Coil component, low-voltage electric appliance with coil component and coil component preparation method

Abstract

The invention belongs to the technical field of low-voltage electric appliances, and discloses a coil assembly, a low-voltage electric appliance with the coil assembly and a coil assembly preparation method. The coil assembly comprises a conductive piece, a connecting piece and a coil. The conductive piece is provided with a through connecting hole. The connecting piece penetrates through the connecting hole and is partially located outside the connecting hole. And the coil is welded with the part of the connecting piece outside the connecting hole. The connecting piece is made of a welding material, so that additional welding brazing filler metal is not needed in the welding process, compared with a mode of welding the coil and the conductive piece through a welding piece, the production efficiency is improved, and the welding position of the conductive piece and the coil is conveniently positioned through the arrangement of the connecting hole. The connecting holes without the connecting pieces are through holes and can be quickly identified on an automatic production line, so that the conductive pieces without the connecting pieces are separated, the problem of abnormal welding caused by the fact that soldering lug missing cannot be identified is effectively solved, the detectability of the product production process is improved, and the product reject ratio is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of low-voltage electrical appliances, and in particular to a coil assembly, a low-voltage electrical appliance having the coil assembly, and a method for preparing the coil assembly. Background Art

[0002] The coils in low-voltage electrical appliances such as starters and circuit breakers are connected to conductive parts such as connecting plates and supports to form coil assemblies, which realize functions such as overload disconnection protection of switch electrical appliances and circuits, and conduction circuits. The quality of the coil assembly is directly related to the performance of low-voltage electrical appliances such as starters and circuit breakers.

[0003] When manufacturing coil assemblies of low-voltage electrical appliances such as starters and circuit breakers, the prior art has the following preparation methods. One is to first punch out a welding sheet, and use the welding sheet as a transition material to weld and connect the coil and the conductive part, which has the problems of low production efficiency and inaccurate welding position; the other is to use the method of pre-riveting welding sheets on the surface of the conductive part to weld and connect the coil and the conductive part. However, in the preparation method of pre-riveting welding sheets, when welding the coil and the conductive part, there is a problem that the missing welding sheet cannot be effectively identified, resulting in abnormal welding between the coil and the conductive part, and it is impossible to weld to form a qualified coil assembly.

[0004] In summary, the existing coil assembly has problems such as low production energy efficiency, low welding positioning accuracy, and inability to effectively identify welding abnormalities caused by missing welding pieces during preparation. Therefore, a coil assembly, a low-voltage electrical appliance having a coil assembly, and a method for preparing a coil assembly are urgently needed to solve the above problems. Summary of the invention

[0005] The object of the present invention is to provide a coil assembly, a low-voltage electrical appliance having a coil assembly and a method for preparing a coil assembly, which can improve the production efficiency and production quality of the coil assembly, reduce abnormal phenomena in the production process, and realize stable and high-quality production of the coil assembly.

[0006] To achieve this object, the present invention adopts the following technical solutions:

[0007] In a first aspect, a coil assembly is provided, comprising:

[0008] A conductive member, wherein a connecting hole is provided through the conductive member;

[0009] A connecting piece, wherein the material of the connecting piece is a welding material; the connecting piece is penetrated and connected to the connecting hole, and a part of the connecting piece is located outside the connecting hole;

[0010] The coil is welded to a portion of the connecting member outside the connecting hole.

[0011] As an optional solution of the coil assembly provided by the present invention, the connecting piece includes a penetration portion and a welding portion;

[0012] The penetration portion is penetrated in the connection hole, and one end of the penetration portion is used for riveting to form the welding portion under the action of external force; the welding portion is located outside the connection hole and abuts against the conductive member; the welding portion is welded to the coil.

[0013] As an optional solution of the coil assembly provided by the present invention, the connecting member further includes a stopper, the stopper and the welding portion are arranged at two ends of the penetration portion, the stopper is located outside the connecting hole and abuts against the conductive member.

[0014] As an optional solution of the coil assembly provided by the present invention, the cross-section of the connecting hole is circular, elliptical or polygonal.

[0015] As an optional solution of the coil assembly provided by the present invention, the material of the connecting piece is any one of pure copper, red copper, oxygen-free copper, iron bronze, brass, tin-phosphor bronze, copper alloy, and dispersion-reinforced copper-based material.

[0016] As an optional solution of the coil assembly provided by the present invention, the material of the conductive member is any one of copper-clad steel, copper-clad brass layered composite material, copper-clad stainless steel layered composite material, copper-clad aluminum layered composite material, particle-reinforced copper-based composite material, and copper alloy;

[0017] And / or, the coil includes a spiral portion and a connecting portion, wherein the connecting portion is connected to one end of the spiral portion and is welded to the connecting piece.

[0018] As an optional solution of the coil assembly provided by the present invention, the portion of the connecting member located outside the connecting hole is provided with a welding surface, the welding surface is welded to the coil, and at least one protruding structure is convexly provided on the welding surface.

[0019] As an optional solution of the coil assembly provided by the present invention, the protrusion structure is a strip-shaped protrusion and is provided in plurality, and the plurality of the strip-shaped protrusions are distributed at intervals or the plurality of the strip-shaped protrusions are distributed crosswise in a mesh shape;

[0020] or,

[0021] The protrusion structure is an annular protrusion and is provided in plurality, the centers of the plurality of annular protrusions are distributed at intervals or the plurality of annular protrusions are distributed in concentric circles;

[0022] or,

[0023] The protrusion structure is a dot-shaped protrusion and is provided in plurality;

[0024] A plurality of the dot-shaped protrusions are distributed at intervals; and / or the dot-shaped protrusions are cylinders, cones, polygons or spheres.

[0025] As an optional solution of the coil assembly provided by the present invention, the connecting piece is covered with a silver layer.

[0026] In a second aspect, a low-voltage electrical appliance having a coil assembly is provided, comprising a housing and the coil assembly as described above, wherein the coil assembly is disposed in the housing.

[0027] In a third aspect, a method for preparing a coil assembly is provided, for preparing the coil assembly as described above, the method comprising:

[0028] A connection hole is provided at a preset position of the conductive member;

[0029] Riveting a connecting piece to the connecting hole so that a portion of the connecting piece is located outside the connecting hole;

[0030] One end of the coil is welded to the portion of the connecting piece located outside the connecting hole.

[0031] Beneficial effects of the present invention:

[0032] The present invention provides a coil assembly, a low-voltage electrical appliance having the coil assembly, and a method for preparing the coil assembly. By pre-arranging a connection hole on a conductive part, and inserting a connection piece made of a welding material into the connection hole, when welding the coil and the connection piece, no additional welding solder is needed to achieve the welding connection between the two, the welding process is simplified, and compared with the method of welding the coil and the conductive part by a welding sheet, the production efficiency is improved, thereby improving the production efficiency of the low-voltage electrical appliance having the coil assembly. Moreover, by setting the connection hole, it is easy to locate the installation position of the connection piece on the conductive part, thereby accurately locating the welding position of the coil and the conductive part, effectively improving the positioning accuracy, and ensuring the excellent quality of the coil assembly after welding. In addition, in the process of welding the coil and the connector, if there is a conductive part in the connecting hole without a connector installed, the conductive part is a through hole at the welding position. The equipment on the automatic production line can quickly identify it so as to separate the conductive part and avoid direct welding of the conductive part to the coil without the connector installed. This effectively solves the problem of welding abnormalities caused by the inability to identify missing welding pieces, improves the detectability of the coil assembly product production process, reduces the quality risk in the coil assembly production process, and is conducive to mass production and improving the product yield rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments of the present invention are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the drawings without creative work.

[0034] Figure 1 It is a schematic structural diagram of a conductive member of a coil assembly provided in one embodiment of the present invention;

[0035] Figure 2 is a schematic diagram of a riveted assembly formed by riveting a conductive member and a connecting member provided by one embodiment of the present invention;

[0036] Figure 3 is a schematic structural diagram of a coil assembly provided in one embodiment of the present invention;

[0037] Figure 4 yes Figure 2 A partial enlarged view of the middle A;

[0038] Figure 5 is a plan view of a riveting assembly provided in one embodiment of the present invention;

[0039] Figure 6 yes Figure 5 A partial enlarged view of point B in the middle;

[0040] Figure 7 is a schematic structural diagram of a conductive member of a coil assembly provided in another embodiment of the present invention;

[0041] Figure 8 is a schematic diagram of a riveted assembly formed by riveting a conductive member and a connecting member provided by another embodiment of the present invention;

[0042] Fig. 9 is a cross-sectional view of a conductive member and a connecting member after riveting provided by another embodiment of the present invention;

[0043] Fig.10 is a structural schematic diagram of a coil assembly provided in another embodiment of the present invention;

[0044] Fig.11 It is a flow chart of a method for preparing a coil assembly provided in a specific embodiment of the present invention.

[0045] In the figure:

[0046] 10. Riveting assembly; 20. Coil assembly;

[0047] 1. Conductive parts; 2. Connectors; 3. Coils;

[0048] 11. a first conductive plate; 12. a second conductive plate;

[0049] 111. Conductive plate segment;

[0050] 121, connection hole;

[0051] 21. welding part; 22. stopping part; 23. piercing part;

[0052] 211, welding surface; 212, raised structure;

[0053] 31. Spiral portion; 32. Connecting portion. DETAILED DESCRIPTION

[0054] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0055] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0056] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0057] In the description of this embodiment, the terms "upper", "lower", "left", "right" and other directions or positional relationships are based on the directions or positional relationships shown in the drawings, and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operate in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.

[0058] In this embodiment, the term "and / or" is only a description of the association relationship of the associated objects, indicating that there can be three relationships. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / " in the present invention generally indicates that the associated objects before and after are in an "or" relationship.

[0059] In the embodiments of the present invention, the same reference numerals denote the same components, and for the sake of brevity, detailed descriptions of the same components are omitted in different embodiments.

[0060] Embodiment 1

[0061] like Figure 1 , Figure 2 as well as Figure 3 As shown, this embodiment provides a coil assembly 20, which can improve the production efficiency and production quality of the coil assembly 20, reduce abnormal phenomena in the production process, and achieve stable production of the coil assembly 20. The coil assembly 20 includes a conductive member 1, a connecting member 2, and a coil 3.

[0062] Among them, Figure 1 As shown in FIG. 1 , it is a schematic diagram of the structure of a conductive member 1 in one embodiment of the present application, and a connecting hole 121 is provided through the conductive member 1. Figure 2 As shown, the connecting member 2 is connected to the connecting hole 121, and a portion of the connecting member 2 is located outside the connecting hole 121, so as to achieve welding with the coil 3. Figure 3 As shown, the coil 3 is connected to the portion of the connecting member 2 outside the connecting hole 121 by welding, and the coil assembly 20 is formed after the welding is completed.

[0063] like Figure 7 As shown, it is a schematic diagram of the structure of the conductive member 1 in another embodiment of the present application, such as Figure 8 and Fig. 9 As shown, it is a schematic diagram after the connecting member 2 is installed in the connecting hole 121 of the conductive member 1. Fig.10 , which is a schematic diagram of a coil assembly 20 formed after the coil 3 and the connecting member 2 are welded in this embodiment.

[0064] In the coil assembly 20 provided in the embodiment of the present application, by pre-arranging the connection hole 121 on the conductive member 1, and inserting the connection member 2 made of welding material into the connection hole 121, when welding the coil 3 and the connection member 2, there is no need to use additional welding brazing material to achieve the welding connection between the two, the welding process is simplified, and compared with the method of welding the coil 3 and the conductive member 1 by welding sheets, the production efficiency is improved, and the production efficiency of the low-voltage electrical appliance having the coil assembly 20 can be improved. Moreover, by setting the connection hole 121, it is easy to locate the installation position of the connection member 2 on the conductive member 1, and then the welding position of the coil 3 and the conductive member 1 can be accurately located, effectively improving the positioning accuracy, and ensuring the excellent quality of the coil assembly 20 after welding.

[0065] In addition, in the process of welding the coil 3 and the connector 2, if there is a conductive part 1 in the connecting hole 121 without the connector 2 installed, then the conductive part 1 is a through hole at the position to be welded, which can be quickly identified by the equipment on the automatic production line to separate the conductive part 1, thereby preventing the conductive part 1 from being directly welded to the coil 3 without the connector 2 installed. This effectively solves the problem of welding abnormalities caused by the inability to identify the missing welding piece, improves the detectability of the production process of the coil assembly 20 product, reduces the quality risk in the production process of the coil assembly 20, and is conducive to mass production and improving the yield rate of the product.

[0066] like Figure 2 , Figure 4 , Figure 5 , Figure 6 , Figure 8 as well as Fig. 9 As shown, in the embodiment of the present application, the connecting member 2 includes a penetration portion 23 (see Fig. 9 ) and a welding portion 21. The penetration portion 23 is penetrated in the connection hole 121, one end of the penetration portion 23 extends out of the connection hole 121, and is used to form the welding portion 21 by riveting under the action of an external force. The welding portion 21 formed by riveting is located outside the connection hole 121, and abuts against the two side surfaces of the conductive member 1 respectively, so as to realize the penetration connection of the connector 2 at the connection hole 121. The welding portion 21 is used to be welded and connected with the coil 3, so as to realize the fixation and conductive connection between the conductive member 1 and the coil 3.

[0067] In some embodiments of the present application, the connector 2 further includes a stopper 22, see Figure 4 and Figure 6 , wherein the first end of the penetration portion 23 is connected to the stop portion 22, and the second end of the penetration portion 23 is used to form the welding portion 21 by riveting under the action of external force. After the welding portion 21 is formed by riveting, the stop portion 22 and the welding portion 21 are respectively arranged on both sides of the connecting hole 121, and both are respectively abutted against the two side surfaces of the conductive member 1, thereby realizing the penetration connection of the connecting member 2 at the connecting hole 121.

[0068] In some other embodiments of the present application, the connector 2 may not include the stopper 22, and the penetration portion 23 is integrally penetrated and connected in the connection hole 121, such as Fig. 9 As shown, the cross-section of one end of the penetration portion 23 away from the welding portion 21 becomes larger, and the edge of the hole opening of the connecting hole 121 is set to a shape that matches the penetration portion 23, so that the penetration portion 23 can be limited in the connecting hole 121.

[0069] Exemplarily, the connector 2 is a rivet, which is riveted in the connection hole 121. The connector 2 does not form the welding portion 21 before riveting, and its penetration portion passes through the connection hole 121, and the stopper 22 stops on one side of the conductive member 1. On the other side of the conductive member 1, the second end of the penetration portion 23 is riveted and pressed by a riveting device to form the welding portion 21 that abuts against the other side surface of the conductive member 1. On the one hand, the connector 2 and the conductive member 1 can be firmly connected, ensuring that the structure of the coil 3 and the conductive member 1 is stable after being connected, and is not easy to disconnect. On the other hand, the welding portion 21 formed by riveting can expand the welding area, improve the stability of the coil 3 and the welding portion 21 after welding, further improve the welding quality, and ensure good conductivity between the conductive member 1 and the coil 3.

[0070] like Figure 2 FIG. 1 is a schematic diagram of the connection member 2 after riveting at the connection hole 121 of the conductive member 1. Figure 3 , which is a schematic diagram of the coil assembly 20 formed after the coil 3 and the welding portion 21 are welded.

[0071] In the embodiment of the present application, the cross section of the connection hole 121 can be circular, elliptical or polygonal, but is not limited to the above-mentioned shapes. The polygonal shape is, for example, a triangle, square, pentagon, hexagon, etc., as long as the penetration portion 23 of the connector 2 can pass through and achieve riveting with the connector 2.

[0072] Specifically in this embodiment Figure 1 The cross section of the connecting hole 121 is circular. As a circular hole, it is more convenient to process and manufacture. The connecting hole 121 can be drilled or formed by a stamping process.

[0073] The cross-sectional shape of the penetration portion 23 may be consistent with the cross-sectional shape of the connection hole 121. For example, when the connection hole 121 is a circular hole, the cross-sectional shape of the penetration portion 23 is circular, and the outer diameter of the penetration portion 23 is substantially the same as or slightly smaller than the inner diameter of the connection hole 121. Of course, the cross-sectional shape of the penetration portion 23 may also be different from the cross-sectional shape of the connection hole 121. For example, when the connection hole 121 is a circular hole, the cross-sectional shape of the penetration portion 23 is a hexagon inscribed in the circular hole.

[0074] The size of the connection hole 121 is adjusted according to different current levels of low-voltage electrical appliances such as starters, circuit breakers, etc. and the wire diameter of the coil 3 .

[0075] In the embodiment of the present application, the material of the connector 2 is any one of pure copper, red copper, oxygen-free copper, iron bronze, brass, tin-phosphor bronze, copper alloy, and dispersion-enhanced copper-based materials, and is certainly not limited to the materials listed above. The above materials all contain copper components, have excellent wettability and high solder joint strength, are suitable for working in high temperature environments, and can ensure the stability of the welded connection. At the same time, the above materials containing copper components have better electrical conductivity, ensuring good electrical conduction between the conductive member 1 and the coil 3.

[0076] In the prior art, pre-stamped silver alloy solder sheets are usually used to weld the conductive part 1 and the coil 3, which is relatively costly. The material selected for the connecting part 2 in the embodiment of the present application can be used as a welding solder to achieve the welding of the conductive part 1 and the coil 3, while saving the use of precious metal silver alloy solder, thereby greatly reducing the production cost.

[0077] In the embodiment of the present application, the material of the conductive member 1 is any one of copper-clad steel, copper-clad brass layered composite material, copper-clad stainless steel layered composite material, copper-clad aluminum layered composite material, particle-reinforced copper-based composite material, and copper alloy, and is certainly not limited to the materials listed above. The above materials all contain copper components, have high strength and excellent electrical conductivity, can ensure that the coil assembly 20 has high electrical conductivity, reduce the heat generated by the coil assembly 20 during operation, and have low cost, which is suitable for mass production.

[0078] The copper-clad steel material is a material formed by coating copper on the surface of a steel core, which combines the conductivity of copper with the strength of steel and has excellent conductivity and mechanical properties. The metal layered composite material is a material composed of two or more layers of different metals, and its performance is better than that of a single metal. Different metal layers can be selected as needed to have a variety of excellent properties, such as the copper-clad brass layered composite material, copper-clad stainless steel layered composite material, and copper-clad aluminum layered composite material.

[0079] See also Figure 1 and Figure 3 In some embodiments of the present application, the conductive member 1 includes a first conductive plate 11 and a second conductive plate 12, the second conductive plate 12 is bent and connected to one end of the first conductive plate 11, and the connecting hole 121 passes through the second conductive plate 12. The coil 3 includes a spiral portion 31 and a connecting portion 32, the connecting portion 32 is connected to one end of the spiral portion 31, and extends along the axial direction of the spiral portion 31, the connecting portion 32 is located on the side of the second conductive plate 12 facing away from the first conductive plate 11, and is welded to the connecting member 2. By providing the second conductive plate 12 bent relative to the first conductive plate 11, and providing the connecting portion 32 extending along the axial direction of the spiral portion 31, the welding operation is more convenient, so that the welding operation has enough space, and the welding difficulty is reduced.

[0080] Further, the first conductive plate 11 includes three conductive plate segments 111 that are bent and connected in sequence. The three conductive plate segments 111 are roughly Z-shaped, and are respectively the first conductive plate segment, the second conductive plate segment and the third conductive plate segment. The second conductive plate segment is bent and connected to one side of the first conductive plate segment along the first direction and extends to the second direction. The third conductive plate segment is bent and connected to one side of the second conductive plate segment along the first direction and extends to the first direction. The second conductive plate 12 is connected to one side of the first conductive plate segment along the third direction, and the thickness direction of the second conductive plate 12 is the third direction, that is, the axial direction of the connecting hole 121 is the third direction. The first direction, the second direction and the third direction are perpendicular to each other, and the second direction is the axial direction of the spiral portion 31 of the coil 3, and the first direction and the third direction are both radial directions of the spiral portion 31. The connecting portion 32 of the coil 3 is located on the side of the second conductive plate 12 that is not facing the first conductive plate 11, and is welded and connected to the welding portion 21. The layout is reasonable and the welding operation is convenient.

[0081] In some other embodiments of the present application, see Figure 7 The conductive member 1 may also be in other structural forms, such as a flat plate with a connection hole 121 disposed thereon. The shape and structure of the conductive member 1 may be set according to the adaptability of the specific switchgear, and is not limited to the above-mentioned Figure 1 and Figure 7 The structure shown in the figure does not limit the specific structural form of the conductive member 1, as long as the connecting hole 121 is set through the conductive member 1.

[0082] In some other embodiments of the present application, the relative positions of the spiral portion 31 and the connecting portion 32 of the coil 3 are different from the above-mentioned manner. That is, the extension direction of the connecting portion 32 is not along the axial direction of the spiral portion 31, it can bend vertically and then extend axially, or be inclined relative to the axial direction of the spiral portion 31, and can be set according to the local adaptability of the internal space of the switching device. Furthermore, the coil 3 can be located on the side of the second conductive plate 12 facing away from the first conductive plate 11, or on the side facing the first conductive plate 11, or on the other two side surfaces of the second conductive plate 12. That is, the coil 3 can be located on any side of the conductive member 1, and its axial direction can be perpendicular to one of the conductive plates of the conductive member 1, or can be parallel to the conductive member 1 or have an angle with the conductive member 1. It can be designed and adjusted according to the adaptability of the internal spatial layout of the switching device, and is not limited to the above-mentioned scheme. No limitation is made here on the structure and relative position of the coil 3 and the conductive member 1. See. Figure 4 , Figure 5 as well as Figure 6The portion of the connector 2 outside the connection hole 121 is provided with a welding surface 211, that is, the welding portion 21 is provided with a welding surface 211, the welding surface 211 is welded to the coil 3, and at least one protruding structure 212 is protruded on the welding surface 211. By protruding the protruding structure 212 on the welding surface 211, the welding area can be increased, and the welding strength between the coil 3 and the conductive member 1 can be improved, thereby improving the welding quality of the produced coil assembly 20 product.

[0083] Specifically, when the connecting member 2 is riveted, the riveting head of the riveting equipment has a structure that matches the protruding structure 212 , so that the protruding structure 212 is formed on the welding surface 211 after riveting.

[0084] In some embodiments of the present application, the protrusion structure 212 is a strip-shaped protrusion and is provided in plurality, wherein the plurality of strip-shaped protrusions are distributed at intervals or the plurality of strip-shaped protrusions are distributed in a mesh-like cross pattern. Figure 4 and Figure 6 As shown, multiple strip-shaped protrusions are spaced apart so that the connection strength distribution at the welding position is more uniform. The cross section of the strip-shaped protrusion can be Figure 6 The triangle shown may be a square, an arch, etc.

[0085] Alternatively, in some embodiments of the present application, the protrusion structure 212 is an annular protrusion and is provided with a plurality of them, and the centers of the plurality of annular protrusions are spaced apart or the plurality of annular protrusions are distributed in concentric circles, which can also increase the welding area and improve the welding strength. The cross section of the annular protrusion can be triangular, square, arched, etc.

[0086] Alternatively, in some embodiments of the present application, the protrusion structure 212 is a dot-shaped protrusion and is provided in plurality, and the multiple dot-shaped protrusions are distributed at intervals and further can be evenly distributed to evenly enhance the welding strength. For example, the multiple dot-shaped protrusions are distributed in a rectangular array or a circular array. The dot-shaped protrusions can be cylinders, cones, polygons or spheres, but are not limited to the shapes listed.

[0087] In the embodiment of the present application, the connector 2 is covered with a silver layer. Specifically, before the connector 2 is riveted to the connecting hole 121, the outer surface of the connector 2 is silver-plated to form a silver layer, and the connector 2 covered with the silver layer is riveted to the connecting hole 121 of the conductive member 1. The welding portion 21 formed after riveting has the above-mentioned raised structure 212. The provision of the silver layer can further improve the contact reliability between the connector 2 and the conductive member 1, and can reduce the melting point of the solder during the welding process, thereby achieving fast and reliable welding. After the conductive member 1 and the coil 3 are welded and connected using the silver-plated connector 2, the contact resistance between the conductive member 1 and the coil 3 can be reduced, ensuring good conductivity at the connection between the two.

[0088] Of course, in some other embodiments of the application, the outer surface of the connector 2 may not be covered with a silver layer. During the specific welding operation, the silver layer or not is selected according to the material of the coil 3 and the conductive member 1.

[0089] Several different coil assemblies 20 are listed below with reference to two embodiments.

[0090] Implementation 1:

[0091] In the coil assembly 20 of this embodiment, the coil 3 is made of copper, the conductive member 1 is made of copper-clad steel, and the connector 2 is made of H62 brass. A circular connecting hole 121 is pre-punched in the conductive member 1 made of copper-clad steel and runs through the thickness direction of the conductive member 1 .

[0092] Implementation 2:

[0093] The coil assembly 20 of this embodiment includes a conductive member 1 made of Cu / SUS340 / Cu, a connector 2 made of T2 copper, and a coil 3 made of copper. The conductive member 1 made of Cu / SUS340 / Cu is provided with an elliptical connection hole 121 at the position to be welded, which is used for riveting the connector 2 made of T2 copper. The connector 2 made of T2 copper forms a protruding structure 212 after riveting, and the coil 3 made of copper is welded at the position of the protruding structure 212.

[0094] Compared with the existing connection method of pre-punching out welding pieces, the structure of the coil assembly 20 provided in the embodiment of the present application can effectively improve the yield rate, welding strength and welding quality.

[0095] Embodiment 2

[0096] The present embodiment provides a low-voltage electrical appliance having a coil assembly 20, comprising a housing and the coil assembly 20 as described above, wherein the coil assembly 20 is disposed in the housing. The low-voltage electrical appliance having the coil assembly 20 can improve the production efficiency of the low-voltage electrical appliance, reduce the production cost of the low-voltage electrical appliance, improve the quality performance of the low-voltage electrical appliance, and maintain a high production quality stability of the low-voltage electrical appliance, because the coil assembly 20 has the advantages of low cost, high production energy efficiency, high quality, and high quality stability.

[0097] Exemplarily, the low-voltage electrical appliance may be a switch device such as a starter of an AC motor, a circuit breaker, etc., but is not limited to the switch devices listed.

[0098] Embodiment 3

[0099] like Fig.11 As shown, this embodiment provides a method for preparing a coil assembly, which is used to prepare the coil assembly 20 as described above, and the preparation method includes:

[0100] S1, punching: opening a connection hole 121 at a preset position of the conductive member 1;

[0101] S2, riveting: riveting the connecting member 2 to the connecting hole 121 so that a portion of the connecting member 2 is located outside the connecting hole 121;

[0102] S3, welding: welding one end of the coil 3 to the portion of the connector 2 outside the connection hole 121 .

[0103] In step S1 , a preset position is determined on the conductive member 1 according to the position to be welded between the conductive member 1 and the coil 3 . Specifically, a through hole can be punched in the thickness direction of the conductive member 1 by a stamping process to form the connection hole 121 .

[0104] Before step S2, the method further includes: silver-plating the connector 2 to form a silver layer on the outer surface of the connector 2. The beneficial effects of the silver-plating treatment are as described above. In step S2, a protruding structure 212 is formed on the welding portion 21 formed by riveting the connector 2 to increase the welding area and improve the welding strength and quality. Figure 2 The riveted assembly 10 is shown.

[0105] In step S3, the connection portion 32 of the coil 3 is welded to the protruding structure 212 of the riveted assembly 10 obtained in step S2 by any one of resistance welding, ultrasonic welding, and laser welding, and finally the desired coil assembly 20 is obtained. Figure 3 shown.

[0106] In the coil assembly preparation method provided in the embodiment of the present application, by pre-setting a connection hole 121 at the position to be welded of the conductive member 1, and inserting and riveting a connector 2 made of welding material in the connection hole 121, when welding the coil 3 and the connector 2, there is no need to use additional welding brazing material to achieve the welding connection between the two, the welding process is simplified, and compared with the method of welding the coil 3 and the conductive member 1 by a welding sheet, the production efficiency is improved, and the production efficiency of the low-voltage electrical appliance having the coil assembly 20 can be improved. Moreover, by setting the connection hole 121, it is easy to locate the installation position of the connector 2 on the conductive member 1, and then the welding position of the coil 3 and the conductive member 1 can be accurately located, effectively improving the positioning accuracy, and ensuring the excellent quality of the coil assembly 20 after welding.

[0107] In addition, in the process of welding the coil 3 and the connector 2, if there is a conductive part 1 in the connecting hole 121 without riveting the connecting part 2, the conductive part 1 is a through hole at the welding position at this time, which can be quickly identified by the equipment on the automatic production line to separate the conductive part 1, thereby preventing the conductive part 1 from being directly welded to the coil 3 without installing the connecting part 2. This effectively solves the problem of welding abnormalities caused by the inability to identify the missing welding piece, improves the detectability of the coil assembly 20 product production process, reduces the quality risk in the coil assembly 20 production process, and is conducive to mass production and improving the product yield rate.

[0108] The preparation method is further specifically described by assuming that the material of the coil 3 is copper, the material of the conductive member 1 is copper-clad steel, and the material of the connecting member 2 is H62 brass.

[0109] Step S1: Punching: A circular connection hole 121 penetrating the thickness direction of the conductive member 1 is pre-punched at a preset position of the conductive member 1 made of copper-clad steel.

[0110] Step S2: Riveting. A connector 2 (rivet) made of H62 brass is riveted to the connection hole 121 processed on the conductive member 1 in step S1 to obtain a riveted assembly 10 with a protruding structure 212 on the surface of the nail cap (welding portion 21); the protruding structure 212 is a strip-shaped protrusion with a triangular cross section, so that the surface of the nail cap is formed as follows: Figure 6 The sawtooth structure shown.

[0111] Step S3: welding. The connection portion 32 of one end of the copper coil 3 is resistance welded to the nail cap (welding portion 21) of the riveted assembly 10 obtained in step S2, and finally the desired coil assembly 20 is obtained.

[0112] Compared with the existing connection method of pre-punching out welding pieces, the coil assembly preparation method provided in the embodiment of the present application can increase the yield rate by 16% and the welding strength by 8%.

[0113] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, various obvious changes, readjustments and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A coil assembly, characterized in that include: A conductive member (1), wherein a connecting hole (121) is provided through the conductive member (1); A connecting piece (2), wherein the material of the connecting piece (2) is a welding material; the connecting piece (2) is penetrated and connected to the connecting hole (121), and a portion of the connecting piece (2) is located outside the connecting hole (121); A coil (3), the coil (3) being connected to a portion of the connecting member (2) located outside the connecting hole (121) by welding.

2. The coil assembly according to claim 1, characterized in that: The connecting piece (2) comprises a penetration portion (23) and a welding portion (21); The penetration portion (23) is penetrated in the connection hole (121); one end of the penetration portion (23) is used to form the welding portion (21) by riveting under the action of an external force; the welding portion (21) is located outside the connection hole (121) and abuts against the conductive member (1); the welding portion (21) is welded to the coil (3).

3. The coil assembly according to claim 2, characterized in that: The connecting member (2) further comprises a stopper (22), wherein the stopper (22) and the welding portion (21) are respectively arranged at two ends of the penetration portion (23), and the stopper (22) is located outside the connecting hole (121) and abuts against the conductive member (1).

4. The coil assembly according to claim 1, characterized in that: The cross section of the connecting hole (121) is circular, elliptical or polygonal.

5. The coil assembly according to claim 1, characterized in that: The material of the connecting piece (2) is any one of pure copper, red copper, oxygen-free copper, iron bronze, brass, tin-phosphor bronze, copper alloy, and dispersion-reinforced copper-based material.

6. The coil assembly according to claim 1, characterized in that: The material of the conductive element (1) is any one of copper-clad steel, copper-clad brass layered composite material, copper-clad stainless steel layered composite material, copper-clad aluminum layered composite material, particle-reinforced copper-based composite material, and copper alloy; And / or, the coil (3) comprises a spiral portion (31) and a connecting portion (32), wherein the connecting portion (32) is connected to one end of the spiral portion (31) and is welded to the connecting piece (2).

7. The coil assembly according to any one of claims 1 to 6, characterized in that: The portion of the connecting member (2) located outside the connecting hole (121) is provided with a welding surface (211), the welding surface (211) is connected to the coil (3) by welding, and at least one protruding structure (212) is protruded from the welding surface (211).

8. The coil assembly according to claim 7, characterized in that: The protrusion structure (212) is a strip-shaped protrusion and is provided in plurality, wherein the plurality of strip-shaped protrusions are distributed at intervals or the plurality of strip-shaped protrusions are distributed crosswise in a mesh shape; or, The protrusion structure (212) is an annular protrusion and is provided in plurality, the centers of the plurality of annular protrusions being distributed at intervals or the plurality of annular protrusions being distributed in concentric circles; or, The protrusion structure (212) is a dot-shaped protrusion and is provided in plurality; A plurality of the dot-shaped protrusions are distributed at intervals; and / or the dot-shaped protrusions are cylinders, cones, polygons or spheres.

9. The coil assembly according to any one of claims 1 to 6, characterized in that: The connecting piece (2) is covered with a silver layer.

10. A low-voltage electrical apparatus having a coil assembly, characterized in that: It comprises a shell and a coil assembly as claimed in any one of claims 1 to 9, wherein the coil assembly is arranged in the shell.

11. A method for preparing a coil assembly, characterized in that: For preparing the coil assembly according to any one of claims 1 to 9, the preparation method comprising: A connection hole (121) is provided at a preset position of the conductive member (1); Riveting the connecting piece (2) to the connecting hole (121) so that a portion of the connecting piece (2) is located outside the connecting hole (121); One end of the coil (3) is welded to a portion of the connecting member (2) located outside the connecting hole (121).

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