Magnetic core assembly for new energy vehicle

Abstract

This application discloses a magnetic core assembly for new energy vehicles, comprising: a magnetic core body, a plastic sheath, a coil, a copper sheet assembly, a metal shell, a thermally conductive film, and a terminal assembly. The magnetic core body is made of nanocrystalline core material, and the plastic sheath wraps around the outer side of the magnetic core body in a ring-shaped structure. Multiple ribs are provided on the outer surface of the plastic sheath, dividing the surface into 3+3 winding areas on each side. The coil is wound with enameled wire in the winding area. A limiting groove is also provided on the outer surface of the plastic sheath. The copper sheet assembly includes 4+4 copper sheets and a crossbeam. After the copper sheets are inserted into the corresponding limiting grooves, they are welded to the corresponding crossbeams to form a high-current circuit. The metal shell is fitted over the plastic sheath, and the thermally conductive film is assembled inside the metal shell and adheres to the coil and copper sheets. The terminal assembly includes a small terminal adapted to the coil and a large terminal adapted to the copper sheets. The application of nanocrystalline core material significantly optimizes magnetic permeability and reduces energy loss; the ring-shaped plastic sheath balances core material protection and magnetic field distribution optimization.

Description

Technical Field

[0001] This application relates to the field of new energy vehicle technology, and in particular to a magnetic core component for new energy vehicles. Background Technology

[0002] With the rapid iteration of the new energy vehicle industry, the performance of the vehicle-mounted AC magnetic core assembly (AC-CMC), as the core magnetic component for vehicle power conversion and energy transmission, directly determines the efficiency, reliability and integration of the vehicle electronic system. The market has put forward stringent requirements for it, including high permeability, compact structure, multi-current adaptability and stable protection.

[0003] However, existing AC-CMC core assemblies have many technical shortcomings, making it difficult to meet the above requirements. Specific problems include: low permeability and poor magnetic properties of the core material, leading to insufficient AC-CMC efficiency; lack of dedicated protective structure for the core, making it prone to damage during winding and resulting in large winding position deviations; inability to handle both large and small current transmissions, resulting in low space utilization; and the absence of a proper heat dissipation structure, hindering effective heat conduction. Utility Model Content

[0004] The main purpose of this application is to propose a magnetic core component for new energy vehicles, which aims to solve the problems of low magnetic permeability and poor magnetic properties of existing magnetic core materials, resulting in insufficient AC-CMC efficiency; lack of dedicated protective structure for magnetic cores, easy damage to core materials during winding, large deviation in winding position; inability of magnetic cores to handle both large and small current transmission, resulting in low space utilization; and lack of heat dissipation structure for magnetic cores, resulting in ineffective heat conduction.

[0005] To achieve the above objectives, the new energy vehicle magnetic core assembly proposed in this application includes: a magnetic core body, a plastic shell, a coil, a copper sheet assembly, a metal shell, a thermally conductive film, and a terminal assembly; The magnetic core body is made of nanocrystalline core material, and the plastic shell is wrapped around the outside of the magnetic core body and has a ring structure. The outer surface of the plastic protective shell is provided with multiple ribs, which divide the surface of the plastic protective shell into a 3+3 winding area with 3 on each side. The coil is made of enameled wire wound in the winding area. The outer surface of the plastic shell is also provided with a limiting groove. The copper sheet assembly includes a 4+4 structure of copper sheets and a crossbeam. After the copper sheet is inserted into the corresponding limiting groove, it is welded to the corresponding crossbeam to form a high-current circuit. The metal shell is fitted over the plastic protective shell, and the thermally conductive film is assembled inside the metal shell and adheres to the coil and the copper sheet; The plug assembly includes a small plug that adapts to the coil and a large plug that adapts to the copper sheet.

[0006] Optionally, the interior of the metal shell is filled with thermally conductive adhesive, which fills the gaps between the metal shell, the plastic sheath, the coil, and the copper sheet assembly.

[0007] Optionally, the plastic protective shell and the metal shell are connected by a snap-fit ​​structure, the snap-fit ​​structure including a snap protrusion on the outer wall of the plastic protective shell and a snap groove on the inner wall of the metal shell, the snap protrusion and the snap groove engaging in a snap-fit ​​engagement.

[0008] Optionally, the sidewall of the metal shell is provided with a plurality of mounting holes for connecting to the client device, and the plurality of mounting holes are evenly distributed along the circumference of the metal shell.

[0009] Optionally, the crossbeam is made of copper, and both ends of the crossbeam are welded to the copper sheets on both sides of the plastic shell.

[0010] Optionally, the diameter of the enameled wire is 1.5-3mm.

[0011] Optionally, the number of small plug terminals is 6 PCS, and the number of large plug terminals is 2 PCS.

[0012] Optionally, the flatness of the bottom of the metal shell is 0.1 mm and the roughness is 1.6.

[0013] Optionally, the thermally conductive film is a silicone thermally conductive film.

[0014] Optionally, the width of the limiting groove is clearance-fitted with the thickness of the copper sheet, with a clearance value of 0.05-0.1mm.

[0015] This application's technical solution comprises a magnetic core body, a plastic sheath, a coil, a copper sheet assembly, a metal shell, a thermally conductive film, and a terminal assembly. The magnetic core body is made of nanocrystalline core material, and the plastic sheath wraps around the outer side of the magnetic core body in a ring structure. Multiple ribs are provided on the outer surface of the plastic sheath, dividing the surface into 3+3 winding areas on each side. The coil is wound with enameled wire in the winding area. A limiting groove is also provided on the outer surface of the plastic sheath. The copper sheet assembly includes 4+4 copper sheets and a crossbeam. After the copper sheets are inserted into the corresponding limiting grooves, they are welded to the corresponding crossbeams to form a high-current circuit. The metal shell is fitted over the plastic sheath, and the thermally conductive film is assembled inside the metal shell and adheres to the coil and copper sheets. The terminal assembly includes a small terminal for the coil and a large terminal for the copper sheets. When the magnetic core assembly is working, the nanocrystalline magnetic core, with its high magnetic permeability, constructs a stable magnetic circuit, providing the foundation for energy conversion. The coil transmits current through enameled wire, and the copper sheet assembly achieves high-current transmission through a welded circuit. Heat generated by the coil and copper sheets is conducted to the metal shell via a thermally conductive film, and then dissipated by the metal shell, ensuring stable operation of the assembly. The application of nanocrystalline core material significantly optimizes magnetic permeability, reduces energy loss, and improves the working efficiency of the magnetic core assembly and corresponding automotive electronic devices. The annular plastic shell balances core material protection and magnetic field distribution optimization. The 3+3 winding area and 4+4 copper sheet layout improve space utilization, adapting to the compact requirements of new energy vehicle on-board equipment. Ribs divide the winding area, simplifying winding operations, and limiting grooves ensure precise positioning of the copper sheets, reducing assembly errors. The thermally conductive film ensures heat dissipation and insulation, reducing the risk of failure. The functional distinction between small and large plug terminals eliminates the need for additional adapters to meet different current transmission requirements, improving assembly compatibility. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 This is one of the three-dimensional structural schematic diagrams of the magnetic core assembly for new energy vehicles in this application; Figure 2 This is the second three-dimensional structural schematic diagram of the magnetic core assembly for new energy vehicles in this application; Figure 3 This is an exploded view of the structure of the magnetic core component for new energy vehicles in this application.

[0018] Explanation of icon numbers: 1. Magnetic core body; 2. Plastic shell; 201. Winding area; 202. Limiting groove; 3. Coil; 4. Copper sheet assembly; 401. Copper sheet; 402. Crossbeam; 5. Metal shell; 501. Assembly hole; 6. Thermal conductive film; 7. Plug assembly; 701. Small plug; 702. Large plug; 8. Thermal conductive colloid.

[0019] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0021] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly set on the other component; when a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to the other component.

[0022] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0023] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, if the word "and / or" appears throughout the text, it means including three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, the technical solutions of various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0024] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size should still fall within the scope of the technical content disclosed in this application, provided that they do not affect the effects and purposes that this application can produce.

[0025] With the rapid iteration of the new energy vehicle industry, the performance of the vehicle-mounted AC magnetic core assembly (AC-CMC), as the core magnetic component for vehicle power conversion and energy transmission, directly determines the efficiency, reliability and integration of the vehicle electronic system. The market has put forward stringent requirements for it, including high permeability, compact structure, multi-current adaptability and stable protection.

[0026] However, existing AC-CMC core assemblies have many technical shortcomings and are difficult to meet the above requirements. The specific problems are as follows: the core material has low permeability and poor magnetic properties, resulting in insufficient AC-CMC efficiency; the core lacks a dedicated protective structure, making the core material easily damaged during winding and causing large deviations in winding position; the core cannot handle both large and small current transmission, resulting in low space utilization; and the core lacks a heat dissipation structure, making it impossible to effectively conduct heat.

[0027] In view of this, this application proposes a magnetic core component for new energy vehicles.

[0028] In the embodiments of this application, reference is made to Figures 1 to 3 The aforementioned new energy vehicle magnetic core assembly includes: a magnetic core body 1, a plastic sheath 2, a coil 3, a copper sheet assembly 4, a metal shell 5, a thermally conductive film 6, and a terminal assembly 7. The magnetic core body 1 is made of nanocrystalline core material. The plastic sheath 2 wraps around the outside of the magnetic core body 1 and has a ring structure, specifically a racetrack-shaped structure. The outer surface of the plastic sheath 2 is provided with multiple ribs, dividing the surface of the plastic sheath 2 into 3+3 winding areas 201 on each side. The coil 3 is made of enameled wire wound in the winding area 201. 1; The outer surface of the plastic shell 2 is also provided with a limiting groove 202. The copper sheet assembly 4 includes a 4+4 structure copper sheet 401 and a crossbeam 402. After the copper sheet 401 is inserted into the corresponding limiting groove 202, it is welded to the corresponding crossbeam 402 to form a high current circuit. The metal shell 5 is sleeved on the outside of the plastic shell 2. The thermally conductive film 6 is assembled inside the metal shell 5 and fits the coil 3 and the copper sheet 401. The plug assembly 7 includes a small plug 701 adapted to the coil 3 and a large plug 702 adapted to the copper sheet 401.

[0029] Specifically, the plastic protective shell 2 is divided into an upper shell and a lower shell, which are fitted together to easily wrap the magnetic core body 1; the metal shell 5 is a structure made of aluminum.

[0030] Specifically, a nanocrystalline core material is used as the main body 1 of the magnetic core, and a ring-shaped plastic shell 2 is fitted and fixed so that the shell completely covers the outside of the main body 1 of the magnetic core. Multiple ribs on the outer surface of the plastic shell 2 naturally divide the magnetic core into three 3+3 winding areas 201 on each side. Enamelled wire is wound into each independent winding area 201 as needed to form a coil 3. Four+4 copper sheets 401 are inserted one-to-one into the pre-set limiting grooves 202 on the outer surface of the plastic shell 2. Then, the two ends of the crossbeam 402 are... Align the copper sheets 401 on both sides of the protective shell with the metal shell 5, and fix them together by welding to form a complete high-current conduction circuit. Lay the thermally conductive film 6 inside the metal shell 5, and then install the plastic protective shell 2, which is equipped with the magnetic core body 1, coil 3, and copper sheet assembly 4, into the metal shell 5, ensuring that the thermally conductive film 6 is tightly attached to the surface of the coil 3 and the copper sheet 401. Finally, connect the small plug 701 of the plug assembly 7 to the terminal of the coil 3, and the large plug 702 to the terminal of the copper sheet 401 to complete the overall assembly. When the magnetic core assembly is working, the nanocrystalline magnetic core body 1 constructs a stable magnetic circuit with its high magnetic permeability, providing a basis for energy conversion; the coil 3 realizes current transmission through enameled wire, and the copper sheet assembly 4 realizes high-current transmission through the circuit formed by welding; the heat generated by the coil 3 and the copper sheet 401 is conducted to the metal shell 5 through the attached thermally conductive film 6, and then dissipated by the metal shell 5, ensuring stable operation of the assembly.

[0031] Nanocrystalline core materials possess magnetic permeability far exceeding that of traditional silicon steel sheets and ferrites, significantly reducing hysteresis and eddy current losses, improving the energy conversion efficiency of magnetic core components, and providing magnetic circuit support for the efficient operation of automotive electronic devices. The annular plastic housing 2 provides mechanical protection for the nanocrystalline core material and adapts to the spatial layout of automotive equipment (the annular structure is more conducive to uniform magnetic field distribution); the ribs, through physical separation, form a 3+3 winding area 201, clearly defining the winding path and avoiding cross-interference of the coils 3; the limiting groove 202 provides precise positioning for the copper sheet 401, ensuring the positional accuracy of the copper sheet 401 when welding to the crossbeam 402, and guaranteeing the conduction stability of high-current circuits; the thermally conductive film 6, through its thermal conductivity, builds a heat dissipation channel between the coils 3, copper sheet 401, and metal housing 5, while also providing insulation to prevent short circuits; the small plug 701 and large plug 702, through functional partitioning, respectively adapt to the external connection needs of the coil 3 (low current) and copper sheet 401 (high current), eliminating the need for additional adapter structures.

[0032] In this embodiment, thermally conductive adhesive is injected into the metal shell 5 to form a thermally conductive colloid 8, which fills the gaps between the metal shell 5, the plastic protective shell 2, the coil 3, and the copper sheet assembly 4. After the thermally conductive adhesive sheet 6 is laid and the plastic protective shell 2 and internal components are installed into the metal shell 5, thermally conductive adhesive is injected into the metal shell 5. The thermally conductive adhesive flows and fills all the gaps between the metal shell 5 and the plastic protective shell 2, the coil 3, and the copper sheet assembly 4. The final assembly is completed after the thermally conductive adhesive cures. During operation, part of the heat generated by the coil 3 and the copper sheet 401 is directly conducted to the metal shell 5 through the thermally conductive adhesive sheet 6, and the other part is conducted to the metal shell 5 through the thermally conductive adhesive filling the gaps, forming a dual heat dissipation path. The thermally conductive adhesive has a high thermal conductivity and good fluidity. After injection, it can fully fill the tiny gaps inside the metal shell 5 and eliminate air in the gaps. The cured thermally conductive adhesive can not only enhance the heat conduction efficiency, but also fix the internal components through its own adhesion, avoiding displacement caused by vibration.

[0033] In this embodiment, the plastic housing 2 and the metal housing 5 are connected by a snap-fit ​​structure (not shown in the figure). The snap-fit ​​structure includes a snap protrusion on the outer wall of the plastic housing 2 and a snap groove on the inner wall of the metal housing 5, with the snap protrusion and the snap groove engaging. The assembled plastic housing 2 is aligned with the opening of the metal housing 5, ensuring precise alignment of the snap protrusion on the outer wall of the plastic housing 2 with the snap groove on the inner wall of the metal housing 5. Axial pressure is applied to cause a slight elastic deformation of the snap protrusion, which then engages with the snap groove, achieving rapid fixation between the plastic housing 2 and the metal housing 5. Utilizing the elastic deformation characteristics of the plastic housing 2, and through the mechanical engagement of the snap protrusion and the snap groove, a secure connection between the plastic housing 2 and the metal housing 5 can be achieved without additional fasteners.

[0034] In this embodiment, the metal shell 5 has multiple mounting holes 501 on its sidewall for connecting to the client device. These mounting holes 501 are evenly distributed around the circumference of the metal shell 5. After the magnetic core assembly is fully assembled, the magnetic core assembly is precisely connected and fixed to the client device using screws or other fasteners through the multiple mounting holes 501 evenly distributed around the circumference of the sidewall of the metal shell 5, according to the installation interface position of the client device. When it is necessary to disassemble the assembly, the fasteners can be unscrewed to achieve separation. The even distribution of the multiple mounting holes 501 around the circumference of the metal shell 5 ensures that the force points when the assembly is fixed to the client device are evenly distributed, avoiding tilting or displacement of the assembly due to excessive local force. At the same time, the design of multiple mounting holes 501 can adapt to the interface number requirements of different client devices, improving versatility.

[0035] In this embodiment, the crossbeam 402 is made of copper, and its two ends are welded to the copper plates 401 on both sides of the plastic housing 2. The two ends of the copper crossbeam 402 are aligned with the terminals of the copper plates 401 on both sides of the plastic housing 2, and the crossbeam 402 is fixedly connected to each copper plate 401 through welding, forming a complete high-current conduction circuit. During operation, the high current is input through one copper plate 401, shunted through the crossbeam 402 to the other copper plate 401, or converged through the other copper plate 401 and output through the crossbeam 402, achieving stable transmission. Copper has extremely low resistivity, which reduces energy loss during high-current transmission; the welding connection between the crossbeam 402 and the copper plates 401 eliminates contact gaps, reduces contact resistance, avoids localized heating, and ensures the continuity and stability of the conductive path.

[0036] In this embodiment, the enameled wire diameter is 1.5-3mm. Based on the current transmission requirements of coil 3 and the space of winding area 201, the enameled wire is tightly wound within the 3+3 structure winding area 201 of the plastic sheath 2 to form coil 3 adapted to medium-to-high power low current transmission. The wire diameter of the enameled wire directly determines its current carrying capacity and resistance. Compared with traditional fine wire diameter, a wire diameter of 1.5-3mm has lower resistance and stronger current carrying capacity, which can meet the low current transmission requirements of high-power scenarios in new energy vehicles.

[0037] In this embodiment, there are 6 small connectors 701 and 2 large connectors 702. The 6 small connectors 701 are connected one-to-one with the 6 sets of input and output terminals of the coil 3 to achieve external connection for small current of the coil 3; the 2 large connectors 702 are connected to the 2 sets of adapters of the copper sheet assembly 4 to achieve external connection for large current. During operation, small current is input / output to the coil 3 through the small connectors 701, and large current is input / output to the copper sheet assembly 4 through the large connectors 702.

[0038] In this embodiment, the flatness of the bottom of the metal shell 5 is 0.1 mm, and the roughness is 1.6. The bottom of the metal shell 5 is tightly fitted to the water channel structure of the client device. Since the flatness of the bottom of the metal shell 5 is controlled at 0.1 mm and the roughness is controlled at 1.6, there are no obvious gaps or protrusions on the contact surface between the two. During operation, the heat conducted on the metal shell 5 is quickly transferred to the water channel through the tightly fitted contact surface, and then the water channel dissipates the heat to the external environment.

[0039] In this embodiment, the thermally conductive sheet 6 is a silicone thermally conductive sheet 6. Silicone material possesses both excellent thermal conductivity and insulation properties, enabling electrical isolation while transferring heat, preventing short circuits caused by direct contact between the coil 3, copper sheet 401, and metal shell 5. The flexibility of silicone allows it to adapt to the surface contours of the coil 3 and copper sheet 401, ensuring a tight fit and improving heat transfer efficiency. The silicone thermally conductive sheet 6 is cut to a size suitable for the internal space of the metal shell 5 and laid inside the metal shell 5, ensuring that the sheet adheres tightly to both the surface of the coil 3 and the surface of the copper sheet 401. During operation, the heat generated by the coil 3 and copper sheet 401 is rapidly conducted to the metal shell 5 through the silicone thermally conductive sheet 6, while the sheet blocks the current path between the coil 3, copper sheet 401, and metal shell 5, preventing short circuits.

[0040] In this embodiment, the width of the limiting groove 202 is fitted with the thickness of the copper sheet 401 with a clearance of 0.05-0.1mm. This clearance satisfies both the ease of assembly of the copper sheet 401 and the precise positioning of the copper sheet 401 achieved by the constraint of the wall of the limiting groove 202, ensuring the docking accuracy of the copper sheet 401 and the crossbeam 402 during welding. When the copper sheet 401 is aligned with the limiting groove 202 on the plastic housing 2, since the clearance between the groove width and the thickness of the copper sheet 401 is controlled at 0.05-0.1mm, the copper sheet 401 can be smoothly inserted into the limiting groove 202 without significant shaking after insertion. After being inserted into place, the copper sheet 401 fits tightly against the wall of the limiting groove 202, providing a stable positioning foundation for subsequent welding with the crossbeam 402.

[0041] This application's technical solution comprises a magnetic core body, a plastic sheath, a coil, a copper sheet assembly, a metal shell, a thermally conductive film, and a terminal assembly. The magnetic core body is made of nanocrystalline core material, and the plastic sheath wraps around the outer side of the magnetic core body in a ring structure. Multiple ribs are provided on the outer surface of the plastic sheath, dividing the surface into 4+4 winding areas on each side. The coil is wound with enameled wire in the winding area. Limiting grooves are also provided on the outer surface of the plastic sheath. The copper sheet assembly includes 4+4 copper sheets and crossbeams. After the copper sheets are inserted into the corresponding limiting grooves, they are welded to the corresponding crossbeams to form a high-current circuit. The metal shell is fitted over the plastic sheath, and the thermally conductive film is assembled inside the metal shell and adheres to the coil and copper sheets. The terminal assembly includes a small terminal for the coil and a large terminal for the copper sheets. When the magnetic core assembly is working, the nanocrystalline magnetic core, with its high magnetic permeability, constructs a stable magnetic circuit, providing the foundation for energy conversion. The coil transmits current through enameled wire, and the copper sheet assembly achieves high-current transmission through a welded circuit. Heat generated by the coil and copper sheets is conducted to the metal shell via a thermally conductive film, and then dissipated by the metal shell, ensuring stable operation of the assembly. The application of nanocrystalline core material significantly optimizes magnetic permeability, reduces energy loss, and improves the working efficiency of the magnetic core assembly and corresponding automotive electronic devices. The annular plastic shell combines core material protection with optimized magnetic field distribution. The 4+4 winding area and copper sheet layout improve space utilization, adapting to the compact requirements of new energy vehicle on-board equipment. Ribs divide the winding area, simplifying winding operations, and limiting grooves ensure precise positioning of the copper sheets, reducing assembly errors. The thermally conductive film ensures heat dissipation and insulation, reducing the risk of failure. The functional distinction between small and large plug terminals eliminates the need for additional adapters to meet different current transmission requirements, improving assembly compatibility.

[0042] The above description is merely an optional embodiment of this application and does not limit the patent scope of this application. Any equivalent structural transformations made based on the inventive concept of this application and the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this application.

Claims

1. A magnetic core component for new energy vehicles, characterized in that, include: The magnetic core body, plastic sheath, coil, copper sheet assembly, metal shell, thermally conductive film, and terminal assembly; The magnetic core body is made of nanocrystalline core material, and the plastic shell is wrapped around the outside of the magnetic core body and has a ring structure. The outer surface of the plastic protective shell is provided with multiple ribs, which divide the surface of the plastic protective shell into a 3+3 winding area with 3 on each side. The coil is made of enameled wire wound in the winding area. The outer surface of the plastic shell is also provided with a limiting groove. The copper sheet assembly includes a 4+4 structure of copper sheets and a crossbeam. After the copper sheet is inserted into the corresponding limiting groove, it is welded to the corresponding crossbeam to form a high-current circuit. The metal shell is fitted over the plastic protective shell, and the thermally conductive film is assembled inside the metal shell and adheres to the coil and the copper sheet; The plug assembly includes a small plug that adapts to the coil and a large plug that adapts to the copper sheet.

2. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The metal shell is filled with thermally conductive adhesive, which fills the gaps between the metal shell, the plastic shell, the coil, and the copper sheet assembly.

3. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The plastic protective shell and the metal shell are connected by a snap-fit ​​structure, which includes a snap-fit ​​protrusion on the outer wall of the plastic protective shell and a snap-fit ​​groove on the inner wall of the metal shell, wherein the snap-fit ​​protrusion and the snap-fit ​​groove engage in a snap-fit ​​relationship.

4. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The metal shell sidewall has multiple assembly holes for connecting to the client device, and the multiple assembly holes are evenly distributed along the circumference of the metal shell.

5. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The crossbeam is made of copper, and its two ends are welded to the copper sheets on both sides of the plastic shell.

6. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The diameter of the enameled wire is 1.5-3mm.

7. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The number of small plug terminals is 6 PCS, and the number of large plug terminals is 2 PCS.

8. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The flatness of the bottom of the metal shell is 0.1 mm, and the roughness is 1.

6.

9. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The thermally conductive sheet is a silicone thermally conductive sheet.

10. The new energy vehicle magnetic core assembly as described in claim 1, characterized in that, The width of the limiting groove is fitted with the thickness of the copper sheet with a clearance value of 0.05-0.1mm.

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