An assembly structure of a special-shaped copper bar and a filter plate in a limited space

Abstract

The application discloses a kind of assembly cooperation structures of special-shaped copper bar and filter board in limited space, including negative pole parallel module copper bar, positive pole parallel module copper bar, adapter output general copper bar, general output copper bar solid connection, and BUCK board of one module is fixed in the left end, middle and right end of copper bar respectively.Two adapter output general copper bars are back-to-back groove structure, and a 19mm wide Hall inductance magnetic ring is crossed between copper bar.Positive pole and negative pole parallel module copper bar are respectively connected with 1 Y capacitor filter board between shell ground, and 1 X capacitor filter board is connected between positive pole and negative pole parallel module copper bar, and reinforcing holder is provided between filter board and shell.Give up wire soft connection mode, ensure high-quality current, voltage stable output, give consideration to safe overvoltage, overcurrent, overheat reliable guarantee, while meeting the requirements of easy installation operation, suitable for batch production, low cost control and after-sales disassembly and maintenance.

Description

Technical Field

[0001] This invention relates to a power supply device component, and more particularly to an assembly and mating structure of an irregularly shaped copper busbar and a filter board in a confined space. Background Technology

[0002] With the development of electronic science and technology, power supply equipment is becoming increasingly miniaturized, placing higher demands on the internal layout, external dimensions, and assembly methods of power supplies. High-power DC power supplies utilize a 3U standard chassis. The product requirements are: high power and high precision, automatic range output, flexible combination and expansion of different power series models, high-quality electrical performance, high stability under dynamic loads, high ripple rejection ratio, low noise, reliable overcurrent, overvoltage, and overheat protection, aesthetically pleasing overall appearance, and low development cost.

[0003] like Figure 1 As shown, in the prior art:

[0004] 1) The distance between the module and the output copper busbar is approximately 45mm;

[0005] 2) The conductor consists of 6 8mm wires. 2 Square conductor;

[0006] 3) A 19mm wide magnetic ring must pass between the conductor and the copper busbar: 6 8mm wires 2 After the wire is threaded through the magnetic ring, the wire becomes stiff and not easily bent.

[0007] 4) The positive and negative copper busbars are respectively connected to the chassis ground;

[0008] 5) There is a CBB capacitor between the positive and negative copper busbars (the capacitor dimensions are 26mm long x 11mm wide x 24mm high).

[0009] Disadvantages of existing technology:

[0010] The output copper busbar of the high-power DC power supply has only about 45mm of space left at the end. Usually, a flexible wire with high temperature and high voltage resistance is used to connect the output terminals of the BUCK circuit board to the output copper busbar of the whole machine. However, in this narrow space, the materials and shapes of the components are not well matched, and the structural layout and assembly mode are not well matched, resulting in poor performance and indirectly affecting the power supply performance and reliability of the product.

[0011] In view of this, the present invention is hereby proposed. Summary of the Invention

[0012] The purpose of this invention is to provide an assembly and mating structure for irregularly shaped copper busbars and filter boards in a confined space, so as to solve the above-mentioned technical problems existing in the prior art.

[0013] The objective of this invention is achieved through the following technical solution:

[0014] The present invention relates to an assembly and mating structure of a copper busbar and a filter board in a confined space. The irregularly shaped copper busbar includes a negative parallel module copper busbar and a positive parallel module copper busbar. The front of the negative parallel module copper busbar and the positive parallel module copper busbar are respectively fixed to a universal output copper busbar. The front part of each universal output copper busbar is fixed to a universal output copper busbar. A module BUCK board is fixed at the left, middle and right ends of the negative parallel module copper busbar and the positive parallel module copper busbar.

[0015] Compared with the prior art, the assembly and matching structure of the irregular copper busbar and filter board provided by this invention is used for the reasonable structural process layout design of the copper busbar interface of high-power DC power supply output in a small physical space, which ensures effective improvement of product performance parameters and aesthetically pleasing overall effect. It is an innovative process method that cleverly matches and combines irregular copper busbar components with capacitor filter board components. Attached Figure Description

[0016] Figure 1 Wiring diagram for existing technical solutions;

[0017] Figure 2 This is a connection diagram of the irregular copper busbar assembly according to an embodiment of the present invention;

[0018] Figure 3a This is a structural diagram of the irregular copper busbar assembly according to an embodiment of the present invention;

[0019] Figure 3b This is a top view of the irregularly shaped copper busbar assembly according to an embodiment of the present invention;

[0020] Figure 3c This is a 3D exploded view of the irregularly shaped copper busbar assembly according to an embodiment of the present invention;

[0021] Figure 4 This is a schematic diagram of the structure of the reinforcement bracket from the filter board to the housing in an embodiment of the present invention.

[0022] In the picture:

[0023] 1. Negative parallel module copper busbar, 2. Positive parallel module copper busbar, 3. Universal output copper busbar, 4. Universal output copper busbar, 5. 19mm wide Hall effect inductor magnetic ring, 6. X capacitor filter board (1 piece), 7. Y capacitor filter board (2 pieces), 8. Reinforcement brackets from the filter board to the housing (2 pieces). Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them, and do not constitute a limitation on the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0025] First, the following explanations are provided for the terms that may be used in this article:

[0026] The term "and / or" means that either or both can be achieved simultaneously. For example, X and / or Y means that it includes both "X" or "Y" as well as the three cases of "X and Y".

[0027] The terms “including,” “comprising,” “containing,” “having,” or other similar semantic descriptions should be interpreted as non-exclusive inclusion. For example, “including a technical feature element (such as raw material, component, ingredient, carrier, dosage form, material, size, part, component, mechanism, device, step, process, method, reaction conditions, processing conditions, parameter, algorithm, signal, data, product or article of manufacture, etc.)” should be interpreted as including not only the expressly listed technical feature element, but also other technical feature elements that are not expressly listed and are well-known in the art.

[0028] The term "composed of" excludes any technical features not expressly listed. When used in a claim, it closes the claim to exclude all technical features other than those expressly listed, except for associated conventional impurities. If the term appears only in a clause of a claim, it limits the claim to the elements expressly listed in that clause; elements recited in other clauses are not excluded from the overall claim.

[0029] Unless otherwise explicitly specified or limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this document according to the specific circumstances.

[0030] The terms “center,” “longitudinal,” “lateral,” “length,” “width,” “thickness,” “upper,” “lower,” “front,” “back,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” “outer,” “clockwise,” and “counterclockwise” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience and simplification of description and do not imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this document.

[0031] The contents not described in detail in the embodiments of this invention are prior art known to those skilled in the art. Where specific conditions are not specified in the embodiments of this invention, they shall be performed according to conventional conditions in the art or conditions recommended by the manufacturer. Where the manufacturers of the reagents or instruments used in the embodiments of this invention are not specified, they are all conventional products that can be purchased commercially.

[0032] The present invention relates to an assembly and mating structure of a non-standard copper busbar and a filter board in a confined space. The non-standard copper busbar includes a negative parallel module copper busbar and a positive parallel module copper busbar. The front of the negative parallel module copper busbar and the positive parallel module copper busbar are respectively fixed to a universal output copper busbar. The front part of each universal output copper busbar is fixed to a universal output copper busbar. A module BUCK board is fixed at the left, middle and right ends of the negative parallel module copper busbar and the positive parallel module copper busbar.

[0033] The two universal copper busbars for adapter outputs have a back-to-back slotted structure at the rear and a face-to-face L-shaped structure at the front. A 19mm wide Hall effect inductor magnetic ring passes between the copper busbars in the slotted structure section.

[0034] The two universal output copper busbars have an L-shaped structure with their surfaces facing each other, which fits perfectly inside the front L-shaped structure of the two universal output copper busbars.

[0035] Each of the negative parallel module copper busbar and the positive parallel module copper busbar is connected to a Y capacitor filter board between itself and the chassis ground. An X capacitor filter board is connected between the positive and negative parallel module copper busbars. The three capacitor welding components are then used to form a PCBA board assembly.

[0036] A reinforcing bracket is provided between the filter board and the housing.

[0037] The copper busbar is made of copper, 17mm wide, 2mm thick, and nickel-plated.

[0038] In summary, the assembly and mating structure of the irregular copper busbar and filter board in the confined space of the present invention proposes a new design for the connection method in the confined space of 45mm width at the output copper busbar. It abandons the soft wire connection mode, ensures high-quality current and stable voltage output, takes into account the reliable protection against overvoltage, overcurrent and overheating, and meets the requirements of convenient installation and operation, overall aesthetics, applicability to mass production, low cost control and convenient after-sales disassembly and maintenance.

[0039] The main direction of this invention is to make reasonable use of limited space, achieve perfect matching and combination, facilitate processing, and simplify assembly operations.

[0040] This invention relates to a copper busbar assembly, two types of capacitor filter boards, a filter magnetic ring, and a fixing bracket. The rational matching and combination of these components makes full use of existing space, simplifies the assembly process, ensures a firm and reliable installation, and results in a neat and aesthetically pleasing structure. This not only improves product performance and quality but also enhances power capacity safety. At the same time, the simplified and practical production and assembly process saves production time, significantly reduces material damage rates, and improves product qualification rates upon warehousing.

[0041] To more clearly demonstrate the technical solution and its effects provided by the present invention, the embodiments of the present invention will be described in detail below with reference to specific examples.

[0042] like Figure 2 As shown:

[0043] 1) The distance between the module and the output copper busbar is approximately 45mm;

[0044] 2) The positive and negative copper busbars are connected without wires, and the three types of copper busbars are reasonably combined and rigidly connected.

[0045] 3) A 19mm wide magnetic ring passes through the general output copper busbars;

[0046] 4) Use one Y capacitor filter board between the positive and negative copper busbars and the chassis ground. Use one X capacitor filter board between the positive and negative copper busbars.

[0047] 5) The reinforced bracket from the filter board to the housing is used for equipotential grounding of each capacitor filter board, and also provides stability and shielding.

[0048] The main innovations are:

[0049] 1. Replacing wires with output copper busbar assemblies avoids messy and disorderly wire connections, reduces the need for identifying hazards during operation, and the copper busbars have reasonable external dimensions to meet electrical functional requirements and ergonomic design. They are easy to machine and simplify the assembly and production process.

[0050] 2. Replacing the capacitor welding components with capacitor filter boards more effectively improves anti-interference capabilities, outputs a stable DC voltage, and provides an equipotential chassis ground between each component.

[0051] 3. Using a 19mm wide Hall effect inductor as an electromagnetic interference filter can effectively suppress electromagnetic interference.

[0052] 4. Each component must meet the operating environment and equipment requirements to ensure that the electrical performance parameters of the product are not reduced, while also meeting safety and environmental protection requirements.

[0053] 5. Each component should be designed with universality, consistency and interchangeability in mind, and should have error-proofing and foolproofing measures.

[0054] 6. The capacitor filter board assembly and copper busbar assembly should be assembled securely and tightened using general-purpose combination screws.

[0055] 7. Each component makes effective use of limited space, the components are tightly connected, the assembly operation is simple, and the process is reasonable.

[0056] 8. All components should have a good appearance, free from burrs, rust, cracks, and mechanical damage, and should be aesthetically pleasing with clear markings.

[0057] Example 1:

[0058] 1. For example Figure 3a , Figure 3b , Figure 3c As shown, due to space constraints, there are two irregularly shaped output copper busbars, one positive and one negative.

[0059] Made of copper, the copper busbar is 18mm wide and 2mm thick, and the surface is nickel plated.

[0060] The length of the positive and negative copper busbars is 278.5 mm, and the tolerance is in accordance with GB / T1804-m.

[0061] The bending method should meet the actual space requirements, with a bending radius of R1 and an accurate bending angle.

[0062] The appearance must have blunted sharp angles, be deburred, and free of scratches.

[0063] M3 flip-top rivets are used for the positioning holes of the copper busbar.

[0064] Two non-standard universal adapter universal output copper busbars pass through a 19mm wide inductor coil. The positive and negative copper busbar assemblies must pass smoothly through the 19mm wide Hall inductor magnetic ring to filter the output inductor.

[0065] The specifications for the Hall effect inductor magnetic ring are 32*50*19 (inner diameter*outer diameter*thickness, unit: mm).

[0066] Made of copper, the copper busbar is 17mm wide and 2mm thick, and the surface is plated with nickel.

[0067] The dimensions of the two copper busbars with the magnetic rings are 26mm > 19mm (inductor magnetic ring thickness), and the bend width is 19mm < 27mm, to ensure that the inductor magnetic rings can be smoothly inserted into the bends of the copper busbars.

[0068] M3 flip-top rivets are used for the positioning holes of the copper busbar.

[0069] The universal L-shaped output copper busbar is designed for symmetrical and universal use, taking into account error prevention and foolproof design. It is also made of copper, with a width of 17mm, a thickness of 2mm, and a nickel-plated surface.

[0070] M3 flip-top rivets are used for the positioning holes of the copper busbar.

[0071] 2. For example Figure 4 As shown, the reinforcement bracket from the filter board to the housing assembles and reinforces each filter board and copper busbar assembly.

[0072] It uses high-quality galvanized steel sheets and adopts a two-and-a-half-enclosed overall structural design;

[0073] The press-fit rivets that assemble the perimeter and the outer casing not only ensure the ground equipotential of the two Y-shaped capacitor plates but also improve electromagnetic compatibility performance.

[0074] M3 flip-top rivets are used for the positioning holes of the copper busbar.

[0075] The card slot is assembled with the power supply housing to meet an equipotential housing ground.

[0076] 3. Two Y-capacitor filter boards are used for filtering the positive and negative copper busbars and the chassis ground; one X-capacitor filter board is used for filtering between the positive and negative copper busbars.

[0077] The three capacitor welding components were modified into PCBA board components.

[0078] The X-type capacitor filter board has one X-type capacitor soldered in parallel with the positive and negative output copper busbars. To allow for close assembly with the Y-type capacitor, the X-type capacitor board has M3 screw holes for assembly with the Y-type capacitor filter board.

[0079] The Y-type capacitor filter board has two Y-type capacitors soldered on the front side, connected in series between the positive and negative copper busbars. The midpoint of the two capacitors is mounted to the chassis and grounded through the M3 hole fixing screw hole. The bottom layer is grounded, which can effectively reduce electromagnetic interference.

[0080] The circuit board adopts a simple double-layer circuit board, and the wiring is reasonable and follows the principles of "simplified wiring, safe current carrying, and electromagnetic interference resistance".

[0081] In summary, the new process method of matching and combining irregularly shaped output copper busbars with capacitor filter boards meets the connection requirements of output copper busbars in confined spaces: the reasonable assembly of copper busbar components, Y-capacitor filter boards, X-capacitor filter boards, filter magnetic rings, and reinforcing brackets within a confined space achieves signal anti-interference capabilities, while being easy to process; the universal copper busbar components, universal Y-filter boards, and standardized M3 screw holes avoid production assembly errors, save time, enhance operability, greatly improve production efficiency, and also improve the overall quality and warehousing qualification rate of products.

[0082] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims. The information disclosed in the background section is intended only to enhance the understanding of the overall background technology of the present invention and should not be construed as an admission or implication in any way that such information constitutes prior art known to those skilled in the art.

Claims

1. An assembly structure of a special-shaped copper bar and a filter plate in a limited space, characterized in that, The special-shaped copper bar comprises a negative parallel module copper bar and a positive parallel module copper bar, the front of the negative parallel module copper bar and the front of the positive parallel module copper bar are fixedly connected with a switching output general copper bar respectively, the front of each switching output general copper bar is fixedly connected with a general output copper bar respectively, and a BUCK plate of one module is fixed at the left end, the middle and the right end of the negative parallel module copper bar and the positive parallel module copper bar respectively; The rear of the two switching output general copper bars is a back-to-back groove type structure, the front is a face-to-face L type structure, and a 19mm wide Hall inductance magnetic ring is arranged between the copper bars at the groove type structure part; The two general output copper bars are face-to-face L type structures and are just arranged in the inner side of the front L type structure of the two switching output general copper bars; The negative parallel module copper bar and the positive parallel module copper bar are respectively connected with one Y capacitor filter plate between the negative parallel module copper bar and the shell ground and between the positive parallel module copper bar and the shell ground respectively, one X capacitor filter plate is connected between the positive parallel module copper bar and the negative parallel module copper bar, and three capacitor welding assemblies are made into a PCBA plate assembly.

2. The assembly structure of the special-shaped copper bar and the filter plate in a limited space according to claim 1, characterized in that, A reinforcing clamping seat is arranged between the filter plate and the shell.

3. The assembly structure of the special-shaped copper bar and the filter plate in a limited space according to claim 1 or 2, characterized in that, The copper bar is made of red copper material, the width is 17mm, the thickness is 2mm, and the surface is plated with nickel.

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