New energy vehicle magnetic ring plastic packaging

Abstract

The utility model discloses a new energy automobile magnetic ring plastic package relates to injection moulding technology field, including lower plastic shell, the fixed plate is fixedly connected on lower plastic shell, and the support cover is fixedly connected on lower plastic shell side edge, and the inner hole no.

Description

Technical Field

[0001] This utility model relates to the field of injection molding technology, specifically to a plastic-coated magnetic ring for new energy vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the operating frequency and power density of power electronic systems are constantly increasing, and the resulting electromagnetic interference (EMI) problem is becoming increasingly prominent. As a key component for suppressing electromagnetic interference, the performance and reliability of magnetic rings directly affect the electromagnetic compatibility (EMC) performance of the whole vehicle.

[0003] Traditional new energy vehicle magnetic ring components typically adopt a split structure design, which involves first injection molding the outer shell, and then manually or mechanically assembling the magnetic ring and metal parts into the plastic shell in a secondary processing method.

[0004] However, traditional magnetic ring assemblies suffer from low assembly precision and low production efficiency, and the reliability of connections between components is difficult to guarantee. Traditional split structures are prone to loosening under vehicle vibration environments, have unsatisfactory electromagnetic shielding effects, poor heat dissipation performance, and may degrade magnetic ring performance over long periods of operation. These problems limit the EMI suppression effect and long-term reliability of traditional magnetic ring assemblies in the high-voltage, high-frequency operating environment of new energy vehicles. Utility Model Content

[0005] The purpose of this utility model is to provide a plastic-coated magnetic ring for new energy vehicles to solve the problems of low assembly precision and low production efficiency in the existing technology, as well as the difficulty in ensuring the reliability of the connection between components, the easy loosening of traditional split structures under vehicle vibration environment, unsatisfactory electromagnetic shielding effect, poor heat dissipation performance, and the potential for deterioration of magnetic ring performance after long-term operation.

[0006] The technical problem to be solved by this utility model can be achieved through the following technical solution:

[0007] A plastic-coated magnetic ring for new energy vehicles includes a lower plastic shell;

[0008] A fixing plate is fixedly connected to the lower plastic shell, a support sleeve is fixedly connected to the side of the lower plastic shell, and an inner hole one and an inner hole two are provided on the lower plastic shell;

[0009] The lower plastic outer shell is provided with two electrostatic film inner shells. A magnetic ring is provided inside the electrostatic film inner shell. The two ends of the U-shaped magnetic ring extend to the outside of the electrostatic film inner shell and form a conductive connection with the capacitor grounding electrode one and the capacitor grounding electrode two.

[0010] A connecting plate is connected to the lower plastic shell, and a second capacitor grounding electrode is fixedly connected to the connecting plate. A second fixing sleeve is connected between the connecting plate and the lower plastic shell, and a second connecting sleeve is detachably connected to the second fixing sleeve. A first capacitor grounding electrode is connected to the lower plastic shell, and a first fixing sleeve is connected between the first capacitor grounding electrode and the lower plastic shell. A first connecting sleeve is detachably connected to the first fixing sleeve. An insertion hole is provided inside the lower plastic shell.

[0011] As a further embodiment of this utility model, the material of the lower plastic shell is thermally conductive engineering plastic.

[0012] As a further embodiment of this utility model: metal heat sinks are embedded in the inner hole one and the inner hole two.

[0013] As a further embodiment of this utility model, the inner shell of the electrostatic film has a double-layer structure.

[0014] As a further embodiment of this utility model: the inner layer of the electrostatic film inner shell is an insulating film, and the outer layer is a conductive film, with the conductive film connected to the grounding line inside the lower plastic outer shell.

[0015] As a further embodiment of this invention, the magnetic ring has a U-shaped structure.

[0016] As a further embodiment of this utility model: the grounding surfaces of the capacitor grounding electrode one and the capacitor grounding electrode two are provided with raised conductive contacts for directly pressing the pins of the external capacitor.

[0017] As a further embodiment of this utility model: the first fixing sleeve and the second fixing sleeve are metal inserts, which are pre-embedded in the lower plastic shell during injection molding, and the first connecting sleeve and the second connecting sleeve are detachably connected to the fixing sleeve by a buckle.

[0018] As a further embodiment of this invention: the inner wall of the insertion hole is provided with a conductive coating for contacting the shielding layer of the external wire harness to achieve electromagnetic shielding.

[0019] As a further embodiment of this utility model: the lower plastic shell, fixing plate, support sleeve, connecting plate, capacitor grounding electrode one and capacitor grounding electrode two are integrally formed by injection molding process, and the magnetic ring is embedded in the electrostatic film inner shell during injection molding process.

[0020] The beneficial effects of this utility model are:

[0021] 1. This utility model adopts an integrated injection molding process, integrating key components such as the U-shaped magnetic ring and capacitor grounding electrode into the lower plastic shell, optimizing the traditional separate assembly method. The lower plastic shell is made of thermally conductive engineering plastic with built-in metal heat sink, which has both insulation and heat dissipation functions. The U-shaped magnetic ring is embedded in the electrostatic film inner shell, and the two ends are connected to the capacitor grounding electrode to suppress electromagnetic interference. The capacitor grounding electrode is fixed by a metal insert and has raised conductive contacts to facilitate the connection of external capacitors. The electrostatic film inner shell has a double-layer structure to achieve electrostatic protection and electromagnetic shielding. The inner wall of the insertion hole is plated with a conductive layer for connecting shielded wire harnesses and enhancing EMC performance.

[0022] 2. This utility model uses integrated injection molding to replace traditional split assembly, improving production efficiency and consistency. The U-shaped magnetic ring with dual capacitor grounding electrodes optimizes noise filtering. The thermally conductive plastic with metal heat sink solves the high-temperature problem. The electrostatic film inner shell with plug hole conductive coating achieves multiple electromagnetic protection. Through its integrated, modular, and high heat dissipation features, it significantly improves the EMC performance and reliability of the high-voltage system of new energy vehicles. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings.

[0024] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0025] Figure 2 This is a side view structural diagram of the present invention;

[0026] Figure 3 This is a schematic diagram of the magnetic ring and capacitor grounding electrode structure in this utility model;

[0027] Figure 4 This is a side view cross-sectional view of the structure of this utility model.

[0028] In the diagram: 1. Lower plastic outer shell; 2. Support sleeve; 3. Inner hole one; 4. Inner hole two; 5. Electrostatic film inner shell; 6. Magnetic ring; 7. Capacitor grounding electrode one; 8. Fixing sleeve one; 9. Connecting sleeve one; 10. Capacitor grounding electrode two; 11. Fixing sleeve two; 12. Connecting sleeve two; 13. Connecting plate; 14. Fixing plate; 15. Insertion hole. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0030] like Figures 1-4 As shown, a new energy vehicle magnetic ring is plastic-coated, including a lower plastic shell 1, a fixing plate 14 fixedly connected to the lower plastic shell 1, a support sleeve 2 fixedly connected to the side of the lower plastic shell 1, an inner hole 3 and an inner hole 4 provided on the lower plastic shell 1, the material of the lower plastic shell 1 is thermally conductive engineering plastic, and metal heat sinks are embedded in the inner hole 3 and the inner hole 4.

[0031] The lower plastic outer shell 1 is provided with two electrostatic film inner shells 5. A magnetic ring 6 is provided inside the electrostatic film inner shell 5. The magnetic ring 6 has a U-shaped structure. The two ends of the U-shaped magnetic ring 6 extend to the outside of the electrostatic film inner shell 5 and form a conductive connection with the capacitor grounding electrode 1 7 and the capacitor grounding electrode 2 10. The electrostatic film inner shell 5 has a double-layer structure. The inner layer is an insulating film and the outer layer is a conductive film. The conductive film is connected to the grounding line inside the lower plastic outer shell 1.

[0032] A connecting plate 13 is connected to the lower plastic shell 1. A capacitor grounding electrode 2 10 is fixedly connected to the connecting plate 13. A fixing sleeve 2 11 is connected between the connecting plate 13 and the lower plastic shell 1. A connecting sleeve 2 12 is detachably connected to the fixing sleeve 2 11. A capacitor grounding electrode 1 7 is connected to the lower plastic shell 1. A fixing sleeve 1 8 is connected between the capacitor grounding electrode 1 7 and the lower plastic shell 1. A connecting sleeve 1 9 is detachably connected to the fixing sleeve 1 8.

[0033] The grounding surfaces of capacitor grounding electrode 7 and capacitor grounding electrode 10 are provided with raised conductive contacts for directly pressing the pins of external capacitors.

[0034] The first fixing sleeve 8 and the second fixing sleeve 11 are metal inserts, which are pre-embedded in the lower plastic shell 1 during injection molding. The first connecting sleeve 9 and the second connecting sleeve 12 are detachably connected to the fixing sleeves by buckles. The lower plastic shell 1 is provided with a plug hole 15 inside. The inner wall of the plug hole 15 is provided with a conductive coating for contacting the shielding layer of the external wire harness to achieve electromagnetic shielding.

[0035] The lower plastic shell 1, fixing plate 14, support sleeve 2, connecting plate 13, capacitor grounding electrode 1 7 and capacitor grounding electrode 2 10 are integrally formed by injection molding, and the magnetic ring 6 is embedded in the electrostatic film inner shell 5 during the injection molding process.

[0036] The working principle of this utility model is as follows: This device adopts an integrated injection molding process, integrating key components such as the U-shaped magnetic ring 6 and the capacitor grounding electrode into the lower plastic shell 1, which optimizes the traditional separate assembly method, improves production efficiency and product reliability. The lower plastic shell 1 is made of thermally conductive engineering plastic and has built-in metal heat sinks, which have both insulation and heat dissipation functions. The U-shaped magnetic ring 6 is embedded in the electrostatic film inner shell 5 and connected to the capacitor grounding electrode at both ends to suppress electromagnetic interference. The capacitor grounding electrode is fixed by a metal insert and has raised conductive contacts to facilitate the connection of external capacitors. The electrostatic film inner shell 5 has a double-layer structure to achieve electrostatic protection and electromagnetic shielding. The inner wall of the insertion hole 15 is plated with a conductive layer for connecting the shielded wire harness to enhance EMC performance. The detachable connecting sleeve facilitates maintenance and replacement of the capacitor grounding electrode.

[0037] When a high-frequency current passes through a conductor or busbar, the U-shaped magnetic ring 6 absorbs high-frequency noise and converts it into heat energy by utilizing the magnetic loss characteristics of ferrite material. The two ends of the magnetic ring 6 are connected to the capacitor grounding electrode, forming a low-impedance loop with the external Y capacitor, which guides the residual high-frequency noise into the grounding system. The external capacitor is directly pressed through the raised conductive contacts to construct an LC filter circuit, which further filters out high-frequency interference. The shell material conducts the heat generated by the magnetic ring 6 and the metal insert to the outside. The metal heat sink in the inner hole enhances the local heat dissipation capacity. The inner insulating film prevents short circuits between the magnetic ring 6 and the shell. The outer conductive film connects to the grounding line inside the shell to discharge static charge and prevent ESD damage to the circuit. The conductive coating of the insertion hole 15 contacts the shielding layer of the external wire harness to form a continuous electromagnetic shield to prevent noise radiation or intrusion.

[0038] One-piece injection molding replaces traditional split assembly, improving production efficiency and consistency. The U-shaped magnetic ring 6 with dual capacitor grounding electrodes optimizes noise filtering. Thermally conductive plastic with metal heat sinks solves high-temperature problems. The electrostatic film inner shell 5 with plug hole 15 conductive coating achieves multiple electromagnetic protections. Through its integrated, modular, and high heat dissipation features, it significantly improves the EMC performance and reliability of the high-voltage system of new energy vehicles.

[0039] The above description details one embodiment of the present utility model, but it is merely a preferred embodiment and should not be construed as limiting the scope of the present utility model. All equivalent variations and improvements made within the scope of the present utility model application should still fall within the patent coverage of the present utility model.

Claims

1. A new energy vehicle magnetic ring with plastic coating, comprising a lower plastic shell (1); characterized in that: A fixing plate (14) is fixedly connected to the lower plastic shell (1), a support sleeve (2) is fixedly connected to the side of the lower plastic shell (1), and an inner hole one (3) and an inner hole two (4) are provided on the lower plastic shell (1). The lower plastic outer shell (1) is provided with two electrostatic film inner shells (5), and a magnetic ring (6) is provided inside the electrostatic film inner shell (5). The two ends of the U-shaped magnetic ring (6) extend to the outside of the electrostatic film inner shell (5) and form a conductive connection with the capacitor grounding electrode one (7) and the capacitor grounding electrode two (10). A connecting plate (13) is connected to the lower plastic shell (1). A capacitor grounding electrode two (10) is fixedly connected to the connecting plate (13). A fixing sleeve two (11) is connected between the connecting plate (13) and the lower plastic shell (1). A connecting sleeve two (12) is detachably connected to the fixing sleeve two (11). A capacitor grounding electrode one (7) is connected to the lower plastic shell (1). A fixing sleeve one (8) is connected between the capacitor grounding electrode one (7) and the lower plastic shell (1). A connecting sleeve one (9) is detachably connected to the fixing sleeve one (8). A plug-in hole (15) is provided inside the lower plastic shell (1).

2. The new energy vehicle magnetic ring with plastic coating according to claim 1, characterized in that, The lower plastic shell (1) is made of thermally conductive engineering plastic.

3. The new energy vehicle magnetic ring with plastic coating according to claim 1, characterized in that, Metal heat sinks are embedded in the inner hole one (3) and inner hole two (4).

4. The new energy vehicle magnetic ring with plastic coating according to claim 1, characterized in that, The electrostatic film inner shell (5) has a double-layer structure.

5. The new energy vehicle magnetic ring with plastic coating according to claim 4, characterized in that, The inner layer of the electrostatic film inner shell (5) is an insulating film, and the outer layer is a conductive film. The conductive film is connected to the grounding line inside the lower plastic shell (1).

6. The new energy vehicle magnetic ring with plastic coating according to claim 1, characterized in that, The magnetic ring (6) has a U-shaped structure.

7. The new energy vehicle magnetic ring with plastic coating according to claim 1, characterized in that, The grounding surfaces of capacitor grounding electrode one (7) and capacitor grounding electrode two (10) are provided with raised conductive contacts for directly pressing the pins of external capacitors.

8. The new energy vehicle magnetic ring with plastic coating according to claim 1, characterized in that, The first fixing sleeve (8) and the second fixing sleeve (11) are metal inserts that are pre-embedded in the lower plastic shell (1) during injection molding. The first connecting sleeve (9) and the second connecting sleeve (12) are detachably connected to the fixing sleeve by a buckle.

9. A new energy vehicle magnetic ring with plastic coating according to claim 1, characterized in that, The inner wall of the plug hole (15) is provided with a conductive coating for contacting the shielding layer of the external wire harness to achieve electromagnetic shielding.

10. A new energy vehicle magnetic ring with plastic coating according to claim 1, characterized in that, The lower plastic shell (1), fixing plate (14), support sleeve (2), connecting plate (13), capacitor grounding electrode one (7) and capacitor grounding electrode two (10) are integrally formed by injection molding, and the magnetic ring (6) is embedded in the electrostatic film inner shell (5) during the injection molding process.

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