Three-time injection molding structure for PTC (Positive Temperature Coefficient) busbar

Abstract

The utility model discloses a three-time injection molding structure for a PTC (Positive Temperature Coefficient) busbar, which comprises a plurality of insert main bodies, one-time injection molding parts are arranged on the outer sides of the plurality of insert main bodies, support columns are uniformly mounted on the one-time injection molding parts, and positioning holes are formed in the insert main bodies; on the premise that the structure of the product is not changed, the product is simplified, and the product which cannot be opened is subjected to injection molding through three times of injection molding; the supporting columns are additionally arranged on one-time injection molding, and the positioning holes are formed in the insert main body, so that the insert main body is prevented from moving during injection molding, a safe distance is formed between inserts, a product is ensured to have good electrical performance, and the production and manufacturing efficiency and quality of the product are improved.

Description

Technical Field

[0001] This utility model relates to the field of busbar technology, specifically a three-stage injection molding structure for PTC busbars. Background Technology

[0002] Busbars are important components in PTC battery heating systems. The primary function of PTC busbars is to transmit signals from the system to the central circuit board, thereby improving the efficiency and reliability of the entire circuit system.

[0003] The current method for implementing a bus-like structure is as follows:

[0004] By structurally splitting a bus with a 90-degree angle into two buses, which then need to be joined together by soldering, multiple soldering operations are required between the two buses. These solder joints are exposed within the system, leading to the following problems:

[0005] 1. The manufacturing and welding costs of the busbar are relatively high, which does not meet the cost control requirements of car manufacturers.

[0006] 2. The two busbars are connected by welding. Due to the influence of welding quality, the product reliability and yield are not high.

[0007] 3. The busbar is complex to install in the PTC system, which does not meet the requirements of car manufacturers for simple and convenient installation.

[0008] Meanwhile, existing PTC bus structures are complex, often designed with a 90-degree angle, and contain numerous guide pillars and terminal pins on the vertical surfaces, making injection molding impossible. Furthermore, the numerous inserts and nuts in the bus result in low molding efficiency and yield. During injection molding, the small spacing between inserts makes them susceptible to positional changes due to injection pressure, leading to a risk of short circuits caused by overlap.

[0009] Secondly, the product contains many inserts with short distances between them, making them difficult to position during installation and resulting in low production efficiency. During the filling process, the plastic impacts the inserts, and in areas far from the terminals, there is a risk of inserts coming into contact or protruding from the product surface, ultimately causing poor busbar and discharge performance. Furthermore, the long terminals of the inserts are too long, and only the bottom is fixed, with no effective positioning in the middle and top. This causes the inserts to shift, resulting in excessive positional tolerances for the long terminals and affecting the product's functionality.

[0010] To address this, a three-stage injection molding structure for PTC busbars is proposed. Summary of the Invention

[0011] The purpose of this invention is to provide a three-stage injection molding structure for PTC busbars. By changing the product to three-stage injection molding, the following technical problems are mainly solved:

[0012] 1. Stable insert spacing and insert positioning issues. The PTC bus has seven inserts, which are staggered and spaced only 3mm apart. The inserts are long and weak. Ensuring stable and reliable spacing between the inserts and easy and simple positioning is the key to achieving a PTC-like bus.

[0013] 2. Molding problem of 90-degree busbar structure in PTC system. The existing PTC structure is 90-degree angled, with positioning posts and welding pins on both sides, which makes it impossible to mold the product structure using a slider. How to achieve injection molding of the existing structure is the key to project implementation.

[0014] To achieve the above objectives, this utility model provides the following technical solution: a three-stage injection molding structure for PTC busbars, comprising multiple insert bodies, a primary injection molded part on the outer side of the multiple insert bodies, support columns evenly installed on the primary injection molded part, and positioning holes opened on the insert body;

[0015] A secondary injection molded part is provided on the outer side of the insert body and the primary injection molded part;

[0016] One side of the secondary injection molded part is provided with a tertiary injection molded part.

[0017] Preferably, the secondary injection molded part and the tertiary injection molded part are provided with an anti-detachment groove on the side adjacent to each other.

[0018] Preferably, the three-injection molded part is provided with an anti-detachment block, which is adapted to the anti-detachment groove.

[0019] Preferably, multiple insert bushings are installed on the secondary injection molded part and the tertiary injection molded part respectively.

[0020] Preferably, the positioning hole is formed by stamping.

[0021] Compared with the prior art, the beneficial effects of this utility model are:

[0022] 1. While ensuring the product structure remains unchanged, simplify the product and achieve injection molding of products that cannot be made by mold opening through three injection molding processes;

[0023] 2. Add support pillars to the injection molding process and set positioning holes on the insert body to prevent it from moving during injection molding, so that there is a safe distance between the inserts, ensuring that the product has good electrical properties, and improving the product manufacturing efficiency and quality. Attached Figure Description

[0024] Figure 1 This is a structural schematic diagram of the insert body and the one-time injection molded part of this utility model;

[0025] Figure 2This is a schematic diagram of the structure of the secondary injection molded part of this utility model;

[0026] Figure 3 This is a schematic diagram of the structure of the three-injection molded part of this utility model;

[0027] Figure 4 This is an exploded view of the structure of this utility model;

[0028] Figure 5 This is a schematic diagram of the structure of this utility model.

[0029] In the diagram: 1. Insert body; 2. Positioning hole; 3. First injection molded part; 4. Support column; 5. Second injection molded part; 6. Anti-detachment groove; 7. Third injection molded part; 8. Anti-detachment block; 9. Insert bushing. Detailed Implementation

[0030] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention.

[0031] Please see Figure 1-5 This utility model provides a technical solution: a three-stage injection molding structure for PTC busbars, comprising multiple insert bodies 1, with a primary injection molded part 3 on the outer side of each insert body 1. The busbar first wraps around the multiple insert bodies 1 using the primary injection molded part 3, ensuring the spacing between the multiple insert bodies 1. Support columns 4 are evenly installed on the primary injection molded part 3, and positioning holes 2 are formed by stamping on the insert bodies 1.

[0032] A support column 4 is added to the primary injection molded part 3. The support column 4 provides support for the primary injection molded part 3 during the secondary injection molding process, preventing leakage of the primary injection molded part 3 during filling. The insert body 1 has positioning holes 2 to cooperate with the floating pin structure to ensure the overall position of the primary injection molded part 3 in the secondary injection molded part 5.

[0033] A secondary injection molded part 5 is provided on the outside of the insert body 1 and the primary injection molded part 3. The secondary injection molded part 5 is mainly composed of two primary injection molded parts 3, multiple insert bodies 1 and insert bushings 9. In order to facilitate secondary injection molding, the welding pins of the insert body 1 adopt the method of injection molding first and then bending, which simplifies the secondary injection molding structure. At the same time, in order to avoid the insert being exposed, a cylinder floating pin core pulling structure is used to ensure that the insert is not exposed after secondary injection molding.

[0034] A third injection molded part 7 is provided on one side of the secondary injection molded part 5. In order to avoid overflow at the joint between the secondary injection molded part 5 and the third injection molded part 7 during the third injection process, a decorative groove is specially designed on the secondary injection molded part 5. During the third injection, the decorative groove is subjected to a strong pressure of 0.05, which ensures that the boundary between the secondary and third injection joints is clear without damaging the product.

[0035] like Figure 2 , Figure 3 and Figure 4 As shown: the secondary injection molded part 5 and the tertiary injection molded part 7 are provided with an anti-detachment groove 6 on the side adjacent to each other, and the tertiary injection molded part 7 is provided with an anti-detachment block 8, which is adapted to the anti-detachment groove 6; through the above settings, in order to ensure the connection strength between the secondary injection molded part 5 and the tertiary injection molded part 7, an anti-detachment structure is specially designed on the injection molded part.

[0036] like Figure 2 , Figure 4 and Figure 5 As shown: Multiple insert bushings 9 are installed on the secondary injection molded part 5 and the tertiary injection molded part 7 respectively; through the above settings, the insert body 1 can be more easily connected to the outside world.

[0037] Working principle: The injection-molded part 3 facilitates the placement of the insert body 1, prevents misplacement of the insert, ensures the precise positioning of the insert, and guarantees that the product has good electrical properties and accurate dimensions.

[0038] The secondary injection molded part 5 can facilitate the support column 4 of the primary injection molded part 3 and the positioning hole 2 on the insert body 1. The floating needle mechanism ensures the position of the primary injection molded part 3 during the secondary injection molding process, avoiding the influence of the insert position on the secondary injection molding process.

[0039] The third injection molding process can facilitate the opening and groove of the second injection molded part 5, ensure the connection strength between the second injection molded part 5 and the third injection molded part 7, and ensure the overall quality of the product.

[0040] The bus consists of plastic and insert bodies 1. The insert bodies 1 are arranged side by side in the product, and the insert bodies 1 are filled with plastic to prevent them from contacting each other; the insert bodies 1 contain multiple terminals, which can be connected to other components to provide a current flow path.

[0041] The product has seven insert bodies 1. The insert bodies 1 are long and narrow. The insert bodies 1 are easy to deform during filling. It is beneficial for the primary injection molded part 3 to first wrap the insert bodies 1 to ensure the spacing between the insert bodies 1. At the same time, positioning holes 2 are designed on the insert bodies 1 to ensure the positioning of the primary injection molded part 3 in the secondary injection molded part 5. Support columns 4 are added to the primary injection molded part 3. The support columns 4, together with the floating pin structure, can ensure the positioning of the primary injection molded part 3 and prevent the long terminal from shifting, which would affect the product's position accuracy.

[0042] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A three-stage injection molding structure for PTC busbars, comprising multiple insert bodies (1), characterized in that: Multiple insert bodies (1) are provided with a primary injection molded part (3) on their outer side, and a support column (4) is evenly installed on the primary injection molded part (3). The insert body (1) is provided with a positioning hole (2). A secondary injection molded part (5) is provided on the outside of the insert body (1) and the primary injection molded part (3); The secondary injection molded part (5) has a tertiary injection molded part (7) on one side.

2. The three-stage injection molding structure for PTC bus according to claim 1, characterized in that: The secondary injection molded part (5) is provided with an anti-detachment groove (6) on the side adjacent to the tertiary injection molded part (7).

3. The three-stage injection molding structure for PTC bus according to claim 2, characterized in that: The three-injection molded part (7) is provided with an anti-detachment block (8), which is adapted to the anti-detachment groove (6).

4. The three-stage injection molding structure for PTC bus according to claim 1, characterized in that: Multiple insert bushings (9) are respectively installed on the secondary injection molded part (5) and the tertiary injection molded part (7).

5. A three-stage injection molding structure for a PTC bus according to claim 1, characterized in that: The positioning hole (2) is formed by stamping.

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