Magnetic core assembly, filter and controller
By integrating the magnetic core with the conductive components and fixing them with welding and potting compound, the problems of complex filter installation and increased size are solved, achieving cost savings and a compact structure.
Patent Information
- Application Number
- CN202422646529.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-31
- Publication Date
- 2025-11-14
- Estimated Expiration
- 2034-10-31
AI Technical Summary
The integration and installation of existing filters are complex, involving multiple processes and auxiliary materials, resulting in high costs and increased size.
The magnetic core and conductive components are integrated into one unit and connected by welding copper busbars, eliminating the need for insert injection molding and adhesive processes. The core is fixed inside the controller housing using potting compound, eliminating the need for screw fixing.
It simplifies the installation process, reduces costs, decreases the use of auxiliary materials, shrinks the filter size, and improves structural rigidity and heat dissipation performance.
Smart Images
Figure CN223552363U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of filter technology, specifically relating to a magnetic core assembly, a filter, and a controller. Background Technology
[0002] The filter is one of the core components of the controller. The filter includes a variety of electronic components such as magnetic core, DC copper busbar, and capacitor. In the current technology, these electronic components need to be integrated together through a variety of processes and auxiliary materials.
[0003] The existing integration process is as follows: the DC copper busbar and the mounting bracket are formed into a single injection molded part using an insert injection molding process; the X capacitor and Y capacitor are fixed to the plastic shell on the injection molded part by dispensing; the pins of the X capacitor and Y capacitor are connected to the DC copper busbar by soldering; the magnetic core is fixed to the DC copper busbar by adhesive using an EI or EE combination; the fixing of the magnetic core also requires some accessories, such as pressure plates, foam, etc.; the DC copper busbar is cooled by heat dissipation pads or thermally conductive adhesive, etc.
[0004] The filter also needs to be equipped with multiple mounting points, which increases the size of the filter. The filter is fixedly connected to the housing of the controller by screws inserted into the mounting points.
[0005] It is evident that the integration and installation process of filters is complex, involving insert injection molding, welding, gluing, screw tightening, etc., which not only results in high process and auxiliary material costs, but also increases the size of the filter due to the use of auxiliary materials. Utility Model Content
[0006] To simplify the installation process and save costs, this utility model provides the following technical solution:
[0007] This utility model provides a magnetic core assembly, including a magnetic core and a conductive component. The conductive component includes a first DC input copper busbar and a transition copper busbar. The first DC input copper busbar passes through the magnetic core. The transition copper busbar is welded to both ends of the first DC input copper busbar. The transition copper busbar has welding terminals, which extend in a direction perpendicular to the first DC input copper busbar.
[0008] This invention integrates the magnetic core and conductive components into one unit, facilitating subsequent connection to the circuit board via soldering terminals on the adapter copper busbar. Furthermore, different copper busbars are fixed together by soldering, rather than using screws, which not only saves on screw usage but also, due to the absence of process type switching, allows for integrated soldering operations when connecting the circuit board.
[0009] Furthermore, the conductive component also includes a second DC input copper busbar perpendicular to the first DC input copper busbar; one end of the second DC input copper busbar is welded to the first end of the first DC input copper busbar, and the other end of the second DC input copper busbar has a bent portion; a press-fit nut is provided on the bent portion.
[0010] The second DC input copper busbar is used to connect the high-voltage busbar connector, which is done by using the crimp nut on the bent part.
[0011] Furthermore, the conductive component also includes a capacitor busbar, which is welded to the second end of the first DC input busbar.
[0012] The capacitor busbar is used to connect external capacitors to the filter. Welding the capacitor busbar to the first DC input busbar saves on screws and allows for integrated welding.
[0013] Furthermore, it also includes a magnetic core shell, inside which is provided an insulating hollow column; the magnetic core is disposed in the magnetic core shell and is inserted into the insulating hollow column through a socket on the magnetic core, and the sidewall of the magnetic core is fixed to the inner wall of the magnetic core shell by dispensing or potting sealant; the first DC input copper busbar passes through the magnetic core by inserting into the insulating hollow column.
[0014] This invention features a special core shell for the magnetic core. The insulating hollow column inside the core shell serves to limit the movement of the magnetic core. The insulating hollow column also provides an installation position for the copper busbar to pass through the magnetic core and serves to electrically isolate the magnetic core from the copper busbar. This eliminates the need for the process of inserting and molding the copper busbar and gluing the magnetic core, greatly simplifying the installation process of the copper busbar and the magnetic core.
[0015] Furthermore, the magnetic core has two insertion holes, and the magnetic core shell has two insulating hollow pillars. This satisfies the requirement of simultaneously integrating the positive and negative copper busbars.
[0016] Furthermore, the magnetic core is integrally molded. Compared to assembled magnetic cores, integrally molded magnetic cores are smaller in size and lower in cost.
[0017] Furthermore, the sidewalls of the magnetic core are fixed to the inner wall of the core shell by injecting silicone. After the silicone cures, it has a certain degree of elasticity, preventing the magnetic core from being stressed and causing the inductance to drop.
[0018] Furthermore, the surface of the magnetic core shell is provided with several protrusions. The protrusions can increase the surface area of the magnetic core shell, which can enhance the robustness of the encapsulation when the filter is subsequently encapsulated in the controller housing.
[0019] Furthermore, the magnetic core shell and the insulating hollow column are integrally molded from plastic. This facilitates processing and manufacturing, resulting in light weight and low cost.
[0020] Furthermore, it also includes an end cap, on which a through hole is provided corresponding to the insulating hollow column, and the end cap is sealed to the opening of the magnetic core shell. The sealed connection between the end cap and the magnetic core shell ensures that the magnetic core is sealed inside the magnetic core shell, thus protecting the magnetic core; the through hole on the end cap ensures that the copper busbar can pass smoothly through the magnetic core. This utility model also provides a filter, including the above-mentioned magnetic core assembly, and further including a circuit board with an integrated filter capacitor; the circuit board has a through hole, and the welding terminals on the adapter copper busbar are inserted into the through hole and welded to the circuit board, so that the filter capacitor forms an electrical connection with the conductive component.
[0021] The filter of this invention uses a circuit board with integrated filter capacitors, which reduces the need to install filter capacitors on the circuit board during filter assembly.
[0022] Furthermore, the circuit board includes a first circuit board and a second circuit board respectively disposed at both ends of the first DC input copper busbar; the filter capacitor includes at least one of an X capacitor and a Y capacitor.
[0023] X capacitors are used to eliminate differential-mode interference, and Y capacitors are used to eliminate common-mode interference. The combination of X and Y capacitors can improve the filtering effect.
[0024] This utility model also provides a controller, including the above-mentioned filter, wherein the filter is disposed inside the controller housing and is fixed inside the controller housing by potting and sealing adhesive.
[0025] Compared to using screws to fix the filter to the controller housing, potting compound curing improves the overall structural rigidity, saves screws, and reduces product size. The potting compound is thermally conductive, eliminating the need for additional heat dissipation pads or thermal adhesives to cool the filter. Furthermore, the potting compound has insulating properties, providing electrical isolation for the filter without the need for additional insulation measures. Attached Figure Description
[0026] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0027] Figure 1 This is a schematic diagram of the integrated magnetic core in this specific embodiment;
[0028] Figure 2 This is a schematic diagram of the magnetic core assembly in this specific embodiment;
[0029] Figure 3This is a top view of the filter in this specific embodiment;
[0030] Figure 4 This is a schematic diagram of the structure of the second circuit board in this specific embodiment;
[0031] Figure 5 This is a schematic diagram of the structure of the first circuit board in this specific embodiment;
[0032] Figure 6 This is a partial view of the controller in this specific embodiment. Detailed Implementation
[0033] To simplify the installation process and save costs, this specific embodiment integrates the magnetic core and the magnetic core shell into an integrated magnetic core, and then integrates the integrated magnetic core and the conductive components into a magnetic core assembly.
[0034] First, the integrated magnetic core in this specific embodiment will be described, referring to... Figure 1 As shown, an integrated magnetic core 1 includes a core shell 101 and a magnetic core 102. The core shell 101 has an insulating hollow column 10101 inside. The magnetic core 102 is disposed inside the core shell 101 and is inserted into the insulating hollow column 10101 through a socket on the magnetic core 102. The sidewall of the magnetic core 102 is fixed to the inner wall of the core shell 101 by dispensing or potting encapsulant.
[0035] In this specific embodiment, a special core shell 101 is designed for the magnetic core 102. The insulating hollow column 10101 inside the core shell 101 serves to limit the magnetic core 102. The insulating hollow column 10101 also provides an installation position for the copper busbar to pass through the magnetic core 102 and serves to electrically isolate the magnetic core 102 from the copper busbar. This eliminates the need for the process of inserting and molding the copper busbar and gluing the magnetic core 102, greatly simplifying the installation process of the copper busbar and the magnetic core 102.
[0036] In this specific embodiment, the magnetic core 102 has two insertion holes, and the magnetic core shell 101 has two insulating hollow pillars 10101. This satisfies the requirement of simultaneously integrating the positive and negative copper busbars.
[0037] In this specific embodiment, the magnetic core 102 is integrally formed. Compared with the assembled magnetic core 102, the integrally formed magnetic core 102 is smaller in size and lower in cost.
[0038] Preferably, the sidewall of the magnetic core 102 is fixed to the inner wall of the magnetic core shell 101 by injecting silicone. After the silicone 103 is cured, it has a certain degree of elasticity, which prevents the magnetic core 102 from being subjected to stress and causing the inductance to drop.
[0039] Preferably, the magnetic core shell 101 and the insulating hollow column 10101 are integrally molded from plastic.
[0040] Preferably, the surface of the magnetic core shell 101 is provided with a plurality of protrusions 10102. The protrusions can be strip-shaped, spherical, etc. The protrusions can increase the surface area of the magnetic core shell 101, and can enhance the robustness of the encapsulation when the filter is subsequently encapsulated in the controller housing.
[0041] Preferably, the device further includes an end cap 104, which has a through hole corresponding to the insulating hollow column 10101. The end cap 104 is sealed to the opening of the magnetic core shell 101. The sealed connection between the end cap and the magnetic core shell ensures that the magnetic core is sealed inside the magnetic core shell, thus protecting the magnetic core. The through hole on the end cap ensures that the copper busbar can pass smoothly through the magnetic core.
[0042] refer to Figure 2 As shown, the magnetic core assembly in this specific embodiment includes the integrated magnetic core 1 and a conductive component 2. The conductive component 2 includes a first DC input copper busbar 201 and a transition copper busbar 202. The first DC input copper busbar 201 is inserted into the insulating hollow column 10101 and penetrates the magnetic core shell 101. The transition copper busbar 202 is welded to both ends of the first DC input copper busbar. The transition copper busbar 202 has welding terminals that extend in a direction perpendicular to the first DC input copper busbar 201.
[0043] In this specific embodiment, the magnetic core assembly integrates the magnetic core 102 and the conductive component 2 into one unit, facilitating subsequent connection to the circuit board via the solder terminals on the adapter copper busbar 202. Furthermore, different copper busbars are fixed together by soldering, rather than by screws, which not only saves on screw usage but also facilitates integrated soldering during circuit board connection since there is no process type switching. Soldering methods can include tin soldering, wave soldering, etc.
[0044] The conductive component 2 also includes a second DC input copper busbar 203 perpendicular to the first DC input copper busbar 201; one end of the second DC input copper busbar 203 is welded to the first end of the first DC input copper busbar 201, and the other end of the second DC input copper busbar 203 has a bent portion; a press-fit nut 3 is provided on the bent portion.
[0045] The second DC input copper busbar 203 is used to connect the high-voltage busbar connector, that is, to connect it through the crimp nut 3 on the bent part.
[0046] The conductive component 2 also includes a capacitor copper busbar 204, which is welded to the second end of the first DC input copper busbar 201.
[0047] The capacitor busbar 204 is used to connect external capacitors to the filter. Welding the capacitor busbar 204 to the first DC input busbar 201 saves on screws and allows for integrated welding.
[0048] refer to Figure 3 As shown, this specific embodiment also provides a filter, including the magnetic core assembly described above, and a circuit board with an integrated filter capacitor; the circuit board is provided with a via, and the welding terminal 20201 on the adapter copper busbar 202 is inserted into the via and welded to the circuit board, so that the filter capacitor and the conductive component 2 form an electrical connection.
[0049] In this specific embodiment, a circuit board with integrated filter capacitors is used, which reduces the need to install filter capacitors on the circuit board when assembling the filter.
[0050] refer to Figure 4 and Figure 5 As shown, the circuit board includes a first circuit board 4 and a second circuit board 7 respectively disposed at both ends of the first DC input copper busbar 201; the filter capacitor includes at least one of an X capacitor and a Y capacitor. Each circuit board may have both X capacitors and Y capacitors simultaneously, or it may have only X capacitors or Y capacitors.
[0051] In this specific embodiment, the filter capacitors on the first circuit board 4 include X capacitor 5 and Y capacitor 6; the filter capacitors on the second circuit board 7 include Y capacitor 6.
[0052] X capacitor 5 is used to eliminate differential-mode interference, and Y capacitor 6 is used to eliminate common-mode interference. The combination of X capacitor 5 and Y capacitor 6 can improve the filtering effect.
[0053] refer to Figure 6 As shown, this specific embodiment also provides a controller, including the above-mentioned filter, the filter being disposed inside the controller housing 8 and fixed inside the controller housing by potting encapsulant.
[0054] The potting compound can be epoxy resin, polyacrylate, etc. Before potting, install the grounding screw 9 on the Y capacitor 6. After the potting compound 10 has cured, the filter can be fixed in the controller housing 8.
[0055] Compared to using screws to fix the filter to the controller housing, potting compound curing improves the overall structural rigidity, saves screws, and reduces product size. The potting compound is thermally conductive, eliminating the need for additional heat dissipation pads or thermal adhesives to cool the filter. Furthermore, the potting compound has insulating properties, providing electrical isolation for the filter without the need for additional insulation measures.
[0056] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this application.
Claims
1. A magnetic core assembly, characterized in that, The device includes a magnetic core and a conductive component. The conductive component includes a first DC input copper busbar and a transition copper busbar. The first DC input copper busbar passes through the magnetic core. Transition copper busbars are welded to both ends of the first DC input copper busbar. The transition copper busbar has welding terminals that extend in a direction perpendicular to the first DC input copper busbar.
2. The magnetic core assembly according to claim 1, characterized in that, The conductive component further includes a second DC input copper busbar perpendicular to the first DC input copper busbar; one end of the second DC input copper busbar is welded to the first end of the first DC input copper busbar, and the other end of the second DC input copper busbar has a bent portion; a press-fit nut is provided on the bent portion.
3. The magnetic core assembly according to claim 1, characterized in that, The conductive component also includes a capacitor copper busbar, which is welded to the second end of the first DC input copper busbar.
4. The magnetic core assembly according to claim 1, characterized in that, It also includes a magnetic core housing, inside which is an insulating hollow column; the magnetic core is disposed inside the magnetic core housing and is inserted into the insulating hollow column through a socket on the magnetic core; the sidewall of the magnetic core is fixed to the inner wall of the magnetic core housing by dispensing or potting sealant; the first DC input copper busbar passes through the magnetic core by inserting into the insulating hollow column.
5. The magnetic core assembly according to claim 4, characterized in that, The surface of the magnetic core shell has several protrusions.
6. The magnetic core assembly according to claim 4, characterized in that, It also includes an end cap, on which a through hole is provided corresponding to the insulating hollow column, and the end cap is sealed to the opening of the magnetic core shell.
7. A filter, characterized in that, The magnetic core assembly as described in any one of claims 1 to 6 further includes a circuit board with an integrated filter capacitor; the circuit board has a via, and the welding terminals on the adapter copper busbar are inserted into the via and welded to the circuit board, so that the filter capacitor forms an electrical connection with the conductive component.
8. The filter according to claim 7, characterized in that, The circuit board includes a first circuit board and a second circuit board respectively disposed at both ends of the first DC input copper busbar; the filter capacitor includes at least one of an X capacitor and a Y capacitor.
9. A controller, characterized in that, Includes the filter as described in any one of claims 7 to 8, wherein the filter is disposed within the controller housing and fixed within the controller housing by potting encapsulant.