An integral injection-molded structure of copper busbar and open magnetic ring

Abstract

This utility model discloses an integrated injection-molded structure of copper busbar and open magnetic ring, relating to the field of electrical equipment technology. It includes: an integrated structural body; a first open magnetic ring and a second open magnetic ring respectively disposed on the lower left and right sides of the integrated structural body; a first copper busbar, a second copper busbar, and a third copper busbar sequentially disposed from left to right at the lower end of the integrated structural body; a reinforcing rib disposed on one side of the integrated structural body to enhance its strength and resistance to deformation; and an ear block disposed on the upper outer side of the integrated structural body. This invention addresses the technical problems of conventional installation methods, which involve mechanically fixing or gluing the magnetic ring onto the copper busbar, resulting in cumbersome installation procedures, increased production time and costs, and unstable fixing that may lead to loosening or displacement of the magnetic ring during long-term use, affecting electromagnetic shielding effectiveness. Furthermore, gluing may introduce impurities, affecting electrical performance.

Description

Technical Field

[0001] This utility model relates to the field of electrical equipment technology, specifically to an integrated injection-molded structure of a copper busbar and an open magnetic ring. Background Technology

[0002] In electrical systems, copper busbars are often used to conduct large currents. However, copper busbars generate electromagnetic interference during operation, which can affect the normal operation of surrounding electronic equipment. In order to reduce electromagnetic interference, magnetic rings are usually installed on copper busbars.

[0003] Compared to the existing installation of copper busbars and open magnetic rings, the following drawbacks exist: The conventional installation method involves placing the magnetic ring on the copper busbar and then fixing it using mechanical fixation or adhesive bonding, which makes the installation process cumbersome, increases production time and costs, and the fixation is not secure. During long-term use, the magnetic ring may loosen or shift, affecting the electromagnetic shielding effect. At the same time, using adhesive bonding may introduce impurities, affecting electrical performance. Utility Model Content

[0004] The purpose of this utility model is to provide an integrated injection-molded structure of copper busbar and open magnetic ring, which solves the following technical problems: The conventional installation method is to put the magnetic ring on the copper busbar and fix it by mechanical fixation or glue, which makes the installation process cumbersome, increases production time and cost, and the fixation is not firm. During long-term use, the magnetic ring may loosen or shift, affecting the electromagnetic shielding effect. At the same time, glue may introduce impurities, affecting electrical performance.

[0005] The objective of this utility model can be achieved through the following technical solutions: An integral injection-molded structure of copper busbar and open magnetic ring includes: an integral structural body, wherein a first open magnetic ring and a second open magnetic ring are respectively disposed on the lower left and right sides of the integral structural body, and a first copper busbar, a second copper busbar and a third copper busbar are disposed sequentially from left to right at the lower end of the integral structural body.

[0006] As a further aspect of this utility model, a reinforcing rib is provided on one side of the integrated structural body to enhance the strength and deformation resistance of the integrated structural body.

[0007] As a further embodiment of this utility model: an ear block is provided on the outer side of the upper end of the integrated structural body, and a bushing is provided on the inner side of the ear block.

[0008] As a further embodiment of this utility model: a fixing hole is provided on the outer side of the integrated structure body for fixing the whole to the equipment box by bolts.

[0009] As a further embodiment of this utility model: the reinforcing rib is a ferrite magnetic ring, and the first copper busbar, the second copper busbar and the third copper busbar are arranged in parallel to each other.

[0010] As a further embodiment of this utility model: the upper side of the first open magnetic ring is provided with a first groove located inside the integral structure body, and the upper side of the second open magnetic ring is provided with a second groove located inside the integral structure body.

[0011] As a further aspect of this utility model, the first and second grooves are provided for mounting sensors.

[0012] As a further embodiment of this utility model: the inner sides of the first copper busbar, the second copper busbar and the third copper busbar are all provided with wiring holes located on the integral structure body for connecting to external circuits.

[0013] The beneficial effects of this utility model are: 1. By integrating the magnetic ring and copper busbar into a single injection molding process, production efficiency is improved, avoiding the complex procedures, low assembly efficiency, and unstable quality associated with separate magnetic ring installation. Stability is enhanced, allowing for a tighter bond between the magnetic ring and copper busbar, preventing the risk of the magnetic ring detaching and improving the overall structural stability. Space utilization is optimized, resulting in a more compact overall structure that saves space and meets the demands for product miniaturization, lightweighting, and integration. The grooves on the injection mold that mate with the magnetic ring allow for more precise positioning of the magnetic ring, indicating its electromagnetic induction effect on the copper busbar and improving product reliability. Insulation performance is enhanced, as the injection molding material acts as an insulating protective layer between the magnetic ring and the copper busbar, preventing contact and reducing the probability of short circuits and other malfunctions. Attached Figure Description

[0014] The present invention will be further described below with reference to the accompanying drawings.

[0015] Figure 1 This is a schematic diagram of the overall structure of the integrated body and the ear block of this utility model; Figure 2 This is a schematic diagram of the overall structure of the integrated body of this utility model and the connection of the first copper busbar; Figure 3 This is a frontal cross-sectional structural diagram of the present invention.

[0016] In the figure: 1. Integrated structure body; 2. Reinforcing rib; 3. Ear block; 4. Bushing; 5. Fixing opening; 6. First open magnetic ring; 7. First groove body; 8. Second open magnetic ring; 9. Second groove body; 10. First copper busbar; 11. Second copper busbar; 12. Third copper busbar; 13. Wiring hole. Detailed Implementation

[0017] 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.

[0018] Example 1 Please see Figure 1 , Figure 2 and Figure 3 As shown, this utility model is an integral injection-molded structure of copper busbar and open magnetic ring, including an integral structural body 1. The lower left and right sides of the integral structural body 1 are respectively provided with a first open magnetic ring 6 and a second open magnetic ring 8. The lower end of the integral structural body 1 is provided with a first copper busbar 10, a second copper busbar 11 and a third copper busbar 12 from left to right.

[0019] In this embodiment, preferably, a reinforcing rib 2 is provided on one side of the integral structural body 1 to enhance the strength and deformation resistance of the integral structural body 1.

[0020] In this embodiment, preferably, an ear block 3 is provided on the outer side of the upper end of the integral structure body 1, and a bushing 4 is provided on the inner side of the ear block 3.

[0021] In this embodiment, preferably, a fixing hole 5 is provided on the outer side of the integral structure body 1, so that the whole body can be fixed to the equipment box by bolts.

[0022] In this embodiment, preferably, the reinforcing rib 2 is a ferrite magnetic ring, and the first copper busbar 10, the second copper busbar 11 and the third copper busbar 12 are arranged in parallel to each other.

[0023] In this embodiment, preferably, the upper side of the first open magnetic ring 6 is provided with a first groove 7 located inside the integral structure body 1, and the upper side of the second open magnetic ring 8 is provided with a second groove 9 located inside the integral structure body 1.

[0024] In this embodiment, preferably, the first groove 7 and the second groove 9 are provided for mounting the sensor.

[0025] In this embodiment, preferably, the inner sides of the first copper busbar 10, the second copper busbar 11 and the third copper busbar 12 are all provided with wiring holes 13 located on the integral structure body 1 for connecting to external circuits.

[0026] In summary, the first open magnetic ring 6 and the second open magnetic ring 8 are fitted between the first copper busbar 10, the second copper busbar 11 and the third copper busbar 12. The first copper busbar 10, the second copper busbar 11 and the third copper busbar 12 with the first open magnetic ring 6 and the second open magnetic ring 8 fitted are placed into a customized injection mold. The mold cavity is consistent with the shape of the integral structure body 1. The first groove body 7 and the second groove body 9 are provided on the side at the positions corresponding to the first open magnetic ring 6 and the second open magnetic ring 8. The mold is thick enough to accurately wrap the outer ring of the magnetic ring and prevent it from shifting.

[0027] The first copper busbar 10, the second copper busbar 11, and the third copper busbar 12 are made of T2 copper and are stamped into three long strips with dimensions of 150mm in length, 20mm in width, and 3mm in thickness. They are tin-plated and arranged in parallel with a spacing of 10mm.

[0028] Among them, the first open magnetic ring 6 and the second open magnetic ring 8 are C-type magnetic rings made of manganese zinc ferrite material, with an inner diameter of 25mm and an opening gap of 3mm. The integral structure body 1 is made of PPS-GF40 granules, which are dried and ready for use.

[0029] The injection molding machine parameters are set as follows: barrel temperature 300-320℃, injection pressure 80Mpa. Molten PPS material is injected into the mold cavity, and after holding the pressure and cooling for 30 seconds, the mold is opened and the workpiece is removed.

[0030] Example 2 This embodiment is obtained based on Embodiment 1, with reference to... Figure 1 , Figure 2 and Figure 3 The image shows the second embodiment of this utility model, in which the copper busbar and the open magnetic ring are integrally injection molded, including the following steps: Step 1: Select copper busbar material of appropriate specifications, and stamp and electroplate according to design requirements to ensure that the size and shape of the copper busbar meet the requirements; Step 2: Select an open magnetic ring with high permeability, check its opening size and inner diameter to ensure that it can be smoothly fitted onto the copper busbar; Step 3: Place the open magnetic ring onto the copper busbar, ensuring the magnetic ring is correctly positioned and the opening is correct. Place the copper busbar with the discarded magnetic ring into the injection mold, start the injection molding equipment, and allow the injection material to flow in the mold, evenly wrapping the copper busbar and magnetic ring. After cooling and solidification, a one-piece injection molded structure is formed. Step 4: Perform a visual inspection of the one-piece injection molded structure to ensure that the injection molded surface is smooth and free of defects such as bubbles and cracks. Also, conduct electrical performance tests to check the conductivity of the copper busbars and the insulation performance of the injection molded material.

[0031] Example 3 This embodiment is obtained by combining Embodiment 1 and Embodiment 2.

[0032] The integrated injection molding structure simplifies the production process, improves production efficiency, and reduces labor costs. Because it is molded in one piece, the magnetic ring will not loosen or shift, ensuring a long-term stable electromagnetic shielding effect. The insulation properties of the injection molding material can prevent electrical short circuits between the copper busbar and the outside world, improving electrical safety.

[0033] The above description provides a detailed account of one embodiment of the present invention. However, this description is merely a preferred embodiment and should not be construed as limiting the scope of the present invention. All equivalent variations and improvements made within the scope of the claims of the present invention should still fall within the patent coverage of the present invention.

Claims

1. A copper busbar and an open magnetic ring integrally injection molded structure, characterized in that, include: The integrated structure body (1) has a first open magnetic ring (6) and a second open magnetic ring (8) respectively on the lower left and right sides. The lower end of the integrated structure body (1) has a first copper busbar (10), a second copper busbar (11) and a third copper busbar (12) arranged from left to right.

2. The integral injection-molded structure of copper busbar and open magnetic ring according to claim 1, characterized in that, A reinforcing rib (2) is provided on one side of the integrated structural body (1) to enhance the strength and deformation resistance of the integrated structural body (1).

3. The integral injection-molded structure of copper busbar and open magnetic ring according to claim 2, characterized in that, An ear block (3) is provided on the outer side of the upper end of the integrated structure body (1), and a bushing (4) is provided on the inner side of the ear block (3).

4. The integral injection-molded structure of copper busbar and open magnetic ring according to claim 2, characterized in that, The outer side of the integrated structure body (1) is provided with a fixing hole (5) for fixing the whole to the equipment box by bolts.

5. The integral injection-molded structure of copper busbar and open magnetic ring according to claim 2, characterized in that, The reinforcing rib (2) is a ferrite magnetic ring, and the first copper busbar (10), the second copper busbar (11) and the third copper busbar (12) are arranged in parallel to each other.

6. The integral injection-molded structure of copper busbar and open magnetic ring according to claim 1, characterized in that, The first open magnetic ring (6) has a first groove (7) located inside the integral structure body (1) on its upper side, and the second open magnetic ring (8) has a second groove (9) located inside the integral structure body (1) on its upper side.

7. The integral injection-molded structure of copper busbar and open magnetic ring according to claim 6, characterized in that, The first groove (7) and the second groove (9) are provided for mounting the sensor.

8. The integral injection-molded structure of copper busbar and open magnetic ring according to claim 5, characterized in that, The inner sides of the first copper busbar (10), the second copper busbar (11) and the third copper busbar (12) are provided with wiring holes (13) located on the integral structure body (1) for connecting to external circuits.

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