High-precision EPS terminal block plastic copper forming die

Abstract

The application discloses a high-precision EPS terminal block plastic copper forming die, which comprises an upper die blank, a lower die blank and a plurality of groups of die cavity structures, the upper die cavity structure comprises a first die body and a second die body, the lower die cavity structure comprises an abutting disc, a first abutting ring and a second abutting ring which are connected through a pneumatic cylinder, and the abutting disc comprises a base and an abutting disc body. The application is aimed at the multiple, different orientation and high-precision injection coating of the EPS terminal block annular copper bar and copper piece, so that the terminal block forming and the copper bar isolation from the outside are realized, the influence of the outside water vapor humidity and the like on the copper bar is avoided, the copper bar is stably supported and positioned through structural design, the deformation of the copper bar under the injection pressure is avoided, and the problem that the stability of the terminal block is reduced is solved, and the application has good practicability for the injection coating of the single-layer or multi-layer and complex structure copper bar. The die structure is clear, and the operation is relatively convenient and fast.

Description

Technical Field

[0001] This invention relates to the field of electric power steering system technology, specifically a high-precision EPS terminal block plastic-coated copper molding die. Background Technology

[0002] EPS motor terminal blocks are mostly manufactured by separately producing the copper busbars and insulating bases, and then assembling them or using a process where copper busbars are pre-embedded in injection molding. Compared with the pre-embedded copper busbar manufacturing process, the separate manufacturing of the copper busbars and insulating bases requires separate design of the molds for the upper and lower insulating bases, resulting in higher mold costs. Furthermore, gaps inevitably exist at the connection points within the assembled terminal block, causing the copper busbars to come into contact with the environment. This makes them more susceptible to the effects of environmental moisture, humidity, and other chemical components, leading to a reduced service life, safety risks, and compromised performance of the terminal block.

[0003] For the device mold designed for the injection molding process of embedded copper busbars, support columns are required to fix the copper busbars. However, the support and positioning of the copper busbars are not sufficient. During injection molding, under the injection pressure, the middle area of ​​the copper busbar is prone to bending or displacement. This not only leads to uneven thickness of the injection-molded outer shell of the copper busbar, but also makes it impossible to guarantee the wall thickness of the outer injection-molded layer of the copper busbar. As a result, the electrical properties of the copper busbar, such as its voltage resistance, cannot meet the requirements, and the wiring frame insulation is poor, which seriously affects the safety performance of the product. Summary of the Invention

[0004] The purpose of this invention is to address the problems of high mold costs associated with manufacturing EPS terminal blocks by separating the copper busbars and insulating bases, the inevitable gaps at the connections within the assembled terminal block causing the copper busbars to come into contact with the environment and be significantly affected by ambient moisture, humidity, and other chemical components, and the insufficient support and positioning of the copper busbars in the injection molding pre-embedded copper busbar device mold, which easily leads to bending or displacement in the middle area of ​​the copper busbars, resulting in safety risks, reduced service life, and the inability of the terminal block performance to meet requirements. Therefore, this invention provides a high-precision EPS terminal block plastic-coated copper molding mold.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a high-precision EPS terminal block plastic-coated copper molding die, comprising an upper mold blank and a lower mold blank, with a relatively closed structure set at the edge between the upper mold blank and the lower mold blank; the bottom of the upper mold blank is provided with multiple sets of upper mold cavity structures, each upper mold cavity structure including a first mold body connected by a cylinder for lifting and lowering, and a pair of second mold bodies arranged opposite to the first mold body; the second mold bodies are horizontally slidably connected to the bottom of the upper mold blank by a cylinder; the upper end of the lower mold blank is provided with multiple sets of lower mold cavity structures corresponding to the upper mold cavity structures; the lower mold... The cavity structure includes an abutment plate corresponding to the first mold body, a first abutment ring corresponding to the second mold body, and a second abutment ring disposed between the abutment plate and the first abutment ring. The abutment plate, the first abutment ring, and the second abutment ring are all connected to the lower mold blank by a cylinder for lifting. The abutment plate includes a base and an abutment plate body that is detachably connected to the base by a pin. The corresponding upper mold cavity structure and lower mold cavity structure can perform injection molding on the annular copper part in the terminal frame to form an upper injection molded part and a lower injection molded part covering the annular copper part. Vacuum devices and injection molding devices are provided in the upper mold blank and the lower mold blank.

[0006] As a further description of the above technical solution:

[0007] The upper and lower mold blanks are opened and closed by a lifting cylinder set between the side hinge structure and the flipping or closing structure.

[0008] As a further description of the above technical solution:

[0009] The upper end of the second mold body is equipped with a slider, and the outer side of the slider is horizontally connected to the groove at the bottom of the upper mold blank through a cylinder.

[0010] As a further description of the above technical solution:

[0011] The first mold body, the second mold body, the abutting plate, the first abutting ring, and the second abutting ring are all coaxially arranged.

[0012] As a further description of the above technical solution:

[0013] The outer wall of the first mold body and the inner wall of the second mold body gradually taper inward from top to bottom, corresponding to the structure of the upper injection molded part. An arc-shaped transition surface is provided at the connection between the outer wall of the first mold body and the ground, and the arc-shaped transition surface is strung between the inner walls of the annular copper part.

[0014] As a further description of the above technical solution:

[0015] The vertical cross-section of the first abutment ring is L-shaped, and its bottom outer wall abuts and is positioned on the outer wall of the movable groove of the corresponding cylinder of the second abutment ring.

[0016] As a further description of the above technical solution:

[0017] The side wall at the upper end of the abutment plate extends outward to form a first annular protrusion. A second annular protrusion is provided below the first annular protrusion on the abutment plate. The first and second annular protrusions have the same size and shape. The horizontal projection edges of the first abutment ring, the second abutment ring, the first annular protrusion, and the second annular protrusion overlap.

[0018] In summary, due to the adoption of the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0019] 1. This mold is designed for multiple, high-precision injection molding of the annular copper busbar and other copper components of EPS terminal blocks. This achieves terminal block molding and isolates the copper busbar from the external environment, preventing it from being affected by moisture, humidity, and other factors. The structural design provides stable support and positioning for the copper busbar, preventing deformation under injection pressure and thus avoiding reduced lifespan, safety, and stability of the terminal block. It is highly practical for injection molding single-layer or multi-layer copper busbars with complex structures. The mold structure is clear, and operation is convenient and quick.

[0020] 2. The cylinder drives the first mold body, the abutment plate, the first abutment ring, and the second abutment ring to rise and fall. The paired second mold bodies tighten, forming mold cavities corresponding to the upper and lower injection molded parts of the terminal frame, which facilitates injection molding. Through the batch and orientation injection molding process design, the precision of the injection molded parts is ensured while the stable support of the copper busbar is guaranteed. The paired second mold bodies open, and the pin connection between the abutment plate body and the base facilitates the removal of the terminal frame. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a front sectional view of a terminal block corresponding to a high-precision EPS terminal block plastic-coated copper molding die.

[0023] Figure 2 This is a front sectional view of a high-precision EPS terminal block copper-clad molding die in use.

[0024] Figure 3 This is a front sectional view of a high-precision EPS terminal block copper-clad molding die in use, in its second state.

[0025] Figure 4 This is a front sectional view of a high-precision EPS terminal block plastic-coated copper molding die in use, in state three.

[0026] Figure 5 This is a bottom view of the upper mold blank in a high-precision EPS terminal block plastic-coated copper molding die.

[0027] Figure 6 This is a cross-sectional view showing the connection relationship between the upper mold blank and the second mold body in a high-precision EPS terminal block plastic-coated copper molding die.

[0028] Figure 7 This is a top view of the lower die blank in a high-precision EPS terminal block plastic-coated copper molding die.

[0029] Legend:

[0030] 1. Lower mold blank; 2. Upper mold blank; 3. First mold body; 4. Second mold body; 5. Abutment plate; 6. First abutment ring; 7. Second abutment ring; 8. Terminal block; 11. Slide groove; 41. Slider; 51. Pin; 52. Base; 81. Annular copper part; 82. Upper injection molded part; 83. Lower injection molded part. Detailed Implementation

[0031] 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 some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., 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 this 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. Therefore, they should not be construed as limitations on this invention.

[0033] Please see Figure 1-7This invention provides a technical solution: a high-precision EPS terminal block plastic-coated copper molding die, comprising an upper mold blank 2 and a lower mold blank 1, with opposing closed structures at their edges. The bottom of the upper mold blank 2 is provided with multiple sets of upper mold cavity structures, each including a first mold body 3 connected by a cylinder for lifting and lowering, and a pair of second mold bodies 4 arranged opposite to the first mold body 3. The second mold bodies 4 are horizontally slidably connected to the bottom of the upper mold blank 2 by a cylinder. The upper end of the lower mold blank 1 is provided with multiple sets of lower mold cavity structures corresponding to the upper mold cavity structures. Each lower mold cavity structure includes an abutment plate 5 corresponding to the first mold body 3, a first abutment ring 6 corresponding to the second mold body 4, and a second abutment ring 7 disposed between the abutment plate 5 and the first abutment ring 6. The abutment plate 5, the first abutment ring 6, and the second abutment ring 7 are all connected to the lower mold blank by cylinders for lifting and lowering. On the blank 1, the abutment plate 5 includes a base 52 and an abutment plate body detachably connected to the base 52 via a pin 51. The corresponding upper and lower mold cavity structures can injection mold the annular copper part 81 inside the terminal frame 8 to form an upper injection molded part 82 and a lower injection molded part 83 covering the annular copper part 81. Vacuum devices and injection molding devices are installed in the upper mold blank 2 and the lower mold blank 1. This mold is designed for multiple, different orientations, and high-precision injection molding of the annular copper busbar and copper parts of the EPS terminal frame to achieve terminal frame forming and isolate the copper busbar from the outside world, avoiding its influence by external moisture, humidity, and other factors. The structural design provides stable support and positioning for the copper busbar, preventing deformation under injection pressure, which would reduce the service life, safety, and stability of the terminal frame. It has good practicality for injection molding of single-layer or multi-layer, complex-structured copper busbars. The mold structure is clear, and the operation is relatively convenient and quick.

[0034] The upper mold blank 2 and the lower mold blank 1 are opened and closed by a lifting cylinder set between the side hinge structure and the flipping or closing structure, making the mold opening and closing more convenient and faster.

[0035] The upper end of the second mold body 4 is provided with a slider 41. The outer side of the slider 41 is horizontally connected to the slide groove 11 at the bottom of the upper mold blank 2 through a cylinder, which makes the opening and closing of the second mold body smoother and facilitates the insertion of copper and the removal of the wiring bracket.

[0036] The first mold body 3, the second mold body 4, the abutting plate 5, the first abutting ring 6, and the second abutting ring 7 are all coaxially arranged, which makes the copper busbar injection positioning more accurate and the abutting positioning between components more stable.

[0037] The outer wall of the first mold body 3 and the inner wall of the second mold body gradually taper inward from top to bottom, corresponding to the structure of the upper injection molded part 82. An arc-shaped transition surface is provided at the connection between the outer wall of the first mold body 3 and the ground. The arc-shaped transition surface is strung between the inner walls of the annular copper part 81, which facilitates the receiving and positioning of the copper busbar, making one injection molding faster.

[0038] The vertical cross-section of the first abutting ring 6 is L-shaped, and its bottom outer wall abuts and is positioned on the outer wall of the movable groove of the corresponding cylinder of the second abutting ring 7, making the lower mold cavity structure more stable.

[0039] The upper sidewall of the abutment plate 5 extends outward to form a first annular protrusion. The abutment plate 5 is provided with a second annular protrusion below the first annular protrusion. The first annular protrusion and the second annular protrusion have the same size and shape. The horizontal projection edges of the first abutment ring 6, the second abutment ring 7, the first annular protrusion, and the second annular protrusion overlap, which facilitates the sealing of the mold cavity corresponding to the injection molded part during injection molding and the switching between primary and secondary injection states.

[0040] The working principle of a high-precision EPS terminal block plastic-coated copper molding die in this embodiment includes: This die performs multiple, different-position, and high-precision injection molding coating on the EPS terminal block annular copper busbar and copper parts to achieve terminal block molding. It is practical for injection molding coating of single-layer or multi-layer copper busbars with complex structures. Taking a single-layer copper busbar as an example, the hinge structure between the upper mold blank 2 and the lower mold blank 1 is flipped or driven by a lifting cylinder to move relative to each other, so that the two are opened, and the annular copper part 81 to be injection molded is placed on the placement platform composed of the abutment plate 5, the first abutment ring 6, and the second abutment ring 7. The idle state of the die is the first use state (e.g., Figure 2 In use, the cylinder drives the abutment plate 5, the first abutment ring 6, and the second abutment ring 7 to rise synchronously until the first abutment ring 6 abuts the bottom of the second mold body 4. At the same time, the abutment plate 5 abuts the bottom of the first mold body 3, and the second abutment ring 7 and the first annular protrusion of the abutment plate 5 are at the same horizontal plane. The annular copper part 81 abuts against the first mold body 3 and is fitted on its outside by the upward pushing force of the second abutment ring 7. At this time, a closed cavity corresponding to the upper injection molded part 82 is formed between the first mold body 3, the upper mold blank 2, the second mold body 4, and the second abutment ring 7. This is the second state of use (as shown in the image). Figure 3The process involves creating a vacuum within a sealed cavity using a vacuum device and an injection molding device, injecting molten plastic, and allowing it to cool and solidify, thus completing one injection molding operation. This process covers the upper end and outer side walls of the annular copper part 81. A cylinder moves the first mold body 3 upwards, and the upper injection part 82 abuts against the bottom of the upper mold blank 2, causing the first injection part to detach from the first mold body 3. Simultaneously, the cylinder moves the second abutting ring 7 downwards and the abutting plate 5 upwards, causing its upper end to abut against the bottom of the first mold body 3. At the same time, the second annular protrusions of the second abutting ring 7 and the abutting plate 5 are at the same horizontal plane. At this point, the first annular protrusion, the second annular protrusion, the second mold body 4, the second abutting ring 7, and... The ring-shaped copper part 81 and the upper injection molded part 82 form a closed cavity corresponding to the lower injection molded part 83 between the primary injection molded parts. Vacuuming and injection molding are performed to complete the secondary injection molding. The lower end and inner side wall of the ring-shaped copper part 81 are covered with injection molding. Cooling and shaping are performed to complete the plastic-coated copper forming process of the EPS terminal frame. The cylinder drives the pair of second mold bodies 4 to open. Then the abutment plate 5, the first abutment ring 6 and the second abutment ring 7 are reset and drive the terminal frame 8 to move down, so that the lower mold blank 1 and the upper mold blank 2 open. The terminal frame 8 and the abutment plate body can be pulled out together. The terminal frame 8 is inverted, the abutment plate body is taken out and re-inserted into the base 52 through the pin 51.

[0041] In summary, due to the adoption of the above technical solution, the high-precision EPS terminal block plastic-coated copper molding die of this embodiment has the following advantages compared with the prior art:

[0042] 1. This mold is designed for multiple, high-precision injection molding of the annular copper busbar and other copper components of EPS terminal blocks. This achieves terminal block molding and isolates the copper busbar from the external environment, preventing it from being affected by moisture, humidity, and other factors. The structural design provides stable support and positioning for the copper busbar, preventing deformation under injection pressure and thus avoiding reduced lifespan, safety, and stability of the terminal block. It is highly practical for injection molding single-layer or multi-layer copper busbars with complex structures. The mold structure is clear, and operation is convenient and quick.

[0043] 2. The cylinder drives the first mold body, the abutment plate, the first abutment ring, and the second abutment ring to rise and fall. The paired second mold bodies tighten, forming mold cavities corresponding to the upper and lower injection molded parts of the terminal frame, which facilitates injection molding. Through the batch and orientation injection molding process design, the precision of the injection molded parts is ensured while the stable support of the copper busbar is guaranteed. The paired second mold bodies open, and the pin connection between the abutment plate body and the base facilitates the removal of the terminal frame.

[0044] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-precision EPS terminal block plastic-coated copper molding die, characterized in that, The upper mold blank (2) and the lower mold blank (1) are provided with a closed structure at their edges. The bottom of the upper mold blank (2) is provided with multiple sets of upper mold cavity structures. The upper mold cavity structure includes a first mold body (3) connected by a cylinder for lifting and lowering, and a pair of second mold bodies (4) arranged opposite to the first mold body (3). The second mold bodies (4) are horizontally slidably connected to the bottom of the upper mold blank (2) by a cylinder. The upper end of the lower mold blank (1) is provided with multiple sets of lower mold cavity structures corresponding to the upper mold cavity structure. The lower mold cavity structure includes an abutment plate (5) corresponding to the first mold body (3) and a first mold body (4) corresponding to the second mold body (4). A first abutting ring (6) and a second abutting ring (7) disposed between the abutting plate (5) and the first abutting ring (6). The abutting plate (5), the first abutting ring (6) and the second abutting ring (7) are all connected to the lower mold blank (1) by a cylinder for lifting. The abutting plate (5) includes a base (52) and an abutting plate body detachably connected to the base (52) by a pin (51). The corresponding upper mold cavity structure and lower mold cavity structure can perform injection molding on the annular copper part (81) in the wiring frame (8) to form an upper injection molded part (82) and a lower injection molded part (83) covering the annular copper part (81). A vacuum device and an injection molding device are provided in the upper mold blank (2) and the lower mold blank (1). The first mold body (3), the second mold body (4), the abutting plate (5), the first abutting ring (6), and the second abutting ring (7) are all coaxially arranged; The outer wall of the first mold body (3) and the inner wall of the second mold body have a gradually inward structure corresponding to the structure of the upper injection molded part (82) from top to bottom. An arc-shaped transition surface is provided at the connection between the outer wall of the first mold body (3) and the ground. The arc-shaped transition surface is strung between the inner walls of the annular copper part (81). The vertical cross section of the first abutting ring (6) is L-shaped and its bottom outer wall abuts and is positioned on the outer wall of the movable groove of the corresponding cylinder of the second abutting ring (7); The upper sidewall of the abutment plate (5) extends outward to form a first annular protrusion. The abutment plate (5) is provided with a second annular protrusion below the first annular protrusion. The first annular protrusion and the second annular protrusion have the same size and shape. The horizontal projection edges of the first abutment ring (6), the second abutment ring (7), the first annular protrusion and the second annular protrusion overlap.

2. The high-precision EPS terminal block plastic-coated copper molding die according to claim 1, characterized in that, The upper mold blank (2) and the lower mold blank (1) are opened and closed by flipping the side hinge structure or by operating the lifting cylinder set between the closed structures.

3. The high-precision EPS terminal block plastic-coated copper molding die according to claim 1, characterized in that, The upper end of the second mold body (4) is provided with a slider (41), and the outer side of the slider (41) is horizontally slidably connected to the groove (11) at the bottom of the upper mold blank (2) by a cylinder.

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