Magnetic core copper bar assembly and preparation mold

Abstract

The utility model relates to a magnetic core copper bar assembly and a preparation mold. The magnetic core copper bar assembly comprises a copper bar, a magnetic core part and an installation part. The magnetic core part is fixedly installed on the copper bar through an installation part formed through injection molding, and the magnetic core part is wrapped by the installation part. According to the magnetic core copper bar assembly, the installation part is directly subjected to injection molding through the preparation mold, and assembling of the magnetic core part and the copper bar is completed, so that on one hand, the technological process is simplified, the assembling steps are reduced, the labor cost and the material cost are reduced, and the traditional mode that the magnetic core part is fixed to the copper bar through glue is abandoned; and on the other hand, the wrapping performance of the installation part directly formed on the magnetic core part in an injection molding mode is good, and the structural strength of the magnetic core copper bar assembly can be improved.

Description

Technical Field

[0001] This utility model relates to the technical field of inductors, and in particular to a magnetic core copper busbar assembly and its manufacturing mold. Background Technology

[0002] The main components of an inductor include a copper busbar and a magnetic core. When assembling the magnetic core and the copper busbar, existing inductors typically use a method where double-sided tape or glue is applied to the inside of the magnetic core, and then the two magnetic cores are glued to the outside of the copper busbar. External tape is then wrapped around the outside of the magnetic core, and finally, two plastic shells are used to connect the outside of the tape to fix the magnetic core to the copper busbar. However, this method makes the assembly process of the inductor cumbersome, the assembly technology complex, the assembly production cycle long, and it also wastes manpower and resources. Utility Model Content

[0003] The first objective of this utility model is to provide a magnetic core copper busbar assembly that aims to solve the technical problems of cumbersome assembly process, complex assembly technology, and long assembly production cycle of existing magnetic core copper busbar assemblies.

[0004] To solve the above technical problems, a magnetic core copper busbar assembly is provided, comprising:

[0005] Copper busbar;

[0006] Magnetic core components;

[0007] The mounting component is fixedly mounted on the copper busbar by the injection-molded mounting component, and the mounting component encloses the magnetic core component.

[0008] Furthermore, mounting holes are formed on the copper busbar.

[0009] Furthermore, the magnetic core copper busbar assembly also includes studs formed on the mounting component.

[0010] Furthermore, a welded portion is formed on the copper busbar.

[0011] Furthermore, the magnetic core component includes an upper magnetic core and a lower magnetic core, and the magnetic core copper busbar assembly further includes an air gap pad, which is disposed between the upper magnetic core and the lower magnetic core.

[0012] The second objective of this invention is to provide a manufacturing mold for assembling the aforementioned magnetic core copper busbar assembly, the manufacturing mold comprising:

[0013] The upper mold includes an upper groove for placement and an upper cavity for injection molding, wherein the upper groove and the upper cavity are connected.

[0014] The lower mold includes a placement groove and a lower cavity for injection molding. The placement groove and the lower cavity are connected. The upper mold covers the lower mold so that the upper cavity and the lower cavity together form an injection cavity. The placement groove and the placement groove together form a placement channel.

[0015] Furthermore, the upper mold and / or the lower mold are also provided with injection holes, which are connected to the injection cavity.

[0016] Furthermore, the preparation mold also includes a positioning element, and the upper mold and / or the lower mold are provided with a mounting groove, and the positioning element is fixedly installed in the mounting groove.

[0017] Implementing the embodiments of this utility model will have the following beneficial effects:

[0018] In this embodiment, the magnetic core copper busbar assembly simplifies the process by directly injection molding the mounting parts and assembling the magnetic core components with the copper busbar through a mold. This reduces assembly steps, lowers labor and material costs, and eliminates the complex traditional process of first fixing the magnetic core components to the copper busbar with glue and then wrapping the outside with tape and a plastic shell. Furthermore, the good wrapping properties of the mounting parts, which are directly injection molded onto the magnetic core components, help increase the structural strength of the magnetic core copper busbar assembly. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the magnetic core copper busbar assembly described in Embodiment 1 of this utility model;

[0021] Figure 2 This is a schematic diagram of the structure of the magnetic core copper busbar assembly after the mounting parts have been removed, as described in Embodiment 1 of this utility model;

[0022] Figure 3 This is an exploded view of the magnetic core copper busbar assembly described in Embodiment 1 of this utility model after the mounting parts have been removed;

[0023] Figure 4 This is a schematic diagram of the magnetic core copper busbar assembly described in Embodiment 2 of this utility model;

[0024] Figure 5 This is a schematic diagram of the magnetic core copper busbar assembly described in Embodiment 3 of this utility model;

[0025] Figure 6 This is a schematic diagram of the magnetic core copper busbar assembly described in Embodiment 4 of this utility model;

[0026] Figure 7 This is a schematic diagram of the preparation mold described in an embodiment of the present invention;

[0027] Figure 8 This is an exploded view of the preparation mold described in an embodiment of this utility model.

[0028] Among them: 100, magnetic core copper busbar assembly; 110, copper busbar; 111, mounting hole; 112, welding part; 120, magnetic core component; 121, upper magnetic core; 122, lower magnetic core; 130, mounting part; 140, stud; 150, air gap gasket;

[0029] 200. Mold preparation; 210. Upper mold; 211. Upper cavity; 212. Upper slot placement; 220. Lower mold; 221. Lower cavity; 222. Lower slot placement; 230. Injection cavity; 240. Channel placement; 250. Injection hole; 260. Mounting slot; 270. Positioning component. Detailed Implementation

[0030] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0031] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0032] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0033] Please refer to Figures 1-6This utility model provides a magnetic core copper busbar assembly 100, which includes a copper busbar 110, a magnetic core component 120, and a mounting component 130. The magnetic core component 120 is fixedly mounted on the copper busbar 110 by the injection-molded mounting component 130, and the mounting component 130 encloses the magnetic core component 120. Exemplarily, the mounting component 130 is a plastic shell. It is understood that the mounting component 130 forms a cavity adapted to the magnetic core component 120, so that the magnetic core component 120 is exactly enclosed by the mounting component 130 to fix the magnetic core component 120. In conventional processes, the plastic shell (i.e., the mounting component 130 in this embodiment) needs to be pre-prepared by injection molding. The innovation of this application is that, with the help of a preparation mold 200, the copper busbar 110 and the magnetic core component 120 are positioned, so that the magnetic core copper busbar assembly 100 is assembled at the same time as the mounting component 130 is injection molded. In this embodiment, the thickness of the injection-molded mounting part 130 is 1 mm. This application lists four different shapes of magnetic core copper busbar assemblies 100, among which... Figure 1 , Figure 2 and Figure 3 The image shown is the magnetic core copper busbar assembly 100 of Embodiment 1. Figure 4 The image shown is the magnetic core copper busbar assembly 100 of Embodiment 2. Figure 5 The image shown is the magnetic core copper busbar assembly 100 of Embodiment 3. Figure 6 The image shows the magnetic core copper busbar assembly 100 of Embodiment 4. Except for their shapes, the magnetic core copper busbar assemblies 100 of Embodiments 1 to 4 are assembled in the same way.

[0034] Please refer to Figure 1 , Figure 2 and Figure 3 In this embodiment, the magnetic core copper busbar assembly 100 directly injection molds the mounting part 130 through the preparation mold 200 and completes the assembly of the magnetic core component 120 and the copper busbar 110. On the one hand, it simplifies the process flow, reduces assembly steps, and lowers labor and material costs. It also eliminates the traditional complex process of first fixing the magnetic core component 120 to the copper busbar 110 with glue and then wrapping the outside with tape and plastic shell. On the other hand, the mounting part 130 is directly injection molded on the magnetic core component 120, which has good wrapping properties and helps to increase the structural strength of the magnetic core copper busbar assembly 100.

[0035] Please refer to Figure 1 , Figure 2 and Figure 3In one possible implementation, mounting holes 111 are formed on the copper busbar 110. Exemplarily, in this embodiment, the mounting hole 111 is a circular through hole, which serves to connect the magnetic core copper busbar assembly 100 to the client or device through the mounting hole 111, and also to fix the magnetic core copper busbar assembly 100. It is understood that the mounting hole 111 is used to fix the magnetic core copper busbar assembly 100 to the client or device using screws or bolts. Of course, in specific applications, the shape of the mounting hole 111 is not limited to this. For example, as an alternative, the shape of the mounting hole 111 can also be a rounded rectangular through slot.

[0036] Please refer to Figure 5 and Figure 6 In one possible implementation, the magnetic core copper busbar assembly 100 further includes a stud 140 formed on the mounting member 130. Exemplarily, the stud 140 is used for connection to a PCB board on a client or device.

[0037] Please refer to Figure 4 In one possible implementation, a solder joint 112 is formed on the copper busbar 110. Exemplarily, a PCB board on a client or device can also be fixedly mounted on the magnetic core copper busbar assembly 100 via the solder joint 112.

[0038] Please refer to Figure 1 , Figure 2 and Figure 3 In one possible implementation, the magnetic core component 120 includes an upper magnetic core 121 and a lower magnetic core 122. The magnetic core copper busbar assembly 100 also includes an air gap spacer 150 disposed between the upper magnetic core 121 and the lower magnetic core 122. Exemplarily, a set of magnetic core components 120 includes two magnetic cores. In specific applications, multiple magnetic core components 120 can be disposed on a single copper busbar 110, depending on actual needs; no further limitations are imposed here. The function of the air gap spacer 150 is to improve the efficiency and performance of the magnetic core copper busbar assembly 100 by reducing leakage inductance and lowering the influence of edge magnetic flux in the air gap, while ensuring the reliability and stability of the magnetic core copper busbar assembly 100.

[0039] Please refer to Figure 7 and Figure 8The second objective of this utility model is to provide a preparation mold 200 for assembling the aforementioned magnetic core copper busbar assembly 100. The preparation mold 200 includes an upper mold 210 and a lower mold 220. The upper mold 210 includes an upper placement groove 212 and an upper cavity 211 for injection molding, with the upper placement groove 212 and the upper cavity 211 communicating with each other. The lower mold 220 includes a lower placement groove 222 and a lower cavity 221 for injection molding, with the lower placement groove 222 and the lower cavity 221 communicating with each other. The upper mold 210 and the lower mold 220 cover each other so that the upper cavity 211 and the lower cavity 221 together form an injection molding cavity 230, and the upper placement groove 212 and the lower placement groove 222 together form a placement channel 240. Exemplarily, the preparation mold 200 in this embodiment is used to prepare the magnetic core copper busbar assembly 100 in the first embodiment above, i.e. Figure 1 , Figure 2 and Figure 3 The magnetic core copper busbar assembly 100 shown in Embodiments 2, 3, and 4 can be adapted to fit the shape. Its principle is the same as the preparation mold 200 listed in Embodiment 1, and will not be elaborated further here. Both the upper cavity 211 and the lower cavity 221 are rectangular cavities; of course, their shapes can be specifically determined according to the shape and position of the magnetic core. The placement channel 240 is used to place the copper busbar 110. It is understood that a sealing ring can be set in the placement channel 240 to ensure the sealing of the injection cavity 230 during injection molding. During injection molding, the copper busbar 110 is placed in the placement channel 240, the upper magnetic core 121 is placed in the upper groove 212, and the lower magnetic core 122 is placed in the lower groove 222. At this time, there will be gaps between the injection cavity 230 and the upper and lower magnetic cores 121 and 122. These gaps are filled by injection molding, and after cooling, the mounting part 130 of this embodiment is obtained. After injection molding, the 130-position mounting part is a single unit, which has higher structural strength compared to the traditional assembly process that uses two plastic shells.

[0040] Please refer to Figure 7 and Figure 8 In one possible implementation, the upper mold 210 and / or the lower mold 220 are further provided with injection holes 250, which communicate with the injection cavity 230. Exemplarily, in this embodiment, both the upper mold 210 and the lower mold 220 are provided with one injection hole 250. During injection molding, liquid plastic is injected through the injection hole 250, and the liquid plastic cools to form the mounting part 130. The injection hole 250 is a circular hole. Of course, in specific applications, the shape of the injection hole 250 is not limited to this. For example, as an alternative, the injection hole 250 can also be rectangular, elliptical, or other shapes. Furthermore, it should be noted that the injection hole 250 can also be provided only in the upper mold 210 or the lower mold 220.

[0041] Please refer to Figure 7 and Figure 8In one possible implementation, the preparation mold 200 further includes a positioning element 270, and the upper mold 210 and / or lower mold 220 are also provided with mounting grooves 260, in which the positioning element 270 is fixedly installed. Exemplarily, in this embodiment, mounting grooves 260 are provided in both the upper mold 210 and the lower mold 220, meaning that positioning elements 270 are provided in both the upper mold 210 and the lower mold 220. The function of the positioning element 270 is to fix the magnetic core component 120, preventing it from moving within the injection cavity 230. Specifically, the positioning element 270 installed in the upper mold 210 is used to position the upper magnetic core 121, and the positioning element 270 installed in the lower mold 220 is used to position the lower magnetic core 122. In this embodiment, the positioning element 270 is cylindrical, and two positioning elements 270 are installed in both the upper mold 210 and the lower mold 220. Of course, in specific applications, the shape and number of positioning elements 270 are not limited to this. For example, as an alternative, positioning elements 270 can also be set as rectangular prisms, and the number can be set according to actual needs. For example, three, four, or five can be set; there are no major restrictions here. In addition, it should be noted that positioning elements 270 can also be set only in the upper mold 210 or the lower mold 220, and the positioning elements 270 and the mounting groove 260 are fixedly installed through an interference fit.

[0042] Please refer to Figure 7 and Figure 8 The positioning element 270 helps to precisely position the copper busbar 110 and the magnetic core component 120, ensuring their correct placement within the preparation mold 200. This reduces assembly errors and improves the overall manufacturing precision of the assembly. Using the positioning element 270 reduces the time spent on manual adjustments and alignment, simplifying the process and increasing production efficiency. The positioning element 270 ensures a stable connection between the magnetic core component 120 and the copper busbar 110, preventing displacement during injection molding and enhancing the stability and reliability of the final product. Accurate positioning helps ensure that each produced magnetic core copper busbar assembly 100 conforms to design specifications, thereby improving overall product quality.

[0043] The following are two injection molding methods for the magnetic core copper busbar assembly 100 in this embodiment:

[0044] Method 1: One-time injection molding

[0045] The air gap gasket 150 is fixed to the upper magnetic core 121 and the lower magnetic core 122 with glue. The lower magnetic core 122 is then placed in the lower cavity 221 of the lower mold 220. The copper busbar 110 is placed in the placement groove 222 of the lower mold 220. The upper magnetic core 121 is then placed in the groove. The upper mold 210 and the lower mold 220 are then closed, so that the copper busbar 110 is located in the placement channel 240 and the upper magnetic core 121 is located in the placement groove 212. Injection molding begins. After injection molding is completed, the mold is demolded and the product is taken out, which is the magnetic core copper busbar assembly 100.

[0046] Method 2: Two-stage injection molding

[0047] The air gap gasket 150 is fixed to the upper magnetic core 121 and the lower magnetic core 122 with glue. The lower magnetic core 122 is then placed in the lower cavity 221 of the lower mold 220. The copper busbar 110 is placed in the placement groove 222 of the lower mold 220. Then the upper magnetic core 121 is placed, and the first injection molding is performed through the injection hole 250 of the lower mold 220. After the injection molding is completed, the upper magnetic core 121 is placed, and the upper mold 210 and the lower mold 220 are closed, so that the copper busbar 110 is located in the placement channel 240 and the upper magnetic core 121 is located in the placement groove 212. The second injection molding is performed through the injection hole 250 of the upper mold 210. After the injection molding is completed, the mold is demolded and the product is taken out, which is the magnetic core copper busbar assembly 100.

[0048] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A magnetic core copper busbar assembly, characterized in that, include: Copper busbar; Magnetic core components; The mounting component is fixedly mounted on the copper busbar by the injection-molded mounting component, and the mounting component encloses the magnetic core component. The magnetic core component includes an upper magnetic core and a lower magnetic core, and the magnetic core copper busbar assembly also includes an air gap pad, which is disposed between the upper magnetic core and the lower magnetic core.

2. The magnetic core copper busbar assembly according to claim 1, characterized in that, Mounting holes are formed on the copper busbar.

3. The magnetic core copper busbar assembly according to claim 2, characterized in that, The magnetic core copper busbar assembly also includes studs formed on the mounting component.

4. The magnetic core copper busbar assembly according to claim 2, characterized in that, The copper busbar has a welded section formed on it.

5. A mold for assembling the magnetic core copper busbar assembly according to any one of claims 1-4, characterized in that, The preparation mold includes: The upper mold includes an upper groove for placement and an upper cavity for injection molding, wherein the upper groove and the upper cavity are connected. The lower mold includes a placement groove and a lower cavity for injection molding. The placement groove and the lower cavity are connected. The upper mold covers the lower mold so that the upper cavity and the lower cavity together form an injection cavity. The placement groove and the placement groove together form a placement channel.

6. The preparation mold according to claim 5, characterized in that, The upper mold and / or the lower mold are further provided with injection holes, which are connected to the injection cavity.

7. The mold for preparation according to claim 5, characterized in that, The preparation mold further includes a positioning component, and the upper mold and / or the lower mold are provided with a mounting groove, and the positioning component is fixedly installed in the mounting groove.

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