Coil component assembling method and coil component

Abstract

The invention provides a coil component assembly method and a coil component, and the method comprises the steps: enabling an upper waterproof cover to cover the top of a stator assembly, enabling a lower waterproof cover to cover the bottom of the stator assembly, and enabling an annular gap to be formed between the upper waterproof cover and the lower waterproof cover; injection molding materials are injected into the stator assembly and the annular gap to form an encapsulation structure through injection molding, the encapsulation structure encapsulates the coil assembly of the stator assembly, and the encapsulation structure is connected with the upper waterproof cover and the lower waterproof cover in a sealed mode. According to the scheme, the stator assembly is fully wrapped and protected through the upper waterproof cover, the lower waterproof cover and the wrapping structure between the upper waterproof cover and the lower waterproof cover, so that the waterproof performance of the coil component is improved, and the wrapping structure does not need to wrap the whole outer surface of the stator assembly; therefore, the injection molding difficulty of the encapsulation structure and the injection molding pressure on the interior of the stator assembly are reduced, and the encapsulation structure can be reliably connected with the upper waterproof cover and the lower waterproof cover in the injection molding process and does not need to be connected through an independent process or structure.

Description

Technical Field

[0001] This invention relates to the field of coil components in valves, and more specifically, to a coil component assembly method and a coil component. Background Technology

[0002] The coil component of an electronic expansion valve comprises a stator assembly and an encapsulation structure. The stator assembly has an internal bore through which the valve body passes, and the encapsulation structure encapsulates the coil assembly within the stator assembly. In some designs, the encapsulation structure only encapsulates a portion of the outer surface of the stator assembly, leaving both ends exposed. This allows rainwater and other liquids to easily enter the stator assembly, potentially causing short circuits and affecting product performance. In other designs, the encapsulation structure completely covers the outer surface of the stator assembly, thereby improving its waterproof performance. However, this structure is integrally injection molded inside and outside the stator assembly. This method results in high injection pressure inside the stator assembly and makes the injection molding of the encapsulation structure difficult, increasing the likelihood of injection molding defects. Summary of the Invention

[0003] This invention provides a coil component assembly method and a coil component to solve the problems of poor waterproofing and difficult injection molding of coil components in the prior art.

[0004] To address the above problems, according to one aspect of the present invention, a coil component assembly method is provided, comprising:

[0005] S10. Cover the top of the stator assembly with the upper waterproof cover and cover the bottom of the stator assembly with the lower waterproof cover, and form an annular gap between the upper and lower waterproof covers.

[0006] S20. Inject the injection molding compound into the stator assembly and the annular gap to form an encapsulation structure. The encapsulation structure encapsulates the coil assembly of the stator assembly, and the encapsulation structure is sealed to the upper and lower waterproof covers.

[0007] Furthermore, in S10, at least a portion of the inner wall of the upper waterproof cover is fitted to the outer wall of the stator assembly, the fitting area of ​​which surrounds the stator assembly; the coil component assembly method further includes:

[0008] Before injection molding the encapsulation structure, the assembled structure in S10 is placed into the injection mold, wherein at least a portion of the outer wall of the upper waterproof cover is attached to the inner wall of the injection mold, and the attachment area of ​​the two surrounds the upper waterproof cover.

[0009] Furthermore, in S10, at least a portion of the inner wall of the lower waterproof cover is fitted to the outer wall of the stator assembly, the fitting area of ​​which surrounds the stator assembly; the coil component assembly method further includes:

[0010] Before injection molding the encapsulation structure, the assembled structure in S10 is placed into the injection mold, wherein at least a portion of the outer wall of the lower waterproof cover is attached to the inner wall of the injection mold, and the attachment area of ​​the two surrounds the lower waterproof cover.

[0011] Furthermore, in S10, at least a portion of the inner wall of the upper waterproof cover is attached to the outer wall or top wall of the stator assembly, and the area of ​​attachment of the two forms an upper annular sealing area surrounding the stator assembly; at least a portion of the inner wall of the lower waterproof cover is attached to the outer wall or bottom wall of the stator assembly, and the area of ​​attachment of the two forms a lower annular sealing area surrounding the stator assembly.

[0012] Furthermore, the stator assembly includes an upper inner stator plate, a lower inner stator plate, an upper outer stator plate, a lower outer stator plate, and a cylindrical upper stator housing and a lower stator housing, all coaxially arranged. The upper stator housing surrounds the upper outer stator plate and the two are integrally formed. Multiple pole teeth in the upper outer stator plate and the upper inner stator plate are staggered. A coil assembly is disposed between the upper stator housing, the upper outer stator plate, and the upper inner stator plate. The lower stator housing surrounds the lower outer stator plate and the two are integrally formed. Multiple pole teeth in the lower outer stator plate and the lower inner stator plate are staggered. A coil assembly is disposed between the lower stator housing, the lower outer stator plate, and the lower inner stator plate.

[0013] In S10, the upper waterproof cover is attached to the upper stator housing or to the top wall of the upper outer stator plate to form an upper annular sealing area; the lower waterproof cover is attached to the lower stator housing or to the bottom wall of the lower outer stator plate to form a lower annular sealing area; in S20, injection molding compound is injected into the gaps between the upper stator housing, the upper outer stator plate, and the upper inner stator plate, as well as into the gaps between the lower stator housing, the lower outer stator plate, and the lower inner stator plate to encapsulate the two coil assemblies.

[0014] Alternatively, the stator assembly includes an upper inner stator plate, a lower inner stator plate, an upper outer stator plate, a lower outer stator plate, and a cylindrical stator housing arranged coaxially. Multiple pole teeth in the upper outer stator plate and the upper inner stator plate are staggered, as are multiple pole teeth in the lower outer stator plate and the lower inner stator plate. The upper end of the stator housing is connected to the upper outer stator plate, and the lower end of the stator housing is connected to the lower outer stator plate. A coil assembly is disposed between the stator housing, the upper outer stator plate, and the upper inner stator plate, and a coil assembly is disposed between the stator housing, the lower outer stator plate, and the lower inner stator plate. The stator housing has an axially extending notch to avoid the pins of the coil assembly.

[0015] In S10, the upper waterproof cover is attached to the periphery of the upper outer stator plate or to the top wall of the upper outer stator plate to form an upper annular sealing area; the lower waterproof cover is attached to the periphery of the lower outer stator plate or to the bottom wall of the lower outer stator plate to form a lower annular sealing area; in S20, injection molding compound is injected into the gaps between the stator housing, the upper outer stator plate, and the upper inner stator plate, as well as into the gaps between the stator housing, the lower outer stator plate, and the lower inner stator plate to encapsulate the two coil assemblies.

[0016] Furthermore, the end of the upper waterproof cover facing the lower waterproof cover is an annular upper mating surface, and the upper mating surface has at least one annular upper connecting rib; the end of the lower waterproof cover facing the upper waterproof cover is an annular lower mating surface, and the lower mating surface has at least one annular lower connecting rib; in S20, during the injection molding process to form the encapsulation structure, the injection molding material contacts and connects with the upper mating surface, the upper connecting rib, the lower mating surface, and the lower connecting rib.

[0017] Furthermore, the upper waterproof cover is injection molded. The upper waterproof cover includes a small cylindrical section and a large cylindrical section connected to each other. The diameter of the small cylindrical section is smaller than that of the large cylindrical section. The large cylindrical section covers the top of the stator assembly and is sealed to the encapsulation structure. The end of the small cylindrical section away from the stator assembly has a top wall that covers the inner hole of the coil assembly. The small cylindrical section is used to accommodate the end of the valve body that passes through the stator assembly.

[0018] Furthermore, the lower waterproof cover is injection molded and has a clearance hole for passing through the valve body of the stator assembly. The inner wall of the lower waterproof cover has a sealing groove surrounding the clearance hole, and a sealing ring is provided in the sealing groove to seal the gap between the valve body and the clearance hole.

[0019] Further, in S10, the limiting member is fixedly connected to the top of the stator assembly or to the inner wall of the upper waterproof cover, the limiting member being used to limit the valve body passing through the stator assembly; and / or, the pins in the coil assembly and the ends of the wires in the wire assembly are inserted into the fixing frame, and then the ends of the wires are electrically connected to the corresponding pins; in S20, during the injection molding process to form the encapsulation structure, the injection molding material encapsulates a portion of the fixing frame and the wire assembly.

[0020] Furthermore, before injection molding the encapsulation structure, the assembled structure in S10 is placed into the injection mold. The injection mold includes an upper mold and a lower mold that cooperate with each other. The upper mold has an upper cavity, and the lower mold has a lower cavity. The upper and lower cavities together accommodate the upper waterproof cover, the stator assembly, and the lower waterproof cover. The injection mold also has a wire cavity, which is located in the upper mold and / or the lower mold. The wire cavity connects to an annular gap and accommodates the fixing frame and a part of the wire assembly. The gap in the wire cavity is filled with injection molding material.

[0021] According to another aspect of the present invention, a coil component is provided, the coil component including a stator assembly, an upper waterproof cover, a lower waterproof cover, and an encapsulation structure, the stator assembly having a coil assembly, the upper waterproof cover covering the top of the stator assembly, the lower waterproof cover covering the bottom of the stator assembly, an annular gap being formed between the upper waterproof cover and the lower waterproof cover, the encapsulation structure being an injection-molded structure, the encapsulation structure filling the gap within the stator assembly to encapsulate the coil assembly, the encapsulation structure filling the annular gap and being sealed to the upper waterproof cover and the lower waterproof cover.

[0022] The present invention provides a method for assembling coil components, comprising: S10, covering the top of the stator assembly with an upper waterproof cover and the bottom of the stator assembly with a lower waterproof cover, forming an annular gap between the upper and lower waterproof covers; S20, injecting injection molding material into the stator assembly and the annular gap to form an encapsulation structure, the encapsulation structure encapsulating the coil assembly of the stator assembly, and the encapsulation structure being sealed to the upper and lower waterproof covers. In this solution, the upper and lower waterproof covers and the encapsulation structure between them achieve full encapsulation and protection of the stator assembly, thereby improving the waterproof performance of the coil components. Furthermore, the encapsulation structure in this solution does not need to cover the entire outer surface of the stator assembly, reducing the injection molding difficulty of the encapsulation structure and the injection molding pressure inside the stator assembly. Moreover, the encapsulation structure can achieve a reliable connection with the upper and lower waterproof covers during the injection molding process, eliminating the need for a separate process or structure, simplifying the process. Attached Figure Description

[0023] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0024] Figure 1 A flowchart illustrating the coil component assembly method provided in an embodiment of the present invention is shown;

[0025] Figure 2 A schematic diagram of a coil component is shown;

[0026] Figure 3 It shows Figure 2 A schematic diagram of the stator assembly in the diagram;

[0027] Figure 4 It shows Figure 3 A sectional view;

[0028] Figure 5 A schematic diagram of another coil component is shown;

[0029] Figure 6 It shows Figure 5 A schematic diagram of the stator assembly in the diagram;

[0030] Figure 7 It shows Figure 6 A sectional view;

[0031] Figure 8 This diagram illustrates the fit between the coil component and the injection mold before injection molding in the coil component assembly method.

[0032] Figure 9 This diagram illustrates the fit between the coil component and the injection mold after injection molding in the coil component assembly method.

[0033] The above figures include the following reference numerals:

[0034] 10. Install the waterproof cover; 11. Install the connecting ribs; 12. Small section; 13. Large section;

[0035] 20. Stator assembly; 21. Coil assembly; 211. Pin; 22. Upper inner stator plate; 23. Lower inner stator plate; 24. Upper outer stator plate; 25. Lower outer stator plate; 26. Upper stator housing; 27. Lower stator housing; 28. Stator casing;

[0036] 30. Lower waterproof cover; 31. Lower connecting rib; 32. Clearance hole;

[0037] 40. Encapsulation structure;

[0038] 50. Injection mold; 51. Upper mold; 52. Lower mold;

[0039] 61. Limiting component; 62. Wire assembly; 63. Fixing bracket. Detailed Implementation

[0040] 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. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0041] like Figures 1 to 9As shown, the present invention provides a coil assembly method, including: S10, covering the top of the stator assembly 20 with an upper waterproof cover 10 and covering the bottom of the stator assembly 20 with a lower waterproof cover 30, forming an annular gap between the upper waterproof cover 10 and the lower waterproof cover 30; S20, injecting injection molding compound into the stator assembly 20 and the annular gap to form an encapsulation structure 40, the encapsulation structure 40 encapsulating the coil assembly 21 of the stator assembly 20, and the encapsulation structure 40 being sealed to the upper waterproof cover 10 and the lower waterproof cover 30. The coil assembly 21 includes a frame, a winding wire wound on the frame, and a plurality of pins mounted on the frame, the pins being electrically connected to the winding wire.

[0042] In this solution, the stator assembly 20 is fully enclosed and protected by the upper waterproof cover 10, the lower waterproof cover 30, and the encapsulation structure 40 between them, thereby improving the waterproof performance of the coil components. Furthermore, the encapsulation structure 40 in this solution does not need to cover the entire outer surface of the stator assembly 20, reducing the injection molding difficulty of the encapsulation structure 40 and the injection molding pressure inside the stator assembly 20. Moreover, the encapsulation structure 40 can achieve a reliable connection with the upper waterproof cover 10 and the lower waterproof cover 30 during the injection molding process, without the need for a separate process or structure for connection, thus simplifying the process.

[0043] In this method, in S10, at least a portion of the inner wall of the upper waterproof cover 10 is attached to the outer wall of the stator assembly 20, and the attachment area of ​​the two surrounds the stator assembly 20 (surrounding the stator assembly 20 means that it does not necessarily surround a whole circle, but the surrounding range is greater than half a circle); the coil component assembly method further includes: before injection molding the encapsulation structure 40, placing the structure assembled in S10 into the injection mold 50, wherein at least a portion of the outer wall of the upper waterproof cover 10 is attached to the inner wall of the injection mold 50, and the attachment area of ​​the two surrounds the upper waterproof cover 10.

[0044] In the prior art, when positioning the injection mold and the coil assembly, a mandrel is set in the injection mold and inserted into the inner hole of the stator assembly 20 to achieve positioning. This structure is relatively complex.

[0045] In this solution, through the above-mentioned setup, the injection mold 50 positions the circumferential surface of the upper waterproof cover 10, and the upper waterproof cover 10 positions the circumferential surface of the stator assembly 20. This achieves the limitation of the relative positions of the injection mold 50 and the coil assembly 21 in the stator assembly 20. This ensures that during subsequent injection molding, the injection molding material flows into the appropriate position to encapsulate the winding of the coil assembly 21, guaranteeing a good encapsulation effect. Furthermore, this method eliminates the need for a mandrel in the injection mold 50, simplifying the structure and reducing mold costs.

[0046] Furthermore, in S10, at least a portion of the inner wall of the lower waterproof cover 30 is attached to the outer wall of the stator assembly 20, and the attachment area of ​​the two surrounds the stator assembly 20; the coil component assembly method further includes: before injection molding the encapsulation structure 40, placing the structure assembled in S10 into the injection mold 50, wherein at least a portion of the outer wall of the lower waterproof cover 30 is attached to the inner wall of the injection mold 50, and the attachment area of ​​the two surrounds the lower waterproof cover 30.

[0047] Through the above settings, the injection mold 50 positions the circumferential surface of the lower waterproof cover 30, and the lower waterproof cover 30 positions the circumferential surface of the stator assembly 20, thereby limiting the relative position of the injection mold 50 and the coil assembly 21 in the stator assembly 20 to ensure the injection molding effect. In this solution, the lower waterproof cover 30 and the upper waterproof cover 10 can be used together to position the stator assembly 20, further improving the positioning accuracy.

[0048] In this scheme, in S20, the injection port for the plastic injection can be located between the upper waterproof cover 10 and the lower waterproof cover 30, or it can be located in other suitable positions. In S10, at least a portion of the inner wall of the upper waterproof cover 10 is fitted with the outer wall or top wall of the stator assembly 20, and the area of ​​the fit between the two forms an upper annular sealing area surrounding the stator assembly 20; at least a portion of the inner wall of the lower waterproof cover 30 is fitted with the outer wall or bottom wall of the stator assembly 20, and the area of ​​the fit between the two forms a lower annular sealing area surrounding the stator assembly 20. Both the upper and lower annular sealing areas surround the inner hole of the stator assembly 21 through which the valve body passes.

[0049] With the above configuration, during injection molding, the injection plastic is blocked by the upper and lower annular sealing areas, preventing it from entering the pole teeth of the stator assembly 20 through the gap between the stator assembly 20 and the inner walls of the two waterproof covers. This saves injection plastic, reduces material costs, and avoids the injection plastic from clogging the inner holes of the stator assembly 20. Furthermore, by using the above configuration, the upper waterproof cover 10 and the lower waterproof cover 30 effectively prevent the injection plastic from entering the pole teeth of the stator assembly 20, eliminating the need for additional structures to prevent material from entering the pole teeth.

[0050] like Figures 2 to 4As shown, in one embodiment, the stator assembly 20 includes an upper inner stator plate 22, a lower inner stator plate 23, an upper outer stator plate 24, a lower outer stator plate 25, and a cylindrical upper stator housing 26 and a lower stator housing 27. The upper stator housing 26 surrounds the upper outer stator plate 24 and the two are integrally structured. Multiple pole teeth in the upper outer stator plate 24 and the upper inner stator plate 22 are staggered. A coil assembly 21 is disposed between the upper stator housing 26, the upper outer stator plate 24, and the upper inner stator plate 22. The lower stator housing 27 surrounds the lower outer stator plate 25 and the two are integrally structured. Multiple pole teeth in the lower outer stator plate 25 and the lower inner stator plate 23 are staggered. A coil assembly 21 is disposed between the lower stator housing 27, the lower outer stator plate 25, and the lower inner stator plate 23.

[0051] In S10, the upper waterproof cover 10 is attached to the upper stator housing 26 or to the top wall of the upper outer stator plate 24 to form an upper annular sealing area; the lower waterproof cover 30 is attached to the lower stator housing 27 or to the bottom wall of the lower outer stator plate 25 to form a lower annular sealing area; in S20, injection molding compound is injected through the injection port into the gaps between the upper stator housing 26, the upper outer stator plate 24, and the upper inner stator plate 22, as well as the gaps between the lower stator housing 27, the lower outer stator plate 25, and the lower inner stator plate 23 to encapsulate the two coil assemblies 21.

[0052] Through the above settings, the top of the stator assembly 20 is circumferentially sealed and the bottom of the stator assembly 20 is sealed. After the encapsulation structure 40 is injection molded, no material will be fed between the pole teeth of the stator assembly 20, and the encapsulation effect of the stator assembly 20 is guaranteed.

[0053] like Figures 5 to 7 As shown, in another example, the stator assembly 20 includes an upper inner stator plate 22, a lower inner stator plate 23, an upper outer stator plate 24, a lower outer stator plate 25, and a cylindrical stator housing 28, all coaxially arranged. Multiple pole teeth in the upper outer stator plate 24 and the upper inner stator plate 22 are staggered, as are multiple pole teeth in the lower outer stator plate 25 and the lower inner stator plate 23. The upper end of the stator housing 28 is connected to the upper outer stator plate 24, and the lower end of the stator housing 28 is connected to the lower outer stator plate 25. A coil assembly 21 is disposed between the stator housing 28, the upper outer stator plate 24, and the upper inner stator plate 22, and also between the stator housing 28, the lower outer stator plate 25, and the lower inner stator plate 23. The stator housing 28 has an axially extending notch to accommodate the pins 211 of the coil assembly 21.

[0054] In S10, the upper waterproof cover 10 is attached to the periphery of the upper outer stator plate 24 or to the top wall of the upper outer stator plate 24 to form an upper annular sealing area; the lower waterproof cover 30 is attached to the periphery of the lower outer stator plate 25 or to the bottom wall of the lower outer stator plate 25 to form a lower annular sealing area; in S20, injection plastic is injected through the injection port into the gaps between the stator housing 28, the upper outer stator plate 24, and the upper inner stator plate 22, as well as into the gaps between the stator housing 28, the lower outer stator plate 25, and the lower inner stator plate 23 to encapsulate the two coil assemblies 21.

[0055] In this scheme, although the stator housing 28 has a notch extending along the axial direction, the sealing positions of the upper and lower annular sealing areas ensure that material will not feed between the pole teeth of the stator assembly 20 during injection molding.

[0056] like Figure 2 and Figure 5 As shown, in this scheme, the end of the upper waterproof cover 10 facing the lower waterproof cover 30 is an annular upper mating surface, and the upper mating surface has at least one annular upper connecting rib 11. The cross-sectional area of ​​the upper connecting rib 11 gradually decreases along the direction of the upper waterproof cover 10 towards the lower waterproof cover 30. The end of the lower waterproof cover 30 facing the upper waterproof cover 10 is an annular lower mating surface, and the lower mating surface has at least one annular lower connecting rib 31. The cross-sectional area of ​​the lower connecting rib 31 gradually decreases along the direction of the lower waterproof cover 30 towards the upper waterproof cover 10. In S20, during the injection molding process to form the encapsulation structure 40, the injection molding material contacts and connects with the upper mating surface, the upper connecting rib 11, the lower mating surface, and the lower connecting rib 31. With the above configuration, the upper connecting rib 11 and the lower connecting rib 31 are embedded in the injection molding compound. During the injection molding process, the portion of the upper connecting rib 11 facing the lower waterproof cover 30 is fused with the injection molding compound, and the portion of the lower connecting rib 31 facing the upper waterproof cover 10 is fused with the injection molding compound. This improves the connection strength and sealing effect between the upper waterproof cover 10 and the encapsulation structure 40, and also improves the connection strength and sealing effect between the lower waterproof cover 30 and the encapsulation structure 40, thereby enhancing the reliability of the coil components.

[0057] In this design, both the upper waterproof cover 10 and the lower waterproof cover 30 are first injection molded and then assembled with the stator assembly 20. Injection molding reduces production costs. The lower waterproof cover 30 has a clearance hole 32, which is used to allow the valve body passing through the stator assembly 20 to pass through.

[0058] like Figure 2As shown, the upper waterproof cover 10 includes a small cylindrical section 12 and a large cylindrical section 13 connected to each other. The diameter of the small cylindrical section 12 is smaller than the diameter of the large cylindrical section 13. The large cylindrical section 13 covers the top of the stator assembly 20 and is sealed to the encapsulation structure 40. The end of the small cylindrical section 12 away from the stator assembly 20 has a top wall that covers the inner hole of the coil assembly 21. The small cylindrical section 12 is used to accommodate the end of the valve body that passes through the stator assembly 20. With the above configuration, the upper waterproof cover 10 achieves full coverage of the top of the stator assembly 20, ensuring a sealing effect and preventing interference with the valve body that passes through the stator assembly 20.

[0059] In an embodiment not shown, the inner wall of the lower waterproof cover 30 has a sealing groove, and a sealing ring is disposed in the sealing groove. The sealing ring is used to seal the gap between the valve body and the clearance hole 32. By setting the sealing ring, moisture is prevented from entering the stator assembly 20 through the clearance hole 32, further improving the waterproof effect and corrosion resistance.

[0060] In an embodiment not shown, the inner wall of the lower waterproof cover 30 has an annular rib surrounding the clearance hole 32. A sealing groove is formed between the annular rib and the inner wall of the lower waterproof cover 30. A sealing ring is disposed in the sealing groove to seal the gap between the valve body and the clearance hole 32. By providing the sealing ring, moisture is prevented from entering the stator assembly 20 through the clearance hole 32, further improving the waterproof effect and corrosion resistance.

[0061] like Figure 2 As shown, in this solution, in S10, the limiting member 61 is fixedly connected to the top of the stator assembly 20 or to the inner wall of the upper waterproof cover 10. The limiting member 61 is used to limit the valve body passing through the stator assembly 20; the limiting member 61 can limit the relative position of the coil component and the valve body. The limiting member 61 can be connected to the valve body by means of snap-fit, bolt connection, etc. The limiting member 61 can be connected to the stator assembly 20 or the upper waterproof cover 10 by means of welding, riveting, etc.

[0062] In this design, the pins 211 in the coil assembly 21 and the wire ends in the wire assembly 62 are inserted into the fixing bracket 63, and then the wire ends are electrically connected to the corresponding pins 211. The fixing bracket 63 can position multiple pins 211 and multiple wire ends to facilitate the electrical connection between the wire ends and the corresponding pins 211. Specifically, the wire ends and pins can be electrically connected by crimping, soldering, or other methods.

[0063] In S20, during the injection molding process to form the encapsulation structure 40, the injection-molded plastic encapsulates the pin 211, the retainer 63, and a portion of the encapsulated wire assembly 62. This encapsulates and secures the connection between the pin 211 and the wire end, preventing the pin 211 from detaching from the wire end and providing insulation and protection.

[0064] In this scheme, the assembled structure in S10 is placed into the injection mold 50 before the injection-molded encapsulation structure 40. For example... Figure 8 and Figure 9 As shown, the injection mold 50 includes an upper mold 51 and a lower mold 52 that cooperate with each other. The upper mold 51 has an upper cavity, and the lower mold 52 has a lower cavity. The upper and lower cavities together accommodate the upper waterproof cover 10, the stator assembly 20, and the lower waterproof cover 30. The injection mold 50 also has a wire guide cavity, which can be located in the upper mold 51, the lower mold 52, or the upper mold 51 and the lower mold 52 can jointly form the wire guide cavity. The wire guide cavity is connected to an annular gap and accommodates the fixing frame 63 and a portion of the wire guide assembly 62. The gaps in the wire guide cavity are filled with injection molding material. This injection mold 50 has a simple structure and can position the upper waterproof cover 10, the stator assembly 20, and the lower waterproof cover 30.

[0065] The injection mold 50 can be set in different positions as needed.

[0066] In some embodiments, the gating port can be located at any position around the connection between the pin 211 and the lead assembly 62. For example, the gating port can be located on one or both sides or in the middle of the connection between the pin 211 and the lead assembly 62, or at the root of the lead wire connecting the lead assembly 62 and the pin, or any combination of the above positions.

[0067] In some embodiments, the pouring gate may be located on or around the circumferential surface of the stator housing or stator casing 28 between the upper waterproof cover 10 and the lower waterproof cover 30. For example, the pouring gate may be located on the side of the stator casing 28 between the upper waterproof cover 10 and the lower waterproof cover 30 away from the lead assembly 62. One or more pouring gates may be provided.

[0068] In some embodiments, a plurality of gating ports are provided, wherein at least one gating port is located at any position around the connection between the pin 211 and the lead assembly 62, and at least one gating port is located on or around the circumferential surface of the stator housing or stator casing 28 between the upper waterproof cover 10 and the lower waterproof cover 30.

[0069] This solution also provides a coil component, which includes a stator assembly 20, an upper waterproof cover 10, a lower waterproof cover 30, and an encapsulation structure 40. The stator assembly 20 has a coil assembly 21, which has a skeleton, winding wire, and pins 211. The upper waterproof cover 10 covers the top of the stator assembly 20, and the lower waterproof cover 30 covers the bottom of the stator assembly 20. An annular gap is formed between the upper waterproof cover 10 and the lower waterproof cover 30. The encapsulation structure 40 is an injection-molded structure that fills the gap inside the stator assembly 20 to encapsulate the coil assembly 21. The encapsulation structure 40 fills the annular gap and is sealed to the upper waterproof cover 10 and the lower waterproof cover 30.

[0070] In this solution, the upper waterproof cover 10, the lower waterproof cover 30, and the encapsulation structure 40 between them achieve full wrapping and protection between the depolarizing teeth of the stator assembly 20, thereby improving the waterproof performance of the coil components, saving the use of molding compound during the injection molding process, and reducing production costs. Furthermore, the encapsulation structure 40 in this solution does not need to wrap the entire outer surface of the stator assembly 20, reducing the injection molding difficulty of the encapsulation structure 40 and the injection molding pressure inside the stator assembly 20. Moreover, the encapsulation structure 40 can achieve a reliable connection with the upper waterproof cover 10 and the lower waterproof cover 30 during the injection molding process, eliminating the need for a separate process or structure, simplifying the process.

[0071] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0072] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0073] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as exemplary only and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0074] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0075] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0076] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

Claims

1. A method for assembling a coil component, characterized in that, include: S10. Cover the top of the stator assembly (20) with the upper waterproof cover (10) and cover the bottom of the stator assembly (20) with the lower waterproof cover (30), and form an annular gap between the upper waterproof cover (10) and the lower waterproof cover (30). S20. Injection molding compound into the stator assembly (20) and the annular gap to form an encapsulation structure (40), the encapsulation structure (40) encapsulating the coil assembly (21) of the stator assembly (20), and the encapsulation structure (40) is sealed to the upper waterproof cover (10) and the lower waterproof cover (30).

2. The coil component assembly method according to claim 1, characterized in that, In S10, at least a portion of the inner wall of the upper waterproof cover (10) is fitted to the outer wall of the stator assembly (20), the fitting area of ​​the two surrounding the stator assembly (20); the coil component assembly method further includes: Before injection molding the encapsulation structure (40), the structure assembled in S10 is placed into the injection mold (50), wherein at least a portion of the outer side wall of the upper waterproof cover (10) is attached to the inner wall of the injection mold (50), and the attachment area of ​​the two surrounds the upper waterproof cover (10).

3. The coil component assembly method according to claim 1, characterized in that, In S10, at least a portion of the inner wall of the lower waterproof cover (30) is fitted to the outer wall of the stator assembly (20), the fitting area of ​​the two surrounding the stator assembly (20); the coil component assembly method further includes: Before injection molding the encapsulation structure (40), the structure assembled in S10 is placed into the injection mold (50), wherein at least a portion of the outer wall of the lower waterproof cover (30) is attached to the inner wall of the injection mold (50), and the attachment area of ​​the two surrounds the lower waterproof cover (30).

4. The coil component assembly method according to claim 1, characterized in that, In S10, at least a portion of the inner wall of the upper waterproof cover (10) is attached to the outer wall or top wall of the stator assembly (20), and the area of ​​attachment of the two forms an upper annular sealing area surrounding the stator assembly (20); at least a portion of the inner wall of the lower waterproof cover (30) is attached to the outer wall or bottom wall of the stator assembly (20), and the area of ​​attachment of the two forms a lower annular sealing area surrounding the stator assembly (20).

5. The coil component assembly method according to claim 4, characterized in that, The stator assembly (20) includes an upper inner stator plate (22), a lower inner stator plate (23), an upper outer stator plate (24), a lower outer stator plate (25) arranged coaxially, and a cylindrical upper stator housing (26) and a lower stator housing (27). The upper stator housing (26) surrounds the upper outer stator plate (24) and the two are integrally structured. Multiple pole teeth in the upper outer stator plate (24) and the upper inner stator plate (22) are staggered. A coil assembly (21) is disposed between the upper outer stator plate (24) and the upper inner stator plate (22); the lower stator housing (27) surrounds the lower outer stator plate (25) and the two are integral structures; multiple pole teeth in the lower outer stator plate (25) and the lower inner stator plate (23) are staggered; a coil assembly (21) is disposed between the lower stator housing (27), the lower outer stator plate (25) and the lower inner stator plate (23); In S10, the upper waterproof cover (10) is attached to the upper stator housing (26) or to the top wall of the upper outer stator electrode plate (24) to form the upper annular sealing area; the lower waterproof cover (30) is attached to the lower stator housing (27) or to the bottom wall of the lower outer stator electrode plate (25) to form the lower annular sealing area. In S20, injection molding compound is injected into the gaps of the upper stator housing (26), the upper outer stator plate (24), the upper inner stator plate (22), and the lower stator housing (27), the lower outer stator plate (25), and the lower inner stator plate (23) to encapsulate the two coil assemblies (21).

6. The coil component assembly method according to claim 4, characterized in that, The stator assembly (20) includes an upper inner stator plate (22), a lower inner stator plate (23), an upper outer stator plate (24), a lower outer stator plate (25), and a cylindrical stator housing (28) arranged coaxially. Multiple pole teeth in the upper outer stator plate (24) and the upper inner stator plate (22) are staggered, as are multiple pole teeth in the lower outer stator plate (25) and the lower inner stator plate (23). The upper end of the stator housing (28) is connected to the upper outer stator plate (24). The lower end of the stator housing (28) is connected to the lower outer stator plate (25). A coil assembly (21) is disposed between the stator housing (28), the upper outer stator plate (24), and the upper inner stator plate (22). A coil assembly (21) is also disposed between the stator housing (28), the lower outer stator plate (25), and the lower inner stator plate (23). The stator housing (28) has an axially extending notch to avoid the pins (211) of the coil assembly (21). In S10, the upper waterproof cover (10) is attached to the periphery of the upper outer stator plate (24) or to the top wall of the upper outer stator plate (24) to form the upper annular sealing area; the lower waterproof cover (30) is attached to the periphery of the lower outer stator plate (25) or to the bottom wall of the lower outer stator plate (25) to form the lower annular sealing area. In S20, injection molding compound is injected into the gaps of the stator housing (28), the upper outer stator plate (24), the upper inner stator plate (22), and the gaps of the stator housing (28), the lower outer stator plate (25), and the lower inner stator plate (23) to encapsulate the two coil assemblies (21).

7. The coil component assembly method according to claim 1, characterized in that, The upper waterproof cover (10) has an annular upper mating surface at one end facing the lower waterproof cover (30), and the upper mating surface has at least one annular upper connecting rib (11). The lower waterproof cover (30) has an annular lower mating surface at one end facing the upper waterproof cover (10), and the lower mating surface has at least one annular lower connecting rib (31). In S20, during the process of injection molding to form the encapsulation structure (40), the injection plastic comes into contact with and connects with the upper mating surface, the upper connecting rib (11), the lower mating surface, and the lower connecting rib (31).

8. The coil component assembly method according to claim 1, characterized in that, The upper waterproof cover (10) is injection molded. The upper waterproof cover (10) includes a small cylindrical section (12) and a large cylindrical section (13) connected to each other. The diameter of the small cylindrical section (12) is smaller than the diameter of the large cylindrical section (13). The large cylindrical section (13) covers the top of the stator assembly (20) and is sealed to the encapsulation structure (40). The end of the small cylindrical section (12) away from the stator assembly (20) has a top wall that covers the inner hole of the coil assembly (21). The small cylindrical section (12) is used to accommodate the end of the valve body that passes through the stator assembly (20).

9. The coil component assembly method according to claim 1, characterized in that, The lower waterproof cover (30) is injection molded and has a clearance hole (32). The clearance hole (32) is used to avoid the valve body passing through the stator assembly (20). The inner wall of the lower waterproof cover (30) has a sealing groove around the clearance hole (32). A sealing ring is provided in the sealing groove and is used to seal the gap between the valve body and the clearance hole (32).

10. The coil component assembly method according to claim 1, characterized in that, In S10, the limiting member (61) is fixedly connected to the top of the stator assembly (20) or to the inner wall of the upper waterproof cover (10), the limiting member (61) being used to limit the valve body passing through the stator assembly (20); and / or, the pin (211) in the coil assembly (21) and the end of the wire in the wire assembly (62) are inserted into the fixing bracket (63), and then the end of the wire is electrically connected to the corresponding pin (211); In S20, during the injection molding process of forming the encapsulation structure (40), a portion of the fixing frame (63) and the wire assembly (62) is encapsulated with injection molding material.

11. The coil component assembly method according to claim 10, characterized in that, Before injection molding the encapsulation structure (40), the structure assembled in S10 is placed into the injection mold (50). The injection mold (50) includes an upper mold (51) and a lower mold (52) that cooperate with each other. The upper mold (51) is provided with an upper cavity, and the lower mold (52) is provided with a lower cavity. The upper cavity and the lower cavity together accommodate the upper waterproof cover (10), the stator assembly (20), and the lower waterproof cover (30). The injection mold (50) also has a wire cavity. The wire cavity is disposed in the upper mold (51) and / or the lower mold (52). The wire cavity communicates with the annular gap. The wire cavity accommodates the fixing frame (63) and a part of the wire assembly (62). The gap in the wire cavity is filled with injection molding material.

12. A coil component, characterized in that, The coil component includes a stator assembly (20), an upper waterproof cover (10), a lower waterproof cover (30), and an encapsulation structure (40). The stator assembly (20) has a coil assembly (21). The upper waterproof cover (10) covers the top of the stator assembly (20), and the lower waterproof cover (30) covers the bottom of the stator assembly (20). An annular gap is formed between the upper waterproof cover (10) and the lower waterproof cover (30). The encapsulation structure (40) is an injection-molded structure. The encapsulation structure (40) fills the gap in the stator assembly (20) to encapsulate the coil assembly (21). The encapsulation structure (40) fills the annular gap and is sealed to the upper waterproof cover (10) and the lower waterproof cover (30).

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