A filter structure

Abstract

This invention discloses a filter structure, relating to the field of filter technology. Specifically, the filter structure includes a flexible copper busbar, a primary injection-molded insulator, and a secondary injection-molded insulator. The flexible copper busbar is divided into a head and a tail, which are interlocked and fixedly connected. The primary injection-molded insulator covers the outer side of the head of the flexible copper busbar, and the secondary injection-molded insulator covers the remaining parts of the flexible copper busbar except for the head. Together, they form an overall encapsulated and limiting connection for the flexible copper busbar. This invention employs a segmented double-layer injection-molded encapsulation structure, providing partitioned insulation and encapsulation of the flexible copper busbar. This overcomes the shortcomings of traditional one-piece injection molding, which struggles to simultaneously achieve full sealing of the head and pre-dotted adhesive structure at the root of the flexible copper busbar. The two injection-molded insulator end faces are spliced ​​and bonded together to form a continuous closed insulating encapsulation layer, reliably limiting and fixing the flexible copper busbar. The overall assembly structure is compact and highly integrated, meeting the requirements of 3000V high-voltage operation and adapting to the needs of filter assembly and conductive layout.

Description

Technical Field

[0001] This invention relates to the field of filter technology, specifically to a filter structure. Background Technology

[0002] High-voltage filters used in new energy electrical equipment often use soft copper busbars as conductive connection carriers. In order to meet the 3000V high-voltage insulation conditions, the soft copper busbars need to be integrally injection molded and insulated.

[0003] The existing conventional one-piece injection molding structure has obvious technical defects in actual design and production. In order to meet the IP7 airtightness protection requirements of the product, the industry's conventional design requires the soft copper bus head to be completely enclosed in injection molding and sealed, while the root of the soft copper bus is reserved with a glue structure to improve the sealing and insulation reliability.

[0004] However, traditional single-integral injection molding process is limited by mold structure and injection process, and cannot simultaneously achieve the structural layout of fully sealing the head of soft copper busbar and reserving glue position at the root. One-piece injection molding is prone to process problems such as insufficient injection filling, inadequate sealing, and inability to demold the structure. It is difficult to take into account high voltage insulation, air tightness level and the feasibility of mass production injection molding process.

[0005] Meanwhile, conventional injection-molded copper busbars have large gaps between the copper busbars and the insulation layer, poor overall structural stability, and insufficient insulation coverage, making them unsuitable for the long-term stable operation requirements of new energy high-voltage filters. Existing copper busbar injection molding structures for similar filters have a single molding method, making it impossible to complete segmented injection molding in the same mold, resulting in low production efficiency and shortcomings in structural sealing, assembly integrity, and process adaptability. Summary of the Invention

[0006] This invention provides a filter structure that solves the problems mentioned in the background section.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a filter structure comprising a soft copper busbar, a primary injection-molded insulator, and a secondary injection-molded insulator, wherein the soft copper busbars are embedded and fixedly connected to each other, and the primary injection-molded insulator and the secondary injection-molded insulator form an integral wrapping limiting connection for the soft copper busbars, wherein the soft copper busbars are divided into a head and a tail, the primary injection-molded insulator is disposed on the outer side of the head of the soft copper busbars, and the secondary injection-molded insulator is disposed on the position other than the head of the soft copper busbars.

[0008] Optionally, the primary injection-molded insulator completely covers and adheres to the outer peripheral wall of the soft copper busbar head, and the mating end face of the primary injection-molded insulator is spliced ​​and bonded to the mating end face of the secondary injection-molded insulator.

[0009] Optionally, the thickness of the soft copper busbar is set to 3mm and the width is set to 15mm. The tail area of ​​the soft copper busbar has a built-in glue area, which is attached to the inside of the secondary injection molded insulator.

[0010] Optionally, the primary injection molded insulator and the secondary injection molded insulator are separately injection molded using the same mold, and the soft copper busbar is seamlessly embedded inside the encapsulation cavity formed by the combination of the primary injection molded insulator and the secondary injection molded insulator.

[0011] Optionally, a connecting plate is fixedly installed on the outer wall of the tail of the primary injection molded insulator, and the outer wall of the primary injection molded insulator is sleeved with the inner wall of the secondary injection molded insulator through the connecting plate.

[0012] Optionally, the inner wall of the secondary injection-molded insulator is fixedly installed with an inner annular ring located outside the connecting plate. A second limiting component is provided on the inner side of the inner annular ring, and the inner wall of the second limiting component is engaged with the outer wall of the first limiting component.

[0013] Optionally, the first limiting component includes a positioning ring, a first protrusion, and a first groove. The inner wall of the positioning ring is fixedly sleeved with the outer wall of the primary injection molded insulator. Several first protrusions are equidistantly distributed on both sides of the positioning ring, and a first groove is formed between two adjacent first protrusions. The positioning ring, the first protrusions, and the first groove are all engaged with the second limiting component.

[0014] Optionally, the second limiting component includes a positioning groove, a second protrusion, and a second groove. The positioning groove is provided on the inner side of the inner annular ring, and the inner wall of the positioning groove is sleeved with the outer wall of the positioning ring. Several second protrusions are distributed at equal intervals on both sides of the inner wall of the positioning groove. The outer wall of the second protrusion is inserted into the inner wall of the first groove. A second groove is provided between two adjacent second protrusions, and the inner wall of the second groove is inserted into the outer wall of the first protrusion.

[0015] The present invention has the following beneficial effects:

[0016] 1. This filter structure employs a segmented encapsulation structure combining primary and secondary injection-molded insulators. The head of the soft copper busbar is individually encapsulated by the primary injection-molded insulator, while the remaining parts are entirely wrapped by the secondary injection-molded insulator. This achieves segmented and zoned insulation encapsulation of the soft copper busbar, avoiding the technological challenge of traditional one-piece injection molding, which cannot simultaneously achieve full head sealing and root pre-applied adhesive structures. The end faces of the primary and secondary injection-molded insulators are spliced ​​and bonded together to form a continuous closed insulation layer, reliably limiting and fixing the entire soft copper busbar. The structure has strong overall integrity and is effectively adapted to 3000V high-voltage operating conditions. The structural layout is regular, and the assembly connections are compact, meeting the structural adaptation requirements for filter assembly and conductive layout.

[0017] 3. This filter structure integrates the primary injection molding structure and the secondary injection molding structure on the same mold, enabling segmented sequential injection molding. The entire component can be processed without changing the mold, simplifying the production process and improving mass production efficiency. The soft copper busbar is embedded in the secondary injection-molded insulator within the glued area at its root. Combined with the segmented injection-molded sealing structure, it can meet the IP7 airtightness protection level requirements. At the same time, the soft copper busbar and the two layers of injection-molded insulator are seamlessly embedded and connected, greatly improving insulation protection and structural stability. This solves the technical problems of difficult demolding, numerous molding defects, and insufficient airtightness and insulation reliability of traditional injection-molded structures, resulting in stronger structural adaptability and process practicality. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the present invention;

[0019] Figure 2 This is an injection molding assembly diagram of the primary injection-molded insulator and the soft copper busbar in the structure of this invention;

[0020] Figure 3 This is a schematic diagram of the soft copper busbar in the structure of the present invention;

[0021] Figure 4 This is a schematic diagram of the secondary injection-molded insulator in the structure of the present invention;

[0022] Figure 5 This is a schematic diagram of the connecting plate in the structure of the present invention;

[0023] Figure 6 In the structure of this invention Figure 5 An enlarged schematic diagram of point A;

[0024] Figure 7 This is a schematic diagram of the inner annular ring in the structure of the present invention;

[0025] Figure 8 In the structure of this invention Figure 7 An enlarged schematic diagram of point B.

[0026] In the diagram: 1. Soft copper busbar; 2. Primary injection molded insulator; 3. Secondary injection molded insulator; 4. Connecting plate; 5. Outer annular ring; 6. First limiting component; 601. Positioning ring; 602. First protrusion; 603. First groove; 7. Inner annular ring; 8. Second limiting component; 801. Positioning groove; 802. Second protrusion; 803. Second groove. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Please see Figures 1 to 5 This invention provides a technical solution: a filter structure, mainly including a soft copper busbar 1, a primary injection-molded insulator 2, a secondary injection-molded insulator 3, a connecting plate 4, a first limiting component 6, an inner annular ring 7, and a second limiting component 8; the soft copper busbar 1 has a thickness of 3mm and a width of 15mm, and the soft copper busbar 1 is divided into a head and a tail. The primary injection-molded insulator 2 is wrapped around and attached to the outer peripheral wall of the head of the soft copper busbar 1, and the secondary injection-molded insulator 3 is wrapped around the tail and main body of the soft copper busbar 1 except for the head. The soft copper busbar 1, the primary injection-molded insulator 2, and the secondary injection-molded insulator 3 are inter-embedded and fixed, and the primary injection-molded insulator 2 and the secondary injection-molded insulator 3 together form an overall wrapped limiting connection for the soft copper busbar 1.

[0029] Please see Figures 6 to 8 A connecting plate 4 is fixedly provided on the outer wall of the tail of the primary injection molded insulator 2. The outer wall of the primary injection molded insulator 2 is sleeved with the inner wall of the secondary injection molded insulator 3 through the connecting plate 4. An inner annular ring 7 is fixedly installed on the inner wall of the secondary injection molded insulator 3 and sleeved on the outside of the connecting plate 4. A second limiting component 8 is provided on the inner side of the inner annular ring 7. A first limiting component 6 is provided on the outer wall of the primary injection molded insulator 2. The second limiting component 8 and the first limiting component 6 are mutually engaged and positioned.

[0030] The first limiting component 6 consists of a positioning ring 601, a first protrusion 602, and a first groove 603. The positioning ring 601 is fixedly sleeved on the outer wall of the primary injection molded insulator 2. Multiple sets of first protrusions 602 are equidistantly arranged on the outer side of the positioning ring 601, and a first groove 603 is formed between adjacent first protrusions 602. The second limiting component 8 consists of a positioning groove 801, a second protrusion 802, and a second groove 803. A positioning groove 801 is opened on the inner side of the inner annular ring 7. The inner wall of the positioning groove 801 is sleeved with the outer wall of the positioning ring 601. Multiple sets of second protrusions 802 are equidistantly arranged on the inner side of the positioning groove 801. The second protrusions 802 are inserted into the first groove 603, and the second groove 803 is inserted into the first protrusion 602, thereby achieving circumferential and axial limiting and fixing of the primary injection molded insulator 2 and the secondary injection molded insulator 3.

[0031] In summary, during the fabrication of this filter structure, the primary injection-molded insulator 2 and the secondary injection-molded insulator 3 are sequentially injection-molded using the same mold. First, the soft copper busbar 1 is positioned and placed inside the mold, and the head of the soft copper busbar 1 is subjected to primary injection molding to form the primary injection-molded insulator 2 and the outer first limiting component 6. Keeping the workpiece inside the mold without disassembly or displacement, the secondary injection molding is performed directly to form the secondary injection-molded insulator 3, the inner annular ring 7, and the second limiting component 8. This allows the first limiting component 6 and the second limiting component 8 to automatically align and engage. The soft copper busbar 1 is seamlessly embedded within the encapsulated cavity formed by the primary injection-molded insulator 2 and the secondary injection-molded insulator 3. At the same time, a pre-reserved adhesive area is reserved at the tail of the soft copper busbar 1, and this adhesive area is fitted inside the secondary injection-molded insulator 3.

[0032] During assembly and use, the overall filter assembly is fixedly installed inside the new energy high-voltage filter equipment. The soft copper busbar 1 is connected to the 3000V high-voltage conductive circuit, undertaking the functions of power conduction and filtering connection. The glued area built into the tail of the soft copper busbar 1 is sealed by potting glue, and together with the splicing and sealing structure of the primary injection molded insulator 2 and the secondary injection molded insulator 3, the overall assembly achieves an IP7 airtightness protection level. During operation, the concave-convex plug-in structure of the first limiting component 6 and the second limiting component 8, as well as the sleeve engagement between the connecting plate 4 and the inner annular ring 7, restricts relative rotation and axial displacement between the primary injection molded insulator 2 and the secondary injection molded insulator 3, keeping the soft copper busbar 1 stable and free from displacement. The segmented insulation structure provides full-coverage insulation protection for the soft copper busbar 1, which can be used in the new energy high-voltage working environment for a long time. At the same time, the overall structure has reliable disassembly and assembly limits, and the injection molding process is simple, making it suitable for mass production and whole-machine assembly and use.

[0033] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, unless otherwise explicitly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Moreover, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0034] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A filter structure, characterized by: It includes a soft copper busbar (1), a primary injection molded insulator (2) and a secondary injection molded insulator (3). The soft copper busbars (1) are embedded and fixedly connected to each other. The primary injection molded insulator (2) and the secondary injection molded insulator (3) form an overall wrapping and limiting connection for the soft copper busbars (1). The soft copper busbars (1) are divided into a head and a tail. The primary injection molded insulator (2) is wrapped around the outside of the head of the soft copper busbars (1), and the secondary injection molded insulator (3) is wrapped around the position other than the head of the soft copper busbars (1).

2. A filter structure as claimed in claim 1, characterized in that: The primary injection molded insulator (2) covers and adheres to the outer peripheral wall of the head of the soft copper busbar (1) around the entire circumference, and the mating end face of the primary injection molded insulator (2) is spliced ​​and bonded to the mating end face of the secondary injection molded insulator (3).

3. The filter structure of claim 1, wherein: The thickness of the soft copper busbar (1) is set to 3mm and the width is set to 15mm. The tail area of ​​the soft copper busbar (1) has a built-in glue area, which is attached to the interior of the secondary injection molded insulator (3).

4. The filter structure of claim 1, wherein: The primary injection molded insulator (2) and the secondary injection molded insulator (3) are injection molded separately in the same mold. The soft copper busbar (1) is embedded in the cavity formed by the combination of the primary injection molded insulator (2) and the secondary injection molded insulator (3) without gaps.

5. The filter structure of claim 1, wherein: A connecting plate (4) is fixedly installed on the outer wall of the tail of the primary injection molded insulator (2), and the outer wall of the primary injection molded insulator (2) is sleeved with the inner wall of the secondary injection molded insulator (3) through the connecting plate (4).

6. A filter structure as claimed in claim 5, characterized in that: The inner wall of the secondary injection molded insulator (3) is fixedly installed with an inner annular ring (7) located outside the connecting plate (4). The inner side of the inner annular ring (7) is provided with a second limiting component (8), and the inner wall of the second limiting component (8) is engaged with the outer wall of the first limiting component (6).

7. A filter structure as claimed in claim 6, characterized in that: The first limiting component (6) includes a positioning ring (601), a first protrusion (602) and a first groove (603). The inner wall of the positioning ring (601) is fixedly sleeved with the outer wall of the primary injection molded insulator (2). Several first protrusions (602) are distributed at equal intervals on both sides of the positioning ring (601). A first groove (603) is provided between two adjacent first protrusions (602). The positioning ring (601), the first protrusions (602) and the first groove (603) are all engaged with the second limiting component (8).

8. A filter structure as claimed in claim 7, characterized in that: The second limiting component (8) includes a positioning groove (801), a second protrusion (802), and a second groove (803). The inner side of the inner annular ring (7) is provided with a positioning groove (801), and the inner wall of the positioning groove (801) is sleeved with the outer wall of the positioning ring (601). Several second protrusions (802) are distributed at equal intervals on both sides of the inner wall of the positioning groove (801). The outer wall of the second protrusion (802) is inserted into the inner wall of the first groove (603). A second groove (803) is provided between two adjacent second protrusions (802), and the inner wall of the second groove (803) is inserted into the outer wall of the first protrusion (602).

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