Injection mold, current sensor and vehicle
The integrated connection of the iron core and the copper bar through injection molds solves the complex problems of current sensor assembly and packaging, and achieves cost savings and improved measurement accuracy.
Patent Information
- Application Number
- CN202422386132.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-27
- Publication Date
- 2025-07-11
- Estimated Expiration
- 2034-09-27
AI Technical Summary
In the prior art, the assembly and packaging process of the iron core and copper bar of the current sensor is complex, resulting in high production costs.
The iron core and the copper row are connected by injection molding to form an integrated structure. The position and shape of the iron core are fixed in the injection molding state by using the limiting projection to ensure that the installation space of the Hall chip is not blocked.
The assembly and packaging process is simplified, material and manufacturing costs are reduced, while improving measurement accuracy.
Smart Images
Figure CN223085307U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of sensors, and in particular to an injection mold, a current sensor and a vehicle. Background Art
[0002] In the controller current monitoring of new energy vehicles and other vehicles, the current sensor is a necessary device, which is used to accurately measure the output current of the controller and transmit the current data to the control unit so as to understand the current data in real time and form a closed-loop control.
[0003] However, in the related art, the iron core is placed in the shell, and is usually sealed with glue after assembly, or a fixed cover is installed for packaging, which has a relatively complicated process and a high production cost. Utility Model Content
[0004] The present application provides an injection mold, a current sensor, and a vehicle. The injection mold can fix an iron core on a copper busbar by injection molding, and integrates the assembly, packaging, and assembly of the iron core and the current sensor into one process of injection molding and fixing, thereby saving material costs and manufacturing costs.
[0005] In order to solve the above technical problems, a technical solution adopted in the present application is: to provide an injection mold, which is used for a current sensor, the current sensor includes an iron core and a copper busbar, the iron core is sleeved on the copper busbar, the injection mold is provided with a receiving groove and a through hole, and the through hole is connected to the receiving groove; in the injection molding state, the through hole is configured to penetrate the copper busbar, and the receiving groove is configured to accommodate the iron core, so as to connect the iron core and the copper busbar by injection molding.
[0006] The shape of the accommodating groove is adapted to the iron core.
[0007] Among them, the iron core is provided with an opening, the current sensor also includes a Hall chip, and the opening is used to set the Hall chip; the inner wall of the accommodating groove is provided with a first limiting protrusion; in the injection molding state, the first limiting protrusion is located at the opening.
[0008] Wherein, a first dimension of the opening along the circumferential direction of the core is greater than a second dimension of the first limiting protrusion along the circumferential direction.
[0009] The difference between the first size and the second size is 0.05 mm-0.3 mm.
[0010] Wherein, the inner wall of the accommodating groove is provided with a second limiting protrusion, which is arranged at intervals from the first limiting protrusion along the circumference of the iron core and abuts against the circumferential surface of the iron core along the radial direction of the iron core.
[0011] Wherein, the inner wall of the accommodating groove is provided with a third protrusion, and the third limiting protrusion abuts against the end surface of the iron core along the axial direction of the iron core.
[0012] Among them, the iron core includes several stacked iron sheet layers.
[0013] This application also includes a second technical solution, providing a current sensor, which includes an iron core, a copper bar, and an injection molded housing; the iron core is sleeved on the copper bar, and the iron core is provided with an opening; the injection molded housing is injection molded by the above injection mold, and the injection molded housing is injection connected to the iron core and the copper bar; the current sensor further includes a Hall chip, and the Hall chip is arranged in the opening.
[0014] This application also includes a third technical solution, providing a vehicle, which includes the above current sensor.
[0015] The beneficial effect of this application is: Different from the prior art, the injection mold provided by this application is provided with a receiving groove and a through hole, and the through hole is communicated with the receiving groove. In the injection state, the through hole is configured to pass through the copper bar, and the receiving groove is configured to accommodate the iron core, so as to injection connect the iron core and the copper bar. That is to say, the iron core is fixed on the copper bar by injection molding, and the assembly and encapsulation between the iron core and the copper bar are combined into a process of injection molding and fixing, saving material costs and manufacturing costs. Description of the Drawings
[0016] In order to more clearly illustrate the technical solutions in the embodiments of this application, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are only some embodiments of this application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained according to these drawings, where:
[0017] Figure 1 is the assembly structure schematic diagram of an embodiment of the injection mold of this application;
[0018] Figure 2 is Figure 1 the structure schematic diagram of another part;
[0019] Figure 3 is Figure 2 the structure schematic diagram of the partial enlargement;
[0020] Figure 4 is Figure 1 the partial structure schematic diagram of;
[0021] Figure 5 is the exploded structure schematic diagram of the current sensor of this application, and the current sensor includes an iron core, a copper bar, and an injection molded housing;
[0022] Figure 6 is Figure 5 the assembly structure schematic diagram of;
[0023] Figure 7 is Figure 6The upward view schematic diagram. Specific embodiments
[0024] To make the above objects, features, and advantages of the present application more obvious and understandable, the following will describe the specific embodiments of the present application in detail with reference to the accompanying drawings. It can be understood that the specific embodiments described herein are only used to explain the present application, rather than limiting the present application. Additionally, it should be noted that for the convenience of description, only the parts related to the present application are shown in the drawings, rather than all the structures. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present application.
[0025] Referring to "embodiments" herein means that the specific features, structures, or characteristics described in connection with the embodiments can be included in at least one embodiment of the present application. The phrase appears in various positions in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment mutually exclusive with other embodiments. Those skilled in the art will explicitly and implicitly understand that the embodiments described herein can be combined with other embodiments.
[0026] In the description of the present application, the terms "first" and "second" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" can explicitly or implicitly include one or more of the said features. In the description of the present application, "a plurality" means two or more, unless otherwise specifically defined.
[0027] In the description of the present application, it should be noted that unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, an electrical connection, or can communicate with each other; it can be directly connected, or indirectly connected through an intermediate medium, and can be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.
[0028] Please refer to Figures 1 to 4 , Figure 1 which is the schematic diagram of the assembled structure of an embodiment of the injection mold of the present application, Figure 2 is Figure 1 the schematic diagram of the structure of another part, Figure 3 is Figure 2 the enlarged partial schematic diagram of the structure, Figure 4 is Figure 1Partial structural schematic diagram. In one aspect of the present application, an injection mold 3 is provided. The injection mold 3 is provided with a receiving groove 31 and a through hole 32. The through hole 32 communicates with the receiving groove 31. In the injection state, the through hole 32 is configured to pass through the copper bar 2, and the receiving groove 31 is configured to accommodate the iron core 1, so as to inject and connect the iron core 1 and the copper bar 2. That is to say, the iron core 1 is fixed on the copper bar 2 by injection molding, and the assembly, encapsulation, and synthesis between the iron core 1 and the copper bar 2 are fixed by injection molding in one process, saving material costs and manufacturing costs.
[0029] Specifically, in combination with Figure 5 , Figure 5 is an exploded structural schematic diagram of the current sensor of the present application. The injection mold 3 of the embodiment of the present application is used to prepare the current sensor 100. The current sensor 100 includes an iron core 1 and a copper bar 2. The iron core 1 is sleeved on the copper bar 2. Before injection molding, the copper bar 2 is passed through the through hole 32, and the iron core 1 is aligned and located in the receiving groove 31, so as to inject and connect the iron core 1 and the copper bar 2 in the injection state.
[0030] Furthermore, the injection mold 3 of the present application is provided with a limiting structure. The limiting structure can limit the iron core 1 in all directions, improving or avoiding the situation that due to high-pressure injection molding, the strength of the iron core 1 is not enough to resist the injection pressure, resulting in changes in the position and shape of the iron core 1 during the injection process.
[0031] Furthermore, the iron core 1 includes a plurality of stacked iron sheet layers. That is to say, the manufacturing process of the iron core 1 is to continuously wind thin iron sheet layers on the copper bar 2, so that the iron core 1 is sleeved on the copper bar 2. The process is simple and the manufacturing cost can be reduced.
[0032] In one embodiment of the present application, as Figure 4 shown, the shape of the receiving groove 31 is adapted to the iron core 1.
[0033] Specifically, the shape and position of the iron core 1 are related to the measurement accuracy of the current sensor 100. In a specific embodiment, the iron core 1 is sleeved on the copper bar 2, and the shape of the receiving groove 31 can be set to an arc shape adapted to the iron core 1, so as to facilitate the accommodation and adaptation of the iron core 1, thereby playing a role in fixing the shape and position of the iron core 1, facilitating local reliable positioning, and improving stability and measurement accuracy.
[0034] In one embodiment of the present application, the iron core 1 is provided with an opening 11. The current sensor 100 further includes a Hall chip (not shown in the figure). The opening 11 is used to set the Hall chip, and the Hall chip measures the magnetic flux of the iron core 1. In combination with Figure 1 and Figure 2 , the inner wall of the receiving groove 31 is provided with a first limiting protrusion 311; in the injection state, the first limiting protrusion 311 is located at the opening 11.
[0035] Specifically, the shape of the iron core 1 can be C-shaped, and the opening 11 is the air gap. To prevent the opening 11 of the C-shaped iron core 1 from being blocked by the injection molding material during the injection molding process, a first limiting protrusion 311 is provided on the inner wall of the accommodating groove 31 to block the opening 11, so that after the injection molding is completed, the Hall chip can be installed at the opening 11 to measure the magnetic flux of the iron core 1. The first limiting protrusion 311 is located at the opening 11, which can prevent the injection molding material from being injected at the opening 11, ensure the dimensional accuracy of the opening 11, and thus improve the measurement accuracy.
[0036] In one embodiment of the present application, as Figure 3 shown, a first dimension 12 of the opening 11 along the circumferential direction of the iron core 1 is greater than a second dimension 33 of the first limiting protrusion 311 along the circumferential direction.
[0037] The injection molding pressure is usually as high as 70 - 120 Mpa. In the injection molding state, both ends of the opening 11 of the iron core 1 will inevitably be subjected to pressure and deform and contract, making the opening 11 smaller, that is, the first dimension 12 becomes smaller. Therefore, in order to reduce or avoid damage caused by the iron core 1 squeezing or colliding with the first limiting protrusion 311 under the influence of the injection molding pressure, the first dimension 12 can be set to be greater than the second dimension 33. In this way, in the injection molding state, the first dimension 12 decreases due to the injection molding pressure. After the injection molding is completed, the size of the reduced first dimension 12 is equal to the size of the second dimension 33. The size of the second dimension 33 can be set to the size of the Hall chip to facilitate the installation of the Hall chip.
[0038] Furthermore, in the non-injection molding state, the difference between the first dimension 12 and the second dimension 33 is 0.05 mm - 0.3 mm, such as 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, and 0.3 mm, etc., so as to meet the requirements of the Hall chip and injection molding. In another embodiment, this difference can also be slightly less than 0.05 mm, such as 0.04 mm. In other embodiments, this difference can also be slightly greater than 0.3 mm, such as 0.31 mm.
[0039] Please continue to refer to Figure 1 and Figure 4 , in one embodiment of the present application, a second limiting protrusion 312 is provided on the inner wall of the accommodating groove 31. The second limiting protrusion 312 is spaced from the first limiting protrusion 311 along the circumferential direction of the iron core 1 and abuts against the circumferential surface of the iron core 1 along the radial direction of the iron core 1.
[0040] Specifically, since the iron core 1 is formed by continuously winding a thin iron sheet layer, the mechanical strength in the circumferential direction is weak. By abutting the circumferential surface of the iron core 1 with the second limiting protrusion 312, the iron core 1 can be directly contacted and fixed in the circumferential direction, and prevent the iron core 1 from deforming or moving in the circumferential direction in the injection molding state, thereby improving the measurement accuracy.
[0041] In an embodiment of the present application, a third protrusion is provided on the inner wall of the accommodation groove 31, and the third limiting protrusion 313 abuts against the end face of the iron core 1 along the axial direction of the iron core 1.
[0042] Specifically, since the iron core 1 is sleeved on the copper bar 2, under the injection molding state, the iron core 1 will also be affected by the injection pressure in the axial direction of the iron core 1, resulting in the displacement or deformation of the iron core 1. Therefore, by abutting the end face of the iron core 1 with the third limiting protrusion 313, the iron core 1 can be directly contacted and fixed, preventing the iron core 1 from deforming or moving in the axial direction, thereby improving the measurement accuracy.
[0043] In another embodiment of the present application, the inner wall of the accommodation groove 31 may include opposite side walls and an arc-shaped bottom wall. The side walls can directly contact the end face of the iron core 1 to perform axial limiting on the iron core 1. The bottom wall is adapted to the iron core 1 and can fix the iron core 1 in the circumferential direction.
[0044] Specifically, the first limiting protrusion 311 is located within the opening 11 and connects the two side walls to reserve an installation hole for installing a Hall chip after the injection molding is completed. Due to the winding structure design of the iron core 1, the mechanical strength of the iron core 1 in the circumferential direction is weak. Therefore, a plurality of second limiting protrusions 312 can be spaced on the bottom wall to abut against the circumferential surface of the iron core 1. To prevent the axial movement or deformation of the iron core 1, third limiting protrusions 313 are also provided on the two side walls to abut against the end face of the iron core 1. Under the injection molding state, the deformation or movement of the iron core 1 can be prevented only through the above structure, improving the measurement accuracy.
[0045] The injection molding die 3 of the embodiment of the present application can fix the iron core 1 on the copper bar 2 through injection molding, with high measurement accuracy, and the assembly, encapsulation, and assembly of the iron core 1 and the current sensor 100 are synthesized into a process of injection molding and fixing, saving material costs and manufacturing costs.
[0046] Please refer to Figures 5 to 7 , Figure 6 which Figure 5 is the schematic assembly structure diagram of Figure 7 and Figure 6 is the bottom view schematic diagram of
[0047] Specifically, the iron core 1 is sleeved on the copper bar 2, and the iron core 1 is provided with an opening 11. The injection molding housing 4 is injection molded by the above injection molding die 3, and the injection molding housing 4 is injection molded and connected to the iron core 1 and the copper bar 2. Further, the current sensor 100 further includes a Hall chip, and the Hall chip is disposed in the opening 11.
[0048] Since the current sensor 100 integrally forms the injection-molded housing 4, the iron core 1, and the copper bar 2 through the above-mentioned injection mold 3, it also has the beneficial effects of the above-mentioned injection mold 3, which will not be elaborated here.
[0049] As Figure 7 shown, further, a first limiting hole 41 and a second limiting hole 42 are formed on the outer surface of the injection-molded housing 4. The first limiting hole 41 and the second limiting hole 42 respectively correspond to the positions of the second limiting protrusion 312 and the third limiting protrusion 313. That is to say, in the injection-molding state, the second limiting protrusion 312 and the third limiting protrusion 313 protrude from the inner wall of the accommodating groove 31 and abut against the iron core 1. After the injection molding is completed, the positions of the second limiting protrusion 312 and the third limiting protrusion 313 form the first limiting hole 41 and the second limiting hole 42 because no plastic is injected.
[0050] As Figure 6 shown, further, a third limiting hole 43 is also formed on the outer surface of the injection-molded housing 4. The third limiting hole 43 corresponds to the position of the first limiting protrusion 311 in the injection-molding state and communicates with the opening 11, which is convenient for the installation of the Hall chip.
[0051] In another aspect of the present application, a vehicle is provided, and the vehicle includes the above-mentioned current sensor 100. Specifically, since the vehicle includes the current sensor 100 described in the above embodiment, it also has the beneficial effects of the above-mentioned current sensor 100, which will not be elaborated here.
[0052] It should be noted that terms such as "horizontal" and "vertical" do not mean that the components are absolutely horizontal or vertical, but can be slightly inclined; terms such as "parallel" and "perpendicular" do not mean that the fittings are absolutely parallel or perpendicular to each other, but can form a certain angular deviation. For example, "horizontal" only means that its direction is more horizontal relative to "vertical", and does not mean that the structure must be completely horizontal, but can be slightly inclined. In addition, the orientation or positional relationship indicated by terms such as "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc. is based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the products of the present application are usually placed during use. It is only for the convenience of describing the embodiments of the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be construed as a limitation to the present application.
[0053] It can be understood that the meaning of "a plurality of" in this text is at least two, such as two, three, etc., unless there are specific restrictive descriptions. In addition, the terms "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally further include steps or units not listed, or may optionally further include other steps or units inherent to these processes, methods, products or devices. The term "and / or" is merely a description of the association relationship between associated objects, indicating that three relationships can exist. For example, A and / or B can represent three situations: A exists alone, A and B exist simultaneously, and B exists alone. In addition, the character " / " in this text generally indicates that the associated objects before and after are in an "or" relationship.
[0054] The above description is only an implementation manner of the present application, and does not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made by using the content of the specification and drawings of the present application, or directly or indirectly applied in other related technical fields, shall be equally included in the patent protection scope of the present application.
Claims
1. An injection mold, characterized in that, For preparing a current sensor, the current sensor includes an iron core (1) and a copper bar (2), the iron core (1) is sleeved on the copper bar (2), the injection mold (3) is provided with a receiving groove (31) and a through hole (32), and the through hole (32) communicates with the receiving groove (31); In the injection molding state, the through hole (32) is configured to penetrate the copper bar (2), and the receiving groove (31) is configured to accommodate the iron core (1) to injection-mold and connect the iron core (1) and the copper bar (2).
2. The injection mold according to claim 1, wherein The shape of the receiving groove (31) is adapted to the iron core (1).
3. The injection mold according to claim 2, wherein, The iron core (1) is provided with an opening (11), and the current sensor further includes a Hall chip, and the opening (11) is used for arranging the Hall chip; The inner wall of the receiving groove (31) is provided with a first limiting protrusion (311); in the injection molding state, the first limiting protrusion (311) is located at the opening (11).
4. The injection mold according to claim 3, characterized in that, A first dimension (12) of the opening (11) along the circumferential direction of the iron core (1) is greater than a second dimension (33) of the first limiting protrusion (311) along the circumferential direction.
5. The injection mold according to claim 4, characterized in that, The difference between the first dimension (12) and the second dimension (33) is 0.05 mm - 0.3 mm.
6. The injection mold according to claim 3, wherein, The inner wall of the receiving groove (31) is provided with a second limiting protrusion (312), and the second limiting protrusion (312) is arranged at an interval with the first limiting protrusion (311) along the circumferential direction of the iron core (1) and abuts against the circumferential surface of the iron core (1) along the radial direction of the iron core (1).
7. The injection mold according to claim 3, characterized in that, The inner wall of the receiving groove (31) is provided with a third limiting protrusion (313), and the third limiting protrusion (313) abuts against the end face of the iron core (1) along the axial direction of the iron core (1).
8. The injection mold according to any one of claims 1-7, characterized in that, The iron core (1) includes a plurality of stacked iron sheet layers.
9. A current sensor, characterized in that, The current sensor includes an iron core (1), a copper bar (2) and an injection molded housing (4); The iron core (1) is sleeved on the copper bar (2), and the iron core (1) is provided with an opening (11); The injection molded housing (4) is injection molded by the injection mold (3) according to any one of claims 1-7, and the injection molded housing (4) is injection molded and connected with the iron core (1) and the copper bar (2); The current sensor further includes a Hall chip, and the Hall chip is arranged in the opening (11).
10. A vehicle, characterized in that, Including the current sensor according to claim 9.