Vehicle-mounted filter inductor based on injection molding framework

Abstract

The vehicle-mounted filter inductor based on the injection molding framework comprises a shell, the framework, copper bars, a magnetic core and a coil, the shell is used for containing the framework, the magnetic core and the coil, the magnetic core and the framework are assembled, and the framework isolates the magnetic core and the coil; the framework and the copper bars are integrated in an injection molding mode during injection molding. The framework and the shell are assembled in a clamping groove mode. One end of the copper bar is connected with the coil, and the other end of the copper bar extends to the outer side of the shell and is used for being installed and connected with a client.

Description

Technical Field

[0001] The utility model relates to a vehicle-mounted filter inductor based on an injection-molded frame, belonging to the technical field of electronic components. Background Art

[0002] The on-board filter inductor is a device specifically used to suppress circulating current in the power system. It can achieve the purpose of suppressing circulating current by controlling the current in the loop so that the current between each loop remains balanced.

[0003] At present, vehicle-mounted filter inductors are mainly used in the electronic control systems of electric heavy-duty trucks. They are required to be shock-resistant, fog-proof, waterproof, etc. The product has high reliability requirements and must be miniaturized in size, have high power density, and good heat dissipation.

[0004] However, the existing vehicle-mounted filter inductors still need to be improved in terms of shock resistance; in addition, the existing design scheme has the following defects:

[0005] 1) When assembling the frame and the aluminum shell, most of the time, it is necessary to add glue dispensing to block the assembly gap between the frame and the aluminum shell to prevent glue leakage when the thermal conductive glue is poured later, resulting in low production efficiency;

[0006] 2) The copper bar structure has low welding efficiency, slow heat dissipation, and is prone to scalding adjacent frames;

[0007] 3) The aluminum shell is not designed to be contoured, and needs to be cooled by thermally conductive silicone. However, the thermal conductivity of thermally conductive silicone is worse than that of aluminum, and the price is higher for the same volume.

[0008] 4) For the hard-connected installation method of the client, the copper busbar cannot unload the force during installation, causing the frame assembled with the copper busbar to be easily broken by the force generated by the copper busbar, resulting in product damage. Utility Model Content

[0009] In order to make up for the defects of the above-mentioned prior art, the utility model proposes a vehicle-mounted filter inductor based on an injection molded frame to improve the product's shock resistance, reliability and assembly efficiency, improve product leakage and heat dissipation, and improve product quality.

[0010] A vehicle-mounted filter inductor based on an injection-molded skeleton comprises a shell, a skeleton, a copper busbar, a magnetic core and a coil, wherein the shell is used to accommodate the skeleton, the magnetic core and the coil, the magnetic core is assembled with the skeleton, and the skeleton isolates the magnetic core from the coil; the skeleton is integrally injection-molded with the copper busbar during injection molding; the skeleton and the shell are assembled in a slot-type manner; one end of the copper busbar is connected to the coil, and the other end extends outside the shell for installation connection with a client.

[0011] Furthermore, a slot is provided on the frame for realizing the slot-type assembly of the frame and the shell.

[0012] Furthermore, the skeleton includes a first skeleton and a second skeleton, the copper bar includes a first copper bar and a second copper bar, the first skeleton is integrally molded with the first copper bar during injection molding, and the second skeleton is integrally molded with the second copper bar during injection molding; the first skeleton is butt-jointed with the second skeleton, and the pre-wound coil is sleeved on the first skeleton and the second skeleton.

[0013] Furthermore, the first copper bar includes a first part, a second part and a third part from the inside to the outside of the shell, the first part is located on the inside of the shell and connected to the coil, the second part is located on the outside of the shell and has a U-shaped concave design, and the third part has a mounting hole.

[0014] Furthermore, the first portion of the first copper bar is provided with an L-shaped first welding portion for welding with the first lead wire of the coil; the portion of the second copper bar located on the inner side of the shell is provided with an L-shaped second welding portion for welding with the second lead wire of the coil.

[0015] Furthermore, the first copper bar is provided with a first U-shaped groove at a position adjacent to the first welding portion, and the second copper bar is provided with a second U-shaped groove at a position adjacent to the second welding portion, and the first U-shaped groove and the second U-shaped groove are used to reduce the heat transfer path during welding.

[0016] Furthermore, below the second welding portion, the frame is provided with an elliptical slot structure.

[0017] Furthermore, a protruding positioning column is provided on the outer side surface of the frame.

[0018] Furthermore, the shell is an aluminum shell and has a contoured structure design.

[0019] Furthermore, the magnetic core is a U-shaped magnetic core, and the skeleton has a hollow portion for inserting the U-shaped magnetic core.

[0020] Compared with the prior art, the beneficial effects of the technical solution of the utility model are embodied in:

[0021] 1) The vehicle-mounted filter inductor of the utility model adopts a frame and copper bar injection molding integrated design, which saves assembly time and improves the reliability and shock resistance of the product;

[0022] 2) The vehicle-mounted filter inductor of the utility model has a frame and a shell that are assembled in a slot-type manner, thereby ensuring a firm assembly of the frame and the shell and achieving an effect of preventing glue leakage.

[0023] In a further technical solution, an L-shaped welding part is used at the welding point between the copper busbar and the coil, which is more convenient for welding and improves welding efficiency; and a U-shaped groove is made adjacent to the welding part to reduce the heat transfer path and prevent the welding heat from scalding the adjacent frame.

[0024] In a further technical solution, the copper busbar is designed with a U-shaped concave design, which can effectively remove the downward pressure generated during client installation and prevent the copper busbar mounting hole from being pressed down when the inductor is hard-connected and installed at the client, and being unable to unload the force, resulting in damage to the frame or product failure and other abnormalities.

[0025] In further technical solutions, the aluminum housing was contoured to maximize the heat dissipation effect of the product and improve the efficiency of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of a vehicle-mounted filter inductor according to an embodiment of the utility model.

[0027] Figure 2 yes Figure 1 The exploded structure diagram of the vehicle-mounted filter inductor is shown.

[0028] Figure 3 and Figure 4 It is a schematic structural diagram of the vehicle-mounted filter inductor of the embodiment of the utility model from different viewing angles.

[0029] Figure 5 It is a skeleton schematic diagram of the vehicle-mounted filter inductor according to an embodiment of the utility model.

[0030] Figure 6-1 and Figure 6-2 It is a schematic diagram of the inductor body of the vehicle-mounted filter inductor according to an embodiment of the utility model.

[0031] Figure 7 It is a schematic diagram of an aluminum housing of a vehicle-mounted filter inductor according to an embodiment of the utility model. DETAILED DESCRIPTION

[0032] The present invention is further described below in conjunction with the accompanying drawings and specific implementation methods and examples. The purpose of providing the examples is only for illustration, not for any limitation. In addition, the spatial orientation words such as "left", "right", "top", and "bottom" used in the description of the technical solution of the present invention are convenient for describing the relative position relationship between the components of the product, and do not mean that the product has only the swing direction shown in the figure. In actual use, as the product swing direction is different, the spatial related description used to describe its swing direction should also be interpreted in a similar way. In addition, the words "first", "second", etc. are only used to distinguish components. It should be understood that these components should not be limited by such words. They themselves do not mean that these elements have the aforementioned ordinal numbers, nor do they represent the arrangement order of a component and another component or the order of the manufacturing method.

[0033] Please refer to Figure 1 The embodiment of the utility model provides a vehicle-mounted filter inductor based on an injection-molded skeleton, including a shell 1, a skeleton 2, a copper busbar 3, a magnetic core and a coil 5. The shell 1 is used to accommodate the skeleton, the magnetic core and the coil. The magnetic core is assembled with the skeleton, and the skeleton isolates the magnetic core and the coil; the skeleton 2 is integrally molded with the copper busbar 3 during injection molding, eliminating the need for assembly; the skeleton 2 and the shell 1 are assembled in a card slot type. Specifically, a card slot can be set on the skeleton, and the card slot is stuck to the corresponding position on the shell during assembly to achieve card slot assembly; one end of the copper busbar 3 is connected to the coil 5, and the other end extends outside the shell 1 for installation and connection with the client.

[0034] Please refer to Figure 2 In a specific embodiment, the skeleton of the vehicle-mounted filter inductor includes two groups of four skeletons, the four skeletons correspond to four magnetic cores 4, and the skeletons are assembled one by one; each group of skeletons includes a first skeleton 21 and a second skeleton 22, and the first skeleton of each group of skeletons is butt-jointed and assembled with the second skeleton; each group of skeletons corresponds to two coils; the magnetic core 4 is a U-shaped magnetic core, and each skeleton is designed with a hollow structure that matches the U-shaped magnetic core, and the two legs of the U-shaped magnetic core are inserted into the hollow structure for assembly; the outside of the hollow structure is the winding part. After the first skeleton 21 of each group of skeletons is butt-jointed with the second skeleton 22, two coils are assembled together. The coil is pre-wound with flat copper wire and is sleeved on the winding part of the skeleton during assembly.

[0035] Continue to refer Figure 2In the above specific implementation, the copper bar integrally molded with the skeleton also includes two groups of copper bars, each group of copper bars includes a first copper bar 31 and a second copper bar 32, the first skeleton 21 is integrally molded with the first copper bar 31 during injection molding, and the second skeleton 22 is integrally molded with the second copper bar 32 during injection molding. The said integral injection molding is, for example, placing the copper bar at a predetermined position in a mold for skeleton injection molding, and when the skeleton is injected, the copper bar is integrally molded with the skeleton, thus eliminating the need for a positioning jig to position and assemble the copper bar and the skeleton, simplifying the assembly process of the product, improving production efficiency, and making the product firm, consistent and reliable.

[0036] refer to Figure 3 The first copper busbar 31 includes a first part 311, a second part 312 and a third part 313 from the inside to the outside of the shell; the first part 311 is located on the inside of the shell 1 and is connected to the coil 5; the second part 312 is located on the outside of the shell 1 and has a U-shaped concave design. This design can prevent the copper busbar mounting hole from being pressed down by force when the product is hard-connected and installed on the client, and the force cannot be unloaded, resulting in abnormalities such as damage to the skeleton or product failure; a mounting hole is provided on the third part 313 for connecting to the client.

[0037] refer to Figure 2 The first part 311 of the first copper bar 31 is provided with L-shaped first welding parts 3111 and 3112 on the left and right sides for welding with the two first lead wires of the two coils on a group of skeletons; the part of the second copper bar 32 located on the inner side of the shell 1 is provided with L-shaped second welding parts 321 and 322 for welding with the two second lead wires of the two coils on the same group of skeletons.

[0038] refer to Figure 4 In a more preferred embodiment, the first copper bar 31 is provided with first U-shaped grooves 3113 and 3114 at positions adjacent to the first welding parts 3111 and 3112, respectively; the second copper bar 32 is provided with second U-shaped grooves 323 at positions adjacent to the second welding parts 321 and 322. The first U-shaped grooves 3113 and 3114 and the second U-shaped grooves 323 are used to reduce the heat transfer path during welding to avoid the frame from being burned as much as possible.

[0039] refer to Figure 5 In a more preferred embodiment, below the second welding parts 321 and 322, the second frame 22 is provided with an elliptical slotted structure 221, which facilitates the assembly of the riveted nut copper busbar and prevents the glue from penetrating into the nut hole during the pouring of glue, thereby blocking the nut hole and causing difficulty in tightening the screws and abnormal cleanliness during installation by the customer.

[0040] Figure 6-1 is a three-dimensional schematic diagram of the inductor body of the vehicle-mounted filter inductor of this embodiment from the top perspective, Figure 6-2: is a three-dimensional schematic diagram of the inductor body of the vehicle-mounted filter inductor of this embodiment from the bottom perspective, wherein the inductor body includes a skeleton, a magnetic core, a coil and a copper bus. Please refer to Figure 6-1 and Figure 6-2 In a more preferred embodiment, a plurality of raised positioning posts 23 and 24 are provided on the outer side of the skeleton, wherein the positioning posts 24 ensure the safety distance between the coil and the housing. At the same time, the relative installation positions of the two skeletons are ensured by interlocking the skeleton positioning posts 23 between the two coils, thereby ensuring that the positions of the injection molded copper busbar mounting holes on the skeleton are not offset, and no additional positioning fixture is required for positioning, thereby improving production efficiency.

[0041] In a preferred embodiment, the housing 1 is made of aluminum. Figure 7 The aluminum shell has a contoured structure design 11. Under the premise of ensuring safety regulations, the distance from the coil to the aluminum shell is reduced as much as possible, which improves the heat dissipation effect of the product.

[0042] The above contents are further detailed descriptions of the present invention in combination with specific preferred implementations, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For technicians in the technical field to which the present invention belongs, several equivalent substitutions or obvious variations can be made without departing from the concept of the present invention, and the performance or use is the same, which should be regarded as belonging to the protection scope of the present invention.

Claims

1. A vehicle-mounted filter inductor based on an injection molded skeleton, characterized in that: It comprises a shell, a frame, a copper bar, a magnetic core and a coil, wherein the shell is used to accommodate the frame, the magnetic core and the coil, the magnetic core is assembled with the frame, and the frame isolates the magnetic core from the coil; The skeleton is integrally injection-molded with the copper bar during injection molding; The frame and the shell are assembled in a slot-type manner; One end of the copper busbar is connected to the coil, and the other end extends outside the shell for installation and connection with the client.

2. The vehicle-mounted filter inductor according to claim 1, characterized in that: The frame is provided with a slot for realizing the slot-type assembly of the frame and the shell.

3. The vehicle-mounted filter inductor according to claim 1, characterized in that: The skeleton includes a first skeleton and a second skeleton, and the copper bar includes a first copper bar and a second copper bar. The first skeleton is integrally molded with the first copper bar during injection molding, and the second skeleton is integrally molded with the second copper bar during injection molding; the first skeleton is butt-jointed with the second skeleton, and the pre-wound coil is sleeved on the first skeleton and the second skeleton.

4. The vehicle-mounted filter inductor according to claim 3, characterized in that: The first copper bar includes a first part, a second part and a third part from the inside to the outside of the shell, the first part is located on the inside of the shell and connected to the coil, the second part is located on the outside of the shell and has a U-shaped concave design, and the third part has a mounting hole.

5. The vehicle-mounted filter inductor according to claim 4, characterized in that: The first portion of the first copper bar is provided with an L-shaped first welding portion for welding with the first lead wire of the coil; the portion of the second copper bar located inside the shell is provided with an L-shaped second welding portion for welding with the second lead wire of the coil.

6. The vehicle-mounted filter inductor according to claim 5, characterized in that: The first copper bar is provided with a first U-shaped groove at a position adjacent to the first welding portion, and the second copper bar is provided with a second U-shaped groove at a position adjacent to the second welding portion. The first U-shaped groove and the second U-shaped groove are used to reduce the heat transfer path during welding.

7. The vehicle-mounted filter inductor according to claim 5, characterized in that: Below the second welding portion, the frame is provided with an elliptical slot structure.

8. The vehicle-mounted filter inductor according to claim 1, characterized in that: The outer side surface of the frame is provided with a raised positioning column.

9. The vehicle-mounted filter inductor according to claim 1, characterized in that: The shell is an aluminum shell and has a contoured structure design.

10. The vehicle-mounted filter inductor according to claim 1, characterized in that: The magnetic core is a U-shaped magnetic core, and the skeleton has a hollow part for the U-shaped magnetic core to be inserted.

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