedded in the lower surface of the plastic cover plate and is enclosed inside. The upper copper busbar is assembled on the upper surface of the plastic cover plate and encapsulated through secondary injection molding.

[0036] In other words, the lower copper busbar is encapsulated and formed first, and then the upper copper busbar is encapsulated and formed. The distinction between the lower and upper copper busbars is that the one installed on the lower part of the plastic cover is the lower copper busbar, and the one installed on the upper part of the plastic cover is the upper copper busbar. Furthermore, the copper busbars are spaced apart and will not interfere with each other.

[0037] To ensure assembly stability, positioning notches and vertical positioning holes are provided on the side wall of the first lower copper busbar, and corresponding positioning blocks and positioning posts are set on the housing to achieve corresponding matching installation.

[0038] Furthermore, to prevent the lower and upper copper busbars from shifting to one side of the shell surface during the forming process, some top pillars can be installed inside the shell to support the lower and upper copper busbars.

[0039] In addition, for some thinner areas on the housing, an additional adhesive layer can be added to increase its thickness. Multiple positioning notches and holes can be provided to achieve positioning at different locations.

[0040] It should be noted that the above description is not intended to limit the present invention. Any obvious substitutions without departing from the inventive concept of the present invention are within the protection scope of the present invention.

Claims

1. A method for molding a filter, characterized in that, The method includes the following steps: Prepare four copper busbars, three of which are lower copper busbars and one is upper copper busbar. Terminals are provided at both ends of the four copper busbars. First, three lower copper busbars are embedded. The three lower copper busbars are arranged in a preset order. Then, the first injection molding is performed to fix the three lower copper busbars. A plastic cover plate for fixing is formed between the three lower copper busbars. A groove for placing the upper copper busbar is formed on the plastic cover plate. A positioning protrusion is formed on the plastic cover plate. The upper copper busbar is placed between two of the lower copper busbars, and the upper copper busbar is clamped into the groove of the plastic cover plate. Then, a second injection molding is performed to form a shell that accommodates all four copper busbars. The shell has through holes, and positioning protrusions are embedded in the through holes. The housing has terminal holes for assembling terminals. A recessed adhesive position is provided on one side of the terminal hole. The positions where the lower copper busbar and the upper copper busbar connect to the terminal are embedded in the recessed adhesive position. The housing is filled with adhesive at the position corresponding to the plastic cover plate to cover the plastic cover plate. During the first injection molding, at least three plastic cover plates are formed, which are located in different areas of the three lower copper busbars and connect and fasten the three lower copper busbars in the radial direction. The lower copper busbar is provided with a positioning notch and a positioning hole. During the second injection molding, a positioning block is formed in the positioning notch and a positioning post is formed in the positioning hole, so that the housing and the lower copper busbar are tightly assembled.

2. The filter molding method according to claim 1, characterized in that, The sidewall of the plastic cover is formed with a radially protruding support wall, which forms a tight connection with the shell during the second injection molding.

3. The filter molding method according to claim 2, characterized in that, The three lower copper busbars are formed inside the plastic cover plate, and the grooves are formed on the upper part of the plastic cover plate and exposed to the outside, so that the upper copper busbars are embedded in the upper part of the plastic cover plate and then contained inside by the shell formed by the second injection molding.

4. The filter molding method according to claim 3, characterized in that, During the second injection molding process, several inwardly protruding top posts are formed on the shell, which abut against the lower copper busbar and the upper copper busbar.

5. A filter prepared by the molding method according to any one of claims 1-4, characterized in that, The filter includes a housing, three lower copper busbars and one upper copper busbar. The three lower copper busbars are connected by a plastic cover plate, which has slots. The upper copper busbar is laid in the slots. The three lower copper busbars and the upper copper busbar are installed inside the housing. The plastic cover plate has positioning protrusions. The housing has through holes, and the positioning protrusions are embedded in the through holes. The lower copper busbars have positioning notches and positioning holes. The housing has positioning blocks and positioning pins. The positioning blocks are installed in the positioning notches, and the positioning pins are inserted in the positioning holes.

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