An integrally molded new housing structure

Abstract

The utility model discloses a kind of integrally formed new shell structure, relate to hall component assembly technical field.The utility model includes plastic shell, and hall component is installed in the inside of plastic shell, laminated riveting magnetic core and copper bar;Hall component, laminated riveting magnetic core and copper bar are integrally formed with plastic shell using injection molding machine, Hall component, laminated riveting magnetic core and copper bar are prepositioned in mold cavity, and seamless fusion of each component and plastic shell is realized by high-temperature plastic melt injection coating solidification, the Hall component is fixed in the left side of plastic shell inner cavity, and its strip-shaped lead passes through shell reserved hole and extends to outside, convenient for welding with external circuit.The product of the utility model is integrally injection molded, so that Hall component, laminated riveting magnetic core, copper bar can be fixed, and the assembly of laminated riveting magnetic core has no difficulty, product can be directly formed on mould, without increasing additional cost.

Description

Technical Field

[0001] This utility model belongs to the field of Hall effect component assembly technology, and in particular relates to a novel one-piece molded shell structure. Background Technology

[0002] The assembly of existing sensor Hall elements, stacked magnetic cores, and copper busbars generally uses clearance fit, with a small gap between the Hall element and the copper busbar.

[0003] There is a small gap between the Hall element and the copper busbar. After assembly, the Hall element can move slightly, which affects the stability of the sensor performance. If the gap between the Hall element, the stacked magnetic core and the copper busbar is 0mm, the assembly will be more difficult. Utility Model Content

[0004] The purpose of this utility model is to provide a new one-piece molded shell structure. Through one-piece injection molding, the Hall element, the stacked magnetic core, and the copper busbar can be fixed. Moreover, the assembly of the stacked magnetic core is not difficult. The product can be directly formed on the mold without adding extra costs. It solves the problem that if there is a small gap between the Hall element and the copper busbar, the Hall element can move slightly after assembly, which affects the stability of the sensor performance. If the gap between the Hall element, the stacked magnetic core, and the copper busbar is mm, the assembly will be more difficult.

[0005] To solve the above-mentioned technical problems, this utility model is achieved through the following technical solution:

[0006] This utility model is a novel one-piece molded shell structure, including a plastic shell, and Hall effect devices, stacked magnetic cores and copper busbars are installed inside the plastic shell;

[0007] The Hall effect components, stacked magnetic cores, and copper busbars are integrally molded with the plastic shell using an injection molding machine. The Hall effect components, stacked magnetic cores, and copper busbars are pre-placed in the mold cavity, and then coated and cured by high-temperature plastic molten injection, achieving seamless integration of each component with the plastic shell.

[0008] Furthermore, the Hall element is fixed to the left side of the inner cavity of the plastic housing, and its strip pins extend to the outside through the reserved hole in the housing, which facilitates soldering to the external circuit.

[0009] Furthermore, the stacked magnetic core is made of multiple silicon steel sheets stacked into a U-shaped structure, with the open end facing the copper busbar to form a closed magnetic circuit to enhance the magnetic field coupling efficiency; multiple stacked magnetic cores arranged laterally are uniformly fixed by injection-molded positioning posts, and the spacing is adjusted according to the magnetic field strength requirements; heat insulation grooves are set between adjacent magnetic cores to reduce eddy current losses.

[0010] Furthermore, the copper busbar is made of T-copper with a tin-plated surface and is embedded in the groove in the middle of the plastic shell. Both sides are wrapped by stacked magnetic cores to form electromagnetic shielding. Insulating sleeves are provided at both ends of the copper busbar that penetrate the shell.

[0011] This utility model has the following beneficial effects:

[0012] 1. The product of this utility model is integrally injection molded, which can fix the Hall element, the stacked magnetic core and the copper busbar. Moreover, the assembly of the stacked magnetic core is not difficult, and the product can be directly formed on the mold without adding extra costs.

[0013] 2. The product of this utility model has good consistency and stable performance after injection molding. The product appearance has no fine gaps caused by assembly gaps, which also improves production efficiency and reduces labor costs and management expenses.

[0014] Of course, any product implementing this utility model does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of this utility model, the accompanying drawings used in the description of the embodiments 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.

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0017] Figure 2 This is a schematic diagram of the internal structure of the plastic shell of this utility model;

[0018] Figure 3 This is a schematic diagram of the overall structure of the stacked riveted magnetic core of this utility model.

[0019] The attached diagram lists the components represented by each number as follows:

[0020] 1. Plastic casing; 2. Hall effect components; 3. Stacked magnetic core; 4. Copper busbar. Detailed Implementation

[0021] 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 of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0022] Please see Figures 1-3 As shown, this utility model is a new one-piece molded shell structure, including a plastic shell 1, and a Hall element 2, a stacked magnetic core 3 and a copper busbar 4 are installed inside the plastic shell 1;

[0023] The Hall element 2, the stacked magnetic core 3, and the copper busbar 4 are integrally molded with the plastic shell 1 using an injection molding machine. The Hall element 2, the stacked magnetic core 3, and the copper busbar 4 are pre-placed in the mold cavity, and then coated and solidified by high-temperature plastic molten injection, achieving seamless integration of each component with the plastic shell 1. Through integral injection molding, the Hall element 2, the stacked magnetic core 3, and the copper busbar 4 can be fixed, and the assembly of the stacked magnetic core 3 is not difficult. The product can be directly molded on the mold without adding extra costs. After injection molding, the product has good consistency, stable performance, and no fine gaps caused by assembly gaps. It also improves production efficiency and reduces labor costs and management expenses.

[0024] The Hall element 2 is fixed to the left side of the inner cavity of the plastic housing 1, and its strip pins extend to the outside through the reserved hole in the housing, which facilitates soldering to the external circuit.

[0025] The stacked magnetic core 3 is made of multiple silicon steel sheets stacked into a U-shaped structure, with the open end facing the copper busbar 4, forming a closed magnetic circuit to enhance the magnetic field coupling efficiency; multiple stacked magnetic cores 3 arranged laterally are uniformly fixed by injection-molded positioning columns, and the spacing is adjusted according to the magnetic field strength requirements. Heat insulation grooves are set between adjacent magnetic cores to reduce eddy current losses.

[0026] The copper busbar 4 is made of T2 copper with a tin-plated surface. It is embedded in the groove in the middle of the plastic shell 1 and is wrapped by the stacked magnetic core 3 on both sides to form electromagnetic shielding. The copper busbar 4 has insulating sleeves at both ends that pass through the shell.

[0027] One specific application of this embodiment is:

[0028] The Hall effect sensor 2, stacked magnetic core 3, and copper busbar 4 are directly placed into the injection molding groove of the mold, allowing them to be pre-molded and fixed in place without secondary assembly. This eliminates gaps or loosening and facilitates transportation and transfer. Once molding is complete, the plastic shell 1 completely encapsulates the Hall effect sensor 2, stacked magnetic core 3, and copper busbar 4. This one-piece injection molding structure ensures a gapless fit, maximizing stable performance. Furthermore, the absence of gaps in the product's appearance improves production efficiency and reduces labor and management costs.

[0029] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0030] The preferred embodiments of this utility model disclosed above are merely illustrative of the present utility model. These preferred embodiments do not exhaustively describe all details, nor do they limit the present utility model to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the present utility model, thereby enabling those skilled in the art to better understand and utilize it. This utility model is limited only by the claims and their full scope and equivalents.

Claims

1. A novel one-piece molded shell structure, comprising a plastic shell (1), characterized in that: The plastic shell (1) contains a Hall element (2), a stacked magnetic core (3), and a copper busbar (4). The Hall element (2), the stacked magnetic core (3) and the copper busbar (4) are integrally formed with the plastic shell (1) using an injection molding machine. The Hall element (2), the stacked magnetic core (3) and the copper busbar (4) are pre-placed in the mold cavity and then coated and solidified by high-temperature plastic melt injection to achieve seamless integration of each component with the plastic shell (1).

2. The novel one-piece molded shell structure according to claim 1, characterized in that, The Hall element (2) is fixed to the left side of the inner cavity of the plastic shell (1), and its strip pins extend to the outside through the reserved hole in the shell, which facilitates soldering to the external circuit.

3. The novel one-piece molded shell structure according to claim 2, characterized in that, The stacked magnetic core (3) is made of multiple silicon steel sheets stacked into a U-shaped structure, with the open end facing the copper busbar (4) to form a closed magnetic circuit to enhance the magnetic field coupling efficiency; multiple stacked magnetic cores (3) arranged laterally are uniformly fixed by injection molding positioning columns, and the spacing is adjusted according to the magnetic field strength requirements. Heat insulation grooves are set between adjacent magnetic cores to reduce eddy current losses.

4. The novel one-piece molded shell structure according to claim 3, characterized in that, The copper busbar (4) is made of T2 copper and tin-plated on the surface. It is embedded in the groove in the middle of the plastic shell (1) and is wrapped by the stacked magnetic core (3) on both sides to form electromagnetic shielding. The copper busbar (4) has insulating sleeves at both ends that pass through the shell.

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