Magnetic core assembly jig and power module assembly method

Abstract

This invention provides a magnetic core assembly fixture and a power module assembly method. The magnetic core assembly fixture is suitable for assembling power modules. The power module includes a power board, a first magnetic core, and a second magnetic core. The first and second magnetic cores are disposed on opposite sides of the power board. A first pressing module includes a first substrate, a first elastic element, a first latch, and a second latch. A plurality of first elastic elements are disposed on the first substrate and abut against the first magnetic core. The first and second latches are disposed opposite to each other on both sides of the first substrate and are used to abut against the connecting structure. A second pressing module includes a second substrate, a second elastic element, a third latch, and a fourth latch. The second elastic element is disposed on the second substrate and abuts against the second magnetic core. The third and fourth latches are disposed opposite to each other on both sides of the second substrate and are used to abut against the first pressing module.

Description

Technical Field

[0001] This invention relates to the field of magnetic core assembly, and more particularly to a magnetic core assembly fixture and a power module assembly method. Background Technology

[0002] With the rapid development of artificial intelligence and data centers, DC (Direct Current) power modules have become an indispensable component. DC power modules offer high energy efficiency, reduce energy loss, and play a crucial role in promoting sustainable energy development and intelligentization. DC power modules typically include magnetic components, whose physical and electrical characteristics allow for control of inductance, improved energy conversion efficiency, and enhanced heat dissipation.

[0003] Generally, DC power modules are suitable for automated production and include a circuit board, a first magnetic component, and a second magnetic component. In the automated production process of a DC power module, the first magnetic component is connected to the first surface of the circuit board through a first adhesive bonding process and a first high-temperature curing process, and the second magnetic component is connected to the second surface of the circuit board through a second adhesive bonding process and a second high-temperature curing process. The first and second surfaces are two opposing surfaces of the circuit board. In this automated production mode, before the adhesive has cured after assembling the first and second magnetic components, the circuit board is prone to vibration during transport on the conveyor line, potentially causing the first and second magnetic components to shift. Furthermore, the adhesive may expand after multiple high-temperature curing processes, altering the gap between the first and second magnetic components and affecting product yield. Moreover, the automated production process of the DC power module requires two high-temperature processes to fix the first and second magnetic components, resulting in energy waste.

[0004] In view of this, it is necessary to develop a magnetic core assembly fixture and a power module assembly method to solve the problems faced by the existing technology. Summary of the Invention

[0005] The purpose of this invention is to provide a magnetic core assembly fixture and a power module assembly method, which can reduce component assembly tolerance, improve component assembly accuracy, improve product yield, and reduce energy waste.

[0006] To achieve the aforementioned objectives, the present invention provides a magnetic core assembly fixture suitable for assembling power modules. The power module includes a connected structure. The connected structure includes a connected substrate and multiple connected units disposed within the connected substrate. Each connected unit includes a power board and multiple magnetic core groups. Each magnetic core group includes a first magnetic core and a second magnetic core disposed opposite to each other. The power board includes multiple magnetic core slots. The multiple magnetic core groups are disposed on the power board through corresponding magnetic core slots. The power board includes a first surface and a second surface disposed opposite to each other. The first magnetic core is disposed within a magnetic core slot on the first surface. The second magnetic core is disposed within a magnetic core slot on the second surface. The magnetic core assembly fixture includes a first pressing mold and a second pressing mold. The first pressing mold includes a first substrate, multiple first elastic members, a first latch, and a second latch. The first substrate includes multiple first through holes. The multiple first elastic members are disposed in the multiple first through holes and abut against the first magnetic cores of the multiple magnetic core groups. The first latch and the second latch are disposed opposite to each other on both sides of the first substrate. One end of the first latch and the second latch is used to abut against the connected structure. The second pressing module includes a second substrate, a plurality of second elastic members, a third latch, and a fourth latch. The second substrate includes a plurality of second through holes. The plurality of second elastic members are disposed in the plurality of second through holes and abut against the second magnetic cores of the plurality of magnetic core assemblies. The third latch and the fourth latch are disposed opposite to each other on both sides of the second substrate. One end of the third latch and the fourth latch is used to abut against the first pressing module.

[0007] To achieve the aforementioned objectives, the present invention provides a power module assembly method, comprising the following steps: (a) providing a magnetic core assembly fixture and a connecting structure, the connecting structure including a connecting substrate and a plurality of connecting units disposed within the connecting substrate, each connecting unit including a power board and a plurality of magnetic core groups, each magnetic core group including a first magnetic core and a second magnetic core disposed opposite to each other, the power board including a plurality of magnetic core slots, the plurality of magnetic core groups being disposed on the power board through the plurality of magnetic core slots, wherein the power board includes a first surface and a second surface disposed opposite to each other, each magnetic core slot including a third surface and a fourth surface disposed opposite to each other, the third surface being disposed close to the first surface and recessed toward the second surface, the fourth surface being disposed close to the second surface and recessed toward the first surface; (b) making the first surface of the power board face upward, and disposing the first magnetic core in the magnetic core slot of the first surface; (c) both the first buckle and the second buckle include a hook-shaped portion, and the hook-shaped portion includes a first flat surface, which, when in the snap-fit ​​state, the first flat surface... (d) The first pressing module and the connecting structure are parallel to the first substrate, so that the connecting structure is disposed between the first substrate and the first plane, and the first elastic member abuts against the first magnetic core accordingly; (e) The second surface of the power board faces upward, and glue is applied to the fourth surface of the magnetic core groove and the surface of the first magnetic core near the second magnetic core, and the second magnetic core is disposed in the magnetic core groove of the second surface; (f) The third and fourth buckles both include hook-shaped portions, and the hook-shaped portions include a second plane. When in the snap-fit ​​state, the second plane is parallel to the second substrate. The first substrate also includes a contact surface for abutting against the second plane, so that the connecting structure and the first pressing module are disposed between the second substrate and the second plane, and the second elastic member abuts against the second magnetic core accordingly; and (g) The connecting structure, the first pressing module and the second pressing module are subjected to high-temperature curing operation, and the first pressing module and the second pressing module are removed, so that the connecting structure forms a power module.

[0008] The beneficial effects of the present invention are that it provides a magnetic core assembly fixture and a power module assembly method. By clamping the first magnetic core between the first elastic member and the power board, and clamping the second magnetic core between the second elastic member and the power board, the risk of the first and second magnetic cores being displaced by vibration before the glue of the magnetic core assembly and the power board has cured is reduced, thereby improving the product yield. Attached Figure Description

[0009] Figure 1 This is a schematic diagram of the magnetic core assembly fixture and power module according to an embodiment of the present invention.

[0010] Figure 2 for Figure 1 The diagram shows an exploded view of the magnetic core assembly fixture and power module.

[0011] Figure 3 for Figure 1 The diagram shows an exploded view of the magnetic core assembly fixture and power module from another perspective.

[0012] Figure 4 for Figure 1 The diagram shows an exploded cross-sectional view of the magnetic core assembly fixture and power module.

[0013] Figure 5 for Figure 1 The diagram shows a cross-sectional view of the first elastic element of the magnetic core assembly fixture in its initial state.

[0014] Figure 6 for Figure 1 The diagram shows a cross-sectional view of the first elastic element of the magnetic core assembly fixture in the pressed state.

[0015] Figure 7 for Figure 4 The diagram shows a cross-sectional view of the first pressing module of the magnetic core assembly fixture in region A.

[0016] Figure 8 for Figure 7 The diagram shows a cross-sectional view of the first pressing module of the magnetic core assembly fixture in the open state.

[0017] Figure 9 This is a flowchart illustrating the steps of a power module assembly method according to an embodiment of the present invention.

[0018] Figures 10 to 14 They are respectively Figure 9 A cross-sectional structural diagram of each step in the power module assembly method described above.

[0019] Figure 15 for Figure 9 A detailed flowchart of step S3 in the power module assembly method described above.

[0020] Figure 16 for Figure 9 A detailed flowchart of step S6 in the power module assembly method described above.

[0021] Figure 17 for Figure 9 A detailed flowchart of step S7 in the power module assembly method described above.

[0022] The reference numerals in the attached figures are explained as follows:

[0023] 100: Core assembly fixture

[0024] 1: First pressing module

[0025] 11: First substrate

[0026] 11a: Top surface of the first substrate

[0027] 11b: Bottom surface of the first substrate

[0028] 11c: Side of the first substrate

[0029] 11d: Contact surface

[0030] 110: First perforation

[0031] 12: First elastic element

[0032] 121: Pipe body

[0033] 121a: Accommodation space

[0034] 121b: First opening

[0035] 121c: Second opening

[0036] 121d: Bottom surface

[0037] 121e: Inner surface

[0038] 122: Top-down unit

[0039] 122a: Head

[0040] 122b: Tail

[0041] 122c: Limiting part

[0042] 122d: Blocking section

[0043] 122e: First surface

[0044] 122f: Second surface

[0045] 122g: Third Surface

[0046] 123: Elastic Unit

[0047] 13: First buckle

[0048] 131: Hook-shaped part

[0049] 131a: First plane

[0050] 132: Shaft

[0051] 133: Arm

[0052] 134: Spring

[0053] 135: convex part

[0054] 14: Second buckle

[0055] 141: Hook-shaped part

[0056] 141a: First plane

[0057] 15: Positioning pin

[0058] 2: Second pressing module

[0059] 21: Second substrate

[0060] 21a: Top surface of the second substrate

[0061] 21b: Bottom surface of the second substrate

[0062] 21c: Side of the second substrate

[0063] 210: Second perforation

[0064] 211: Second positioning hole

[0065] 22: Second elastic element

[0066] 23: Third buckle

[0067] 231: Hook-shaped part

[0068] 231a: Second plane

[0069] 24: Fourth buckle

[0070] 241: Hook-shaped part

[0071] 241a: Second plane

[0072] 25: Fifth buckle

[0073] 26: Sixth buckle

[0074] S1~S7, S31~S33, S61~S63, S71~S74: Steps

[0075] 200: Power Module

[0076] 201: Continuous structure

[0077] 201a: Connected substrate

[0078] 201b: Connected Unit

[0079] 201c: First positioning hole

[0080] 202: Power Board

[0081] 202a: Core slot

[0082] 202b: First Page

[0083] 202c: Second side

[0084] 202d: Third Side

[0085] 202e: The Fourth Page

[0086] 203: Magnetic core assembly

[0087] 203a: First magnetic core

[0088] 203b: Second magnetic core

[0089] A: Area Detailed Implementation

[0090] Some typical embodiments embodying the features and advantages of the present invention will be described in detail in the following description. It should be understood that the present invention can be varied in different ways without departing from its scope, and the descriptions and drawings herein are illustrative in nature and not intended to limit the invention. For example, if the following description of a first feature being disposed on or above a second feature indicates that it includes embodiments where the first and second features are in direct contact, and also includes embodiments where additional features may be disposed between the first and second features, so that the first and second features may not be in direct contact. Furthermore, different embodiments in this disclosure may use repeated reference numerals and / or markings. These repetitions are for simplification and clarity and are not intended to limit the relationships between the various embodiments and / or the described appearance structures. Moreover, to facilitate the description of the relationship between one component or feature and another (or multiple) component or feature in the drawings, spatially related terms such as "above," "below," "left," "right," and similar terms may be used. In addition to the orientations shown in the accompanying drawings, spatially relevant terms are used to cover different orientations of the device in use or operation. The device may also be otherwise positioned (e.g., rotated 90 degrees or located in other orientations), and the descriptions of the spatially relevant terms used will be interpreted accordingly. Furthermore, when a component is referred to as "connected to" or "coupled to" another component, it may be directly connected to or coupled to the other component, or there may be intervening components. Although the numerical ranges and parameters of the broad scope of this disclosure are approximate, values ​​are stated as precisely as possible in specific examples. Additionally, it is understood that while terms such as "first," "second," and "third" may be used in the claims to describe different components, these components should not be limited by these terms, and the components described accordingly in the embodiments are represented by different component symbols. These terms are used to distinguish different components. For example, a first component may be referred to as a second component, and similarly, a second component may be referred to as a first component without departing from the scope of the embodiments. The term "and / or" as thus used includes any or all combinations of one or more of the related listed items.

[0091] Figure 1 This is a schematic diagram of the magnetic core assembly fixture and power module according to an embodiment of the present invention. Figure 2 for Figure 1The diagram shown is an exploded view of the magnetic core assembly fixture and power module. Figure 3 for Figure 1 The diagram shown is an exploded view of the magnetic core assembly fixture and power module from another perspective. Figure 4 for Figure 1 The diagram shows an exploded cross-sectional view of the magnetic core assembly fixture and power module. Figures 1 to 4 As shown, the magnetic core assembly fixture 100 of this embodiment is suitable for assembling a power module 200. The power module 200 includes a connecting structure 201. The connecting structure 201 includes a connecting substrate 201a and a plurality of connecting units 201b disposed within the connecting substrate 201a. Each connecting unit 201b includes a power board 202 and a plurality of magnetic core groups 203. Each magnetic core group 203 includes a first magnetic core 203a and a second magnetic core 203b disposed opposite to each other. Specifically, as shown... Figure 4 As shown, the first magnetic core 203a is an I-type magnetic core, and the second magnetic core 203b is a T-type magnetic core. The magnetic legs of the second magnetic core 203b are connected to the first magnetic core 203a. The power board 202 includes multiple magnetic core slots 202a (e.g., ...). Figure 4 (As shown). Multiple magnetic core assemblies 203 are glued onto a power board 202 via corresponding magnetic core slots 202a. The power board 202 includes a first surface 202b and a second surface 202c disposed opposite to each other. Each magnetic core slot 202a penetrates the first surface 202b and the second surface 202c of the power board 202. Each magnetic core slot 202a includes a third surface 202d and a fourth surface 202e disposed opposite to each other. The third surface 202d of the magnetic core slot 202a is disposed near the first surface 202b of the power board 202 and is recessed toward the second surface 202c of the power board 202. The fourth surface 202e of the magnetic core slot 202a is disposed near the second surface 202c of the power board 202 and is recessed toward the first surface 202b of the power board 202. A first magnetic core 203a is disposed within a core slot 202a on a first surface 202b of the power board 202, and at least a portion of the first magnetic core 203a abuts against a third surface 202d of the core slot 202a. A second magnetic core 203b is disposed within a core slot 202a on a second surface 202c, and at least a portion of the second magnetic core 203b abuts against a fourth surface 202e of the core slot 202a.

[0092] like Figures 1 to 4 As shown, in this embodiment, the magnetic core assembly fixture 100 includes a first pressing module 1 and a second pressing module 2. The first pressing module 1 includes a first substrate 11, a plurality of first elastic members 12, a first latch 13, and a second latch 14. The first substrate 11 includes a plurality of first through holes 110. The plurality of first elastic members 12 are respectively disposed in the plurality of first through holes 110 and are used to abut against the first magnetic core 203a of the plurality of magnetic core assemblies 203 (e.g., ...). Figure 11(As shown). The first latch 13 and the second latch 14 are disposed opposite each other on two opposite sides of the first substrate 11. One end of the first latch 13 and the second latch 14 is used to abut against the continuous structure 201 of the power module 200 (as shown). Figure 11 (As shown). The second pressing module 2 includes a second substrate 21, a plurality of second elastic members 22, a third latch 23, and a fourth latch 24. The second substrate 21 includes a plurality of second through holes 210. The plurality of second elastic members 22 are disposed in the plurality of second through holes 210 and are used to abut against the second magnetic core 203b of the plurality of magnetic core assemblies 203 (as shown). Figure 14 (As shown). The third latch 23 and the fourth latch 24 are disposed opposite each other on two opposite sides of the second substrate 21. One end of the third latch 23 and the fourth latch 24 is used to abut against the first pressing module 1 (as shown). Figure 14 (As shown). By clamping the first magnetic core 203a between the first elastic member 12 and the power board 202, and clamping the second magnetic core 203b between the second elastic member 22 and the power board 202, the risk of vibration displacement of the first magnetic core 203a and the second magnetic core 203b before the adhesive between the magnetic core assembly 203 and the power board 202 has cured is reduced, thereby improving product yield. The continuous structure 201 and the magnetic core assembly fixture 100 only need to undergo a single high-temperature curing operation to cure the adhesive between the first magnetic core 203a and the second magnetic core 203b of the continuous structure 201, as well as between the second magnetic core 203b and the power board 202. This avoids the change in the gap of the magnetic cores caused by multiple high-temperature curing operations in the prior art, thereby improving product yield and achieving the effect of saving energy.

[0093] like Figures 1 to 4 As shown, in this embodiment, the first pressing module 1 of the magnetic core assembly fixture 100 includes at least one positioning pin 15. The at least one positioning pin 15 is disposed on the first substrate 11. The connecting structure 201 includes at least one first positioning hole 201c, and the at least one first positioning hole 201c is disposed corresponding to the at least one positioning pin 15 of the first pressing module 1. The second substrate 21 of the second pressing module 2 includes at least one second positioning hole 211, and the at least one second positioning hole 211 is disposed corresponding to the at least one positioning pin 15 and the at least one first positioning hole 201c. The at least one positioning pin 15 is detachably inserted into the at least one first positioning hole 201c and the at least one second positioning hole 211, and positions the connecting structure 201 and the second pressing module 2 on the same side of the first pressing module 1, thereby reducing assembly tolerances and improving component assembly accuracy and product yield.

[0094] Figure 5 for Figure 1 The diagram shows a cross-sectional view of the first elastic element of the magnetic core assembly fixture in its initial state. Figure 6 for Figure 1 The diagram shows a cross-sectional view of the first elastic element of the magnetic core assembly fixture in the pressed state. (See attached diagram.) Figures 4 to 6 As shown, in this embodiment, the first elastic member 12 and the second elastic member 22 have, for example, but not limited to, the same structure. The first elastic member 12 includes a tube body 121, abutting unit 122, and an elastic unit 123. The tube body 121 includes an accommodating space 121a, a first opening 121b, and a second opening 121c. The first opening 121b and the second opening 121c are disposed on opposite sides of the accommodating space 121a. The abutting unit 122 passes through the accommodating space 121a and includes a head 122a, a tail 122b, and a limiting portion 122c. The head 122a is correspondingly disposed at the first opening 121b, one end of the head 122a is connected to the tail 122b, and the other end of the head 122a is a free end. At least a portion of the head 122a protrudes outside the accommodating space 121a. One end of the tail 122b is connected to the head 122a, and the other end of the tail 122b is a free end, correspondingly disposed at the second opening 121c. At least a portion of the tail 122b protrudes outside the accommodating space 121a. A limiting portion 122c is disposed at the tail 122b, corresponding to the second opening 121c, and located outside the accommodating space 121a. The limiting portion 122c is used to limit the movement range of the abutting unit 122, and the width of the limiting portion 122c is greater than the width or aperture of the second opening 121c, but not limited thereto. An elastic unit 123 is disposed in the accommodating space 121a and elastically supported between the head 122a and the bottom surface 121d of the tube body 121, wherein the bottom surface 121d is located in the accommodating space 121a and faces the first opening 121b. The first elastic member 12 includes a convertible initial state and a pressed state. Figure 5 As shown, in the initial state, the limiting portion 122c of the abutting unit 122 abuts against the second opening 121c of the tube body 121 to restrict the movement of the abutting unit 122. Figure 6 As shown, in the pressed state, the head 122a of the abutting unit 122 is displaced towards the accommodating space 121a by force, causing the elastic unit 123 to be compressed, and the limiting portion 122c of the abutting unit 122 moves away from the second opening 121c. In the pressed state, the elastic unit 123 applies elastic force to the first magnetic core 203a (e.g., through the abutting unit 122) Figure 11 As shown, this design reduces the risk of vibration-induced displacement between the first magnetic core 203a and the second magnetic core 203b (specifically, the magnetic legs of the second magnetic core 203b) before the adhesive between them has cured, thereby improving product yield. Furthermore, the limiting portion 122c restricts the movement of the abutting unit 122, preventing the abutting unit 122 from dislodging from the receiving space 121a and improving the overall stability of the device.

[0095] In this embodiment, the second elastic element 22 and the first elastic element 12 have the same function and structure, so they will not be described again here. In the pressed state, the elastic unit of the second elastic element 22 applies elastic force to the second magnetic core 203b through the abutting unit (e.g., Figure 14 (As shown), this reduces the risk of vibration-induced displacement between the second magnetic core 203b and the power board 202 before the adhesive between them has cured, thereby improving product yield.

[0096] like Figures 4 to 6 As shown, in this embodiment, the head 122a of the abutting unit 122 further includes a blocking portion 122d. The blocking portion 122d directly contacts the elastic unit 123 and is used to compress the elastic unit 123 under force. The blocking portion 122d extends from the head 122a toward the tube body 121 and includes a first surface 122e, a second surface 122f, and a third surface 122g. The first surface 122e and the third surface 122g are two opposing surfaces, with the first surface 122e facing the first opening 121b and the third surface 122g facing the second opening 121c. The second surface 122f connects the first surface 122e and the third surface 122g. The second surface 122f of the blocking portion 122d abuts against the inner surface 121e of the tube body 121 and is movable in a direction parallel to the inner surface 121e of the tube body 121. The elastic unit 123 is elastically supported between the third surface 122g of the blocking portion 122d of the head 122a and the bottom surface 121d of the tube body 121. The blocking portion 122d allows the elastic unit 123 to directly apply elastic force to the abutting unit 122, causing the abutting unit 122 to move in a direction parallel to the inner surface 121e of the tube body 121, thus improving the overall stability of the device.

[0097] like Figures 2 to 4 As shown, in this embodiment, the first substrate 11 of the first pressing module 1 includes a first substrate top surface 11a and a first substrate bottom surface 11b disposed opposite to each other, wherein the first substrate bottom surface 11b is adjacent to the connecting structure 201. The first substrate 11 also includes a plurality of first substrate side surfaces 11c connected between the first substrate top surface 11a and the first substrate bottom surface 11b. The first latch 13 and the second latch 14 are respectively disposed on the two opposite first substrate side surfaces 11c of the first substrate 11 and are configured to elastically rotate and latch the first pressing module 1 and the connecting structure 201.

[0098] like Figures 2 to 4As shown, in this embodiment, both the first latch 13 and the second latch 14 include hook-shaped portions 131 and 141. The hook-shaped portions 131 and 141 respectively include first planes 131a and 141a. When the first latch 13 and the second latch 14 are in a latched state, the first planes 131a and 141a are parallel to the bottom surface 11b of the first substrate 11, and the bottom surface 11b of the first substrate is close to the first planes 131a and 141a. The vertical distance between the bottom surface 11b of the first substrate and the first planes 131a and 141a is greater than the height of the connecting structure 201, allowing the connecting structure 201 to be accommodated between the bottom surface 11b of the first substrate and the first planes 131a and 141a.

[0099] Figure 7 for Figure 4 The diagram shows a cross-sectional view of the first pressing module of the magnetic core assembly fixture in region A. Figure 8 for Figure 7 The diagram shows a cross-sectional view of the first pressing module of the magnetic core assembly fixture in its open state. Figures 1 to 4 , Figure 7 and Figure 8 As shown, the first latch 13 includes a hook-shaped portion 131, a pivot 132, an arm 133, a spring 134, and a protrusion 135. The hook-shaped portion 131 is disposed at one end of the arm 133. The pivot 132 is connected to the side surface 11c of the first substrate 11. The arm 133 is rotatably connected to the pivot 132. The protrusion 135 is disposed on the top surface 11a of the first substrate and extends in a direction away from the bottom surface 11b of the first substrate. One end of the spring 134 is connected to the other end of the arm 133 relative to the hook-shaped portion 131, and the other end of the spring 134 is connected to the protrusion 135. The spring 134 provides elastic support between the arm 133 and the protrusion 135. The first latch 13 includes a convertible latched state and an open state. Figure 7 As shown, in the engaged state, the spring 134 of the first latch 13 is not compressed, and the first plane 131a of the hook-shaped portion 131 is parallel to the bottom surface 11b of the first substrate. Figure 8 As shown, in the open state, the spring 134 of the first latch 13 is compressed by an external force, causing the arm 133 to rotate around the pivot 132, and the hook-shaped part 131 to move away from the first substrate 11, facilitating the assembly of the connecting structure 201. When the external force is removed, the first latch 13 returns to the latched state from the open state, realizing quick assembly and disassembly of the connecting structure 201. In this embodiment, the second latch 14 has the same function and structure as the first latch 13, so it will not be described again here.

[0100] like Figures 1 to 4As shown, in this embodiment, the second substrate 21 of the second pressing module 2 includes a second substrate top surface 21a and a second substrate bottom surface 21b disposed opposite to each other, wherein the second substrate bottom surface 21b is adjacent to the connecting structure 201. The second substrate 21 also includes a plurality of second substrate side surfaces 21c. A third latch 23 and a fourth latch 24 are respectively disposed on two opposite second substrate side surfaces 21c of the second substrate 21, and are configured to elastically rotate and latch the first pressing module 1 and the second pressing module 2.

[0101] like Figure 4 As shown, in this embodiment, both the third latch 23 and the fourth latch 24 include hook-shaped portions 231 and 241, and the hook-shaped portions 231 and 241 include second planes 231a and 241a. When the third latch 23 and the fourth latch 24 are in a latching state, the second planes 231a and 241a are parallel to the bottom surface 21b of the second substrate 21.

[0102] like Figure 2 and Figure 3 As shown, in this embodiment, the second pressing module 2 further includes a fifth latch 25 and a sixth latch 26. The fifth latch 25 and the sixth latch 26 are respectively disposed on two opposite sides 21c of the second substrate 21, and are configured to elastically rotate and latch the first pressing module 1 and the second pressing module 2. In this embodiment, the third latch 23, the fourth latch 24, the fifth latch 25, and the sixth latch 26 have the same function and structure as the first latch 13, and therefore will not be described in detail here.

[0103] like Figure 3 As shown, in this embodiment, the first substrate 11 further includes a plurality of contact surfaces 11d. The contact surfaces 11d are used to abut against the second planes 231a and 241a of the third latch 23 and the fourth latch 24, wherein the bottom surface 21b of the second substrate is close to the second planes 231a and 241a. The vertical distance between the bottom surface 21b of the second substrate and the second planes 231a and 241a is greater than the vertical distance between the second surface 202c of the power board 202 and the contact surfaces 11d, allowing the first pressing module 1 and the connecting structure 201 to be accommodated between the bottom surface 21b of the second substrate and the second planes 231a and 241a (e.g., ...). Figure 14 (As shown).

[0104] Figure 9 This is a flowchart illustrating the steps of a power module assembly method according to an embodiment of the present invention. Figures 10 to 14 They are respectively Figure 9 A cross-sectional structural diagram of each step in the power module assembly method described above. (See attached diagram.) Figures 9 to 14 As shown, the power module assembly method of this embodiment includes the following steps. First, step S1 is performed, providing as follows: Figures 1 to 8The illustrated core assembly fixture 100 provides a connecting structure 201. The connecting structure 201 includes a connecting substrate 201a and a plurality of connecting units 201b disposed within the connecting substrate 201a. Each connecting unit 201b includes a power board 202 and a plurality of core assemblies 203. Each core assembly 203 includes a first core 203a and a second core 203b disposed opposite to each other. The power board 202 includes a plurality of core slots 202a, and the plurality of core assemblies 203 are disposed on the power board 202 through the plurality of core slots 202a. The power board 202 includes a first surface 202b and a second surface 202c disposed opposite to each other, and each core slot 202a penetrates through the first surface 202b and the second surface 202c of the power board 202. Each core slot 202a includes a relatively conductive third surface 202d and a fourth surface 202e, wherein the third surface 202d of the core slot 202a is disposed near the first surface 202b of the power board 202 and recessed toward the first surface 202b of the power board 202, and the fourth surface 202e of the core slot 202a is disposed near the second surface 202c of the power board 202 and recessed toward the second surface 202c of the power board 202. Next, step S2 is performed, the first surface 202b of the power board 202 is oriented upwards, and a first magnetic core 203a is disposed within the core slot 202a of the first surface 202b, with at least a portion of the first magnetic core 203a abutting against the third surface 202d of the core slot 202a, i.e. Figure 10 As shown. Next, step S3 is executed. The first latch 13 and the second latch 14 of the first pressing module 1 both include hook-shaped portions 131 and 141, and the hook-shaped portions 131 and 141 include first planes 131a and 141a. When in a latching state, the first planes 131a and 141a are parallel to the first substrate 11, so that the connecting structure 201 is disposed between the first substrate 11 and the first planes 131a and 141a, and the first elastic member 12 correspondingly abuts against the first magnetic core 203a, that is, as shown. Figure 11 As shown. Next, step S4 is executed, flipping the first pressing module 1 and the connecting structure 201 so that the second surface 202c of the power board 202 faces upward, i.e., as shown. Figure 12 As shown. Next, step S5 is performed, applying adhesive to the fourth surface 202e of the core groove 202a and the surface of the first magnetic core 203a near the second magnetic core 203b, and placing the second magnetic core 203b in the core groove 202a of the second surface 202c, with at least a portion of the second magnetic core 203b abutting against the fourth surface 202e of the core groove 202a, and the magnetic legs of the second magnetic core 203b abutting against the surface of the first magnetic core 203a near the second magnetic core 203b, i.e. Figure 13As shown. Next, step S6 is executed. The third latch 23 and the fourth latch 24 of the second pressing module 2 both include hook-shaped portions 231 and 241, and the hook-shaped portions 231 and 241 include second planes 231a and 241a. When in a latching state, the second planes 231a and 241a are parallel to the second substrate 21. The first substrate 11 also includes a contact surface 11d (e.g., Figure 3 (As shown) is used to abut against the second planes 231a and 241a, so that the continuous structure 201 and the first pressing module 1 are disposed between the second substrate 21 and the second planes 231a and 241a, and the second elastic member 22 correspondingly abuts against the second magnetic core 203b, that is, as Figure 14 As shown. Finally, step S7 is performed to perform a high-temperature curing operation on the continuous structure 201, the first pressing module 1 and the second pressing module 2, and after the high-temperature curing operation, the first pressing module 1 and the second pressing module 2 are removed, so that the continuous structure 201 forms the power module 200.

[0105] In one embodiment, the force exerted by the second elastic member 22 on the second magnetic core 203b is greater than the force exerted by the first elastic member 12 on the first magnetic core 203a, but is not limited thereto.

[0106] In one embodiment, the bottom surface 11b of the first substrate is close to the first planes 131a and 141a, and the vertical distance between the bottom surface 11b of the first substrate and the first planes 131a and 141a is greater than the height of the connecting structure 201, so that the first pressing module 1 and the connecting structure 201 can be accommodated between the bottom surface 21b of the second substrate and the second planes 231a and 241a.

[0107] In one embodiment, the bottom surface 21b of the second substrate is close to the second planes 231a and 241a. The vertical distance between the bottom surface 21b of the second substrate and the second planes 231a and 241a is greater than the vertical distance between the second surface 202c of the power board 202 and the contact surface 11d, so that the first pressing module 1 and the connecting structure 201 can be accommodated between the bottom surface 21b of the second substrate and the second planes 231a and 241a.

[0108] Figure 15 for Figure 9 A detailed flowchart of step S3 in the power module assembly method described above. Figure 7 , Figure 8 , Figure 11 and Figure 15 As shown, in this embodiment, step S3 of the power module assembly method further includes the following steps. First, step S31 is executed to put the first latch 13 and the second latch 14 in the open state (e.g., Figure 8As shown), an external force moves the first substrate 11 to contact the continuous structure 201, and the first elastic member 12 correspondingly abuts against the first magnetic core 203a. Next, step S32 is executed to reset the first latch 13 and the second latch 14 to the engaged state (as shown). Figure 7 As shown), the connecting structure 201 is disposed between the first substrate 11 and the first planes 131a and 141a. Finally, step S33 is executed to remove the external force, and the first elastic member 12 pushes the connecting structure 201, so that the first planes 131a and 141a and the connecting structure 201 come into contact (as shown). Figure 11 (As shown).

[0109] In one embodiment, in step S5 of the power module assembly method, the first substrate 11 is first moved to contact the connecting structure 201 by a first external force, and then adhesive is applied to the fourth surface 202e of the magnetic core groove 202a of the second surface 202c and the surface of the first magnetic core 203a near the second magnetic core 203b. The first external force brings the first substrate 11 into contact with the connecting structure 201, increasing the elastic force applied to the first magnetic core 203a by the first elastic member 12, thereby reducing the risk of adhesive overflowing from the magnetic core groove 202a.

[0110] Figure 16 for Figure 9 A detailed flowchart of step S6 in the power module assembly method is provided. Figure 16 As shown, in this embodiment, step S6 of the power module assembly method further includes the following steps. First, step S61 is executed, causing the third latch 23 and the fourth latch 24 to be in the open state, the second substrate 21 to move to contact the connecting structure 201, and the second elastic member 22 to correspondingly abut against the second magnetic core 203b, so that the first magnetic core 203a, the second magnetic core 203b, and the power board 202 are bonded together. Next, step S62 is executed, causing the third latch 23 and the fourth latch 24 to reset to the latched state, so that the connecting structure 201 and the first pressing module 1 are disposed between the second substrate 21 and the second planes 231a and 241a. Finally, step S63 is executed, the second elastic member 22 pushes the first substrate 11, so that the first substrate 11 contacts the second planes 231a and 241a. Through the above steps, the rapid assembly of the connecting structure 201 and the first pressing module 1 is achieved.

[0111] Figure 17 for Figure 9 A detailed flowchart of step S7 in the power module assembly method is shown below. Figure 17As shown, in this embodiment, step S7 of the power module assembly method further includes the following steps. First, after completing the high-temperature curing process in step S71, the connecting structure 201, the first pressing module 1, and the second pressing module 2 are cooled. Next, step S72 is performed to open the third latch 23 and the fourth latch 24 to remove the second pressing module 2. Next, step S73 is performed to flip the first pressing module 1 and the connecting structure 201. Finally, step S74 is performed to open the first latch 13 and the second latch 14 to remove the first pressing module 1. Through the above steps, the first pressing module 1 and the second pressing module 2 can be removed quickly.

[0112] In summary, this invention provides a magnetic core assembly fixture and a power module assembly method. By clamping a first magnetic core between a first elastic element and a power board, and clamping a second magnetic core between a second elastic element and a power board, the risk of vibration-induced displacement of the first and second magnetic cores before the adhesive on the magnetic core assembly and power board has cured is reduced, thereby improving product yield. Furthermore, the continuous structure and magnetic core assembly fixture only require a single high-temperature curing operation, thus avoiding the changes in magnetic core gaps caused by multiple high-temperature curing operations in prior art, further improving product yield and achieving energy savings.

[0113] Exemplary embodiments of the present invention have been specifically illustrated and described above. It should be understood that the present invention is not limited to the disclosed embodiments; rather, the present invention is intended to cover various modifications and equivalent arrangements contained within the spirit and scope of the appended claims.

Claims

1. A magnetic core assembly fixture, suitable for assembling a power module, characterized in that, The power module includes a continuous structure, which includes a continuous substrate and multiple continuous units disposed within the continuous substrate. Each continuous unit includes a power board and multiple magnetic core groups. Each magnetic core group includes a first magnetic core and a second magnetic core disposed opposite to each other. The power board includes multiple magnetic core slots, and the multiple magnetic core groups are disposed on the power board through corresponding magnetic core slots. The power board includes a first surface and a second surface disposed opposite to each other. The first magnetic core is disposed in the magnetic core slot of the first surface, and the second magnetic core is disposed in the magnetic core slot of the second surface. The magnetic core assembly fixture includes: A first pressing module, comprising: A first substrate, comprising a plurality of first through holes; Multiple first elastic members are disposed in the multiple first through holes and abut against the first magnetic core of the multiple magnetic core assemblies; as well as A first latch and a second latch are disposed opposite each other on both sides of the first substrate, one end of the first latch and the second latch being used to abut against the connecting structure; and A second pressing module, comprising: A second substrate, comprising a plurality of second through holes; Multiple second elastic members are disposed in the multiple second through holes and abut against the second magnetic core of the multiple magnetic core assemblies; as well as A third and a fourth buckle are disposed opposite each other on both sides of the second substrate, and one end of the third and fourth buckles is used to abut against the first pressing module.

2. The magnetic core assembly fixture according to claim 1, wherein the first pressing module includes at least one positioning pin, the at least one positioning pin is disposed on the first substrate, the connecting structure includes at least one first positioning hole and is disposed corresponding to the at least one positioning pin, the second substrate includes at least one second positioning hole and is disposed corresponding to the at least one positioning pin and the at least one first positioning hole, and the at least one positioning pin passes through the at least one first positioning hole and the at least one second positioning hole.

3. The magnetic core assembly fixture according to claim 1, wherein the first elastic element and the second elastic element have the same structure, and both the first elastic element and the second elastic element comprise: A tube body, comprising a receiving space and a first opening and a second opening disposed on opposite sides of the receiving space; A blocking unit, passing through the accommodating space, includes a head, a tail, and a limiting portion, wherein the head is correspondingly disposed at the first opening, and one end of the head is connected to the tail, wherein the limiting portion is disposed at the tail, corresponding to the second opening, and located outside the accommodating space; and An elastic unit is disposed within the accommodating space and elastically supported between the head and the tube body. in, The first elastic member and the second elastic member include a convertible initial state and a compressed state. In the initial state, the limiting portion abuts against the second opening to restrict the movement of the abutting unit. In the compressed state, the head is displaced towards the accommodating space under force, the elastic unit is compressed, and the limiting portion moves away from the second opening.

4. The magnetic core assembly fixture according to claim 3, wherein the head further includes a blocking portion, the blocking portion directly contacting the elastic unit for compressing the elastic unit under force.

5. The magnetic core assembly fixture according to claim 1, wherein the first substrate includes a first substrate top surface and a first substrate bottom surface disposed opposite to each other, the first substrate further includes a plurality of first substrate side surfaces connected between the first substrate top surface and the first substrate bottom surface, wherein the first buckle and the second buckle are respectively disposed on two opposite first substrate side surfaces of the first substrate and are configured to elastically rotate and buckle the first pressing module and the connecting structure.

6. The magnetic core assembly fixture according to claim 5, wherein the first buckle and the second buckle each include a hook-shaped portion, and the hook-shaped portion includes a first plane. When in a snap-fit ​​state, the first plane is parallel to the first substrate, and the bottom surface of the first substrate is close to the first plane. The vertical distance between the bottom surface of the first substrate and the first plane is greater than the height of the connecting structure.

7. The magnetic core assembly fixture according to claim 1, wherein the second substrate includes a second substrate top surface and a second substrate bottom surface disposed opposite to each other, the second substrate further includes a plurality of second substrate side surfaces, wherein the third buckle and the fourth buckle are respectively disposed on two opposite second substrate side surfaces of the second substrate and are configured to elastically rotate and buckle the first pressing module and the second pressing module.

8. The magnetic core assembly fixture according to claim 7, wherein the second pressing module further includes a fifth snap and a sixth snap, the fifth snap and the sixth snap being respectively disposed on two opposite sides of the second substrate and configured to elastically rotate and snap the first pressing module and the second pressing module.

9. The magnetic core assembly fixture according to claim 7, wherein the first substrate includes a first substrate top surface and a first substrate bottom surface disposed opposite to each other, the third buckle and the fourth buckle each include a hook-shaped portion, and the hook-shaped portion includes a second plane, wherein when in a fastening state, the second plane is parallel to the second substrate, the first substrate further includes a contact surface for abutting against the second plane, wherein the bottom surface of the second substrate is close to the second plane, and the vertical distance between the bottom surface of the second substrate and the second plane is greater than the vertical distance between the second surface of the power board and the contact surface.

10. A method for assembling a power module, characterized in that, Includes the following steps: (a) A magnetic core assembly fixture as described in any one of claims 1 to 9 is provided, and a connecting structure is provided, the connecting structure including a connecting substrate and a plurality of connecting units disposed in the connecting substrate, each connecting unit including a power board and a plurality of magnetic core groups, each magnetic core group including a first magnetic core and a second magnetic core disposed opposite to each other, the power board including a plurality of magnetic core slots, the plurality of magnetic core groups being disposed on the power board through the plurality of magnetic core slots, wherein the power board includes a first surface and a second surface disposed opposite to each other, each magnetic core slot including a third surface and a fourth surface disposed opposite to each other, the third surface being disposed close to the first surface and recessed toward the second surface, and the fourth surface being disposed close to the second surface and recessed toward the first surface; (b) Orient the first surface upward and place the first magnetic core in the magnetic core slot of the first surface; (c) Both the first buckle and the second buckle include a hook-shaped portion, and the hook-shaped portion includes a first plane. When in a snap-fit ​​state, the first plane is parallel to the first substrate, so that the connecting structure is disposed between the first substrate and the first plane, and the first elastic member abuts against the first magnetic core. (d) Flip the first pressing module and the connecting structure so that the second surface of the power board faces upward; (e) Apply adhesive to the fourth surface and the surface of the first magnetic core near the second magnetic core, and place the second magnetic core in the magnetic core groove of the second surface; (f) Both the third buckle and the fourth buckle include a hook-shaped portion, and the hook-shaped portion includes a second plane. When in a snap-fit ​​state, the second plane is parallel to the second substrate. The first substrate also includes a contact surface for abutting against the second plane, so that the connecting structure and the first pressing module are disposed between the second substrate and the second plane, and the second elastic member abuts against the second magnetic core accordingly. as well as (g) Perform a high-temperature curing operation on the continuous structure, the first pressing module and the second pressing module, and remove the first pressing module and the second pressing module to form a power module from the continuous structure.

11. The power module assembly method according to claim 10, wherein the force exerted by the second elastic element on the second magnetic core is greater than the force exerted by the first elastic element on the first magnetic core.

12. The power module assembly method according to claim 10, wherein the bottom surface of the first substrate is close to the first plane, and the vertical distance between the bottom surface of the first substrate and the first plane is greater than the height of the continuous structure.

13. The power module assembly method according to claim 10, wherein the bottom surface of the second substrate is close to the second plane, and the vertical distance between the bottom surface of the second substrate and the second plane is greater than the vertical distance between the second surface of the power board and the contact surface.

14. The power module assembly method according to claim 10, wherein step (c) comprises the following steps: (c1) The first latch and the second latch are in an open state, the first substrate is moved to contact the continuous structure, and the first elastic member is correspondingly abutted against the first magnetic core; (c2) Reset the first buckle and the second buckle to the engaged state, so that the continuous structure is disposed between the first substrate and the first plane; as well as (c3) The first elastic element pushes the connecting structure so that the first plane and the connecting structure come into contact.

15. The assembly method of the power module according to claim 10, wherein in step (e), the first substrate is first moved to contact the continuous structure by a first external force, and then glue is applied to the fourth surface and the surface of the first magnetic core near the second magnetic core.

16. The power module assembly method according to claim 15, wherein step (f) includes the following steps: (f1) The third and fourth latches are in an open state, the second substrate moves to contact the continuous structure, and the second elastic member abuts against the second magnetic core, so that the first magnetic core, the second magnetic core and the power board are bonded to each other; (f2) Reset the third and fourth latches to the engaged state, and place the continuous structure and the first pressing module between the second substrate and the second plane; as well as (f3) The second elastic member pushes the first substrate, so that the first substrate and the second plane come into contact.

17. The power module assembly method according to claim 10, wherein step (g) includes the following steps: (g1) After the high-temperature curing operation is completed, the continuous structure, the first pressing module and the second pressing module are cooled. (g2) Put the third and fourth latches in an open state to remove the second pressing module; (g3) Flip the first pressing module and the continuous sheet structure; as well as (g4) Position the first latch and the second latch in the open state to remove the first pressing module.

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