Coil part, electric valve, and manufacturing method for coil part

Abstract

The present application provides a coil part, an electric valve, and a manufacturing method for a coil part. The coil part comprises a stator assembly, a waterproof cover, and a connecting member; the waterproof cover surrounds at least a portion of the stator assembly; one end of the connecting member is fixedly connected to the waterproof cover, and the other end of the connecting member is used for cooperating with another structure so as to fix the stator assembly relative to the other structure. In the present application, by configuring one end of the connecting member to be fixedly connected to the waterproof cover, compared with the existing technical solutions in which the connecting member is directly connected to a stator housing of the stator assembly, the connecting member in the present application does not need to be connected and fixed to the stator housing by means of welding or adhesive filling, thereby not only effectively avoiding loosening or detachment of welding points at a welding position over time, but also avoiding loosening caused by degradation of the strength of a fixing adhesive layer, and therefore ensuring stable fixation of the stator assembly relative to other structures and ensuring the long-term reliable operation of the stator assembly and a subsequent electric valve.

Description

Coil components, electric valves, and coil component processing methods

[0001] This application claims priority to the patent application filed on March 25, 2025, with China National Intellectual Property Administration, application number 202520544423.3, entitled "Coil Components and Electric Valve". Technical Field

[0002] This application relates to the field of valve technology, and more specifically, to a coil component, an electric valve, and a method for processing the coil component. Background Technology

[0003] Currently, the positioning clips on electric valves (e.g., electronic expansion valves) used for connecting to external structures are usually fixed to the stator housing by welding or by potting glue.

[0004] However, in the above methods, the positioning cards fixed to the stator housing by welding are prone to corrosion at the welded positions, and the welds are likely to loosen or fall off over time. In the above methods, the positioning cards fixed to the stator housing by potting glue may loosen during the high-temperature operation of the coil structure in the stator assembly due to the decrease in the strength of the fixing glue layer. Therefore, positioning cards fixed by welding or potting glue are prone to loosening, which in turn causes changes in the relative position of the stator assembly and the valve body of the electric valve, leading to stator assembly failure.

[0005] Application content

[0006] This application provides a coil component, an electric valve, and a method for processing the coil component, in order to solve the problem in the prior art where the positioning card, which is fixed to the stator housing by welding or potting, is prone to loosening, which causes the relative position of the stator assembly and the valve body of the electric valve to change, leading to the failure of the stator assembly.

[0007] To address the aforementioned problems, according to one aspect of this application, a coil component is provided, including a stator assembly, a waterproof cover, and a connector, the waterproof cover surrounding at least a portion of the stator assembly; one end of the connector is fixedly connected to the waterproof cover, and the other end is used to cooperate with other structures to fix the stator assembly relative to other structures.

[0008] Furthermore, the waterproof cover includes an upper waterproof shell and a lower waterproof shell, which are respectively disposed on two parts of the stator assembly along the axial direction; the interior of the upper waterproof shell and the interior of the lower waterproof shell together form at least a part of the waterproof cavity; wherein, at least a part of the stator assembly is located inside the waterproof cavity; one end of the connector is fixedly connected to the lower waterproof shell.

[0009] Furthermore, the waterproof cover is formed by injection molding and is fixedly connected to the connector by injection molding.

[0010] Furthermore, a portion of the connector's structure passes through the waterproof cover and abuts against the stator housing of the stator assembly to ground the stator housing.

[0011] Furthermore, the connector has a through hole, a portion of the waterproof cover extends into the through hole and is positioned within the through hole to secure the connector; and / or, the connector includes a boss, the waterproof cover covers the outer periphery of the boss and is positioned within the boss to secure the connector.

[0012] Furthermore, the connector is fixedly connected to the outer wall of the waterproof cover by riveting or snap-fitting.

[0013] Furthermore, the outer wall of the waterproof cover includes a fixing protrusion, and the connector has a fixing hole. The fixing protrusion is fixedly connected to the fixing hole by riveting or snap-fitting.

[0014] Furthermore, the fixing protrusion is made of plastic. When the connector is fixedly connected to the waterproof cover by riveting, the fixing protrusion passes through the fixing hole, and one end of the fixing protrusion undergoes plastic deformation by thermoplasticization to fix the fixing protrusion to the fixing hole.

[0015] Furthermore, the coil component also includes an encapsulation structure that covers at least a portion of the outer periphery of the stator assembly, and the encapsulation structure and the waterproof cover are sealed together.

[0016] Furthermore, the waterproof cover includes an upper waterproof shell and a lower waterproof shell, which are respectively disposed on two parts of the stator assembly along the axial direction; the encapsulation structure is fixedly connected to the upper waterproof shell by welding, snap-fitting or injection molding, and the encapsulation structure is fixedly connected to the lower waterproof shell by welding, snap-fitting or injection molding.

[0017] Furthermore, the connector is fixedly connected to the lower waterproof shell by one of the following methods: injection molding, riveting, or snap-fitting.

[0018] Furthermore, the connector is connected to the lower waterproof shell by injection molding; the encapsulation structure is connected to the upper and lower waterproof shells by injection molding respectively; the upper and lower waterproof shells are respectively installed on both ends of the stator assembly along the axial direction, and the upper and lower waterproof shells are spaced apart along the axial direction of the stator assembly; an accommodating space is formed between the upper and lower waterproof shells, extending along the circumferential direction of the outer surface of the stator assembly, at least a portion of the encapsulation structure is located in the accommodating space, and is sealed to the upper and lower waterproof shells respectively.

[0019] Furthermore, the connector includes a fixing plate and a connecting plate. One end of the fixing plate is fixedly connected to the waterproof cover, and the other end of the fixing plate is connected to one end of the connecting plate. The other end of the connecting plate is used to cooperate with other structures. The extending direction of the fixing plate and the extending direction of the connecting plate form an angle. And / or, the connector is made of metal and the waterproof cover is made of plastic.

[0020] Furthermore, the connecting piece and the waterproof cover are spaced apart from each other on one end face of the stator assembly along the axial direction; the extending direction of the fixing piece is along the axial direction of the stator assembly, and the extending direction of the connecting piece is along the radial direction of the stator assembly.

[0021] Furthermore, the fixing plate has a fixing hole that penetrates the fixing plate, and the outer wall of the waterproof cover includes a fixing protrusion extending radially along the stator assembly. The fixing protrusion is fixedly connected to the fixing hole by riveting or snap-fitting, so that the connecting plate is fixed on the outer periphery of the waterproof cover.

[0022] Furthermore, there are multiple fixing holes, which are spaced apart, and multiple fixing protrusions, which are arranged one-to-one with the multiple fixing holes.

[0023] Furthermore, the waterproof cover is formed by injection molding, and is fixedly connected to the fixing piece of the connector by injection molding.

[0024] Furthermore, the fixing plate has a through hole, a portion of the waterproof cover extends into the through hole and is limited to fit the through hole to fix the connector; and / or, the fixing plate has a boss, the waterproof cover covers the outer periphery of the boss and is limited to fit the boss to fix the connector.

[0025] Furthermore, the connecting piece has a limiting protrusion, and other structures include a plate-like structure with limiting holes or limiting grooves; when the connecting piece is fixedly connected to other structures, a portion of the plate-like structure is located between the connecting piece and the waterproof cover at one end face along the axial direction of the stator assembly, and at least a portion of the limiting protrusion is located in the limiting hole or limiting groove and is limitedly engaged with the inner wall of the limiting hole or limiting groove to fix the connecting piece and the plate-like structure relative to each other.

[0026] According to another aspect of this application, an electric valve is provided, including a valve body and a valve body fixing structure. The electric valve includes the aforementioned coil component, and the connecting member and the valve body fixing structure are mutually limiting and cooperating to connect the coil component and the valve body.

[0027] According to another aspect of this application, a method for processing a coil component is provided. The method is used to process the aforementioned coil component. The coil component further includes an encapsulation structure. The waterproof cover includes an upper waterproof shell and a lower waterproof shell. The method for processing the coil component includes: assembling a stator assembly, pre-processing an upper waterproof shell and a lower waterproof shell carrying a connector; assembling the upper waterproof shell and the lower waterproof shell to the two ends of the stator assembly along the axial direction, such that the upper waterproof shell and the lower waterproof shell are spaced apart along the axial direction of the stator assembly, and forming a receiving space between the upper waterproof shell and the lower waterproof shell extending in the circumferential direction of the outer surface of the stator assembly, thereby forming an assembly; using the assembly as an insert, forming an encapsulation structure by injection molding; filling the receiving space and the stator assembly with the encapsulation structure so that the encapsulation structure is sealed and connected to the upper waterproof shell and the lower waterproof shell respectively.

[0028] Furthermore, the method for pre-processing the lower waterproof shell carrying the connector is as follows: the lower waterproof shell is injection molded with the connector as an insert.

[0029] Applying the technical solution of this application, this application provides a coil component, including a stator assembly, a waterproof cover, and a connector. The waterproof cover surrounds at least a portion of the stator assembly. One end of the connector is fixedly connected to the waterproof cover, and the other end is used to cooperate with other structures so that the stator assembly is relatively fixed to other structures.

[0030] This application effectively prevents foreign objects from entering the stator assembly by setting a waterproof cover around at least a portion of the stator assembly, thereby ensuring the reliable operation of the coil structure within the stator assembly. By fixing one end of a connector to the waterproof cover, compared to existing solutions where the connector is directly connected to the stator housing, the connector in this application does not require welding or glue application to the stator housing. This not only effectively avoids the loosening or detachment of welds over time but also prevents loosening due to reduced strength of the adhesive layer, thus ensuring the stable fixation of the stator assembly to other structures and guaranteeing the long-term reliable operation of the stator assembly and subsequent electric valves. Furthermore, by fixing the connector to the waterproof cover, this application allows for various connection methods such as welding, snap-fitting, riveting, or injection molding, increasing the selectivity of the connector's fixing method. This allows the connector to adapt to the needs of different electric valve models, facilitating efficient assembly of the connector onto the waterproof cover and improving assembly efficiency for large-scale standardized production. This application has a simple structure, low cost, and is easy to assemble and maintain, making it suitable for large-scale promotion and use. Attached Figure Description

[0031] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:

[0032] Figure 1 shows a schematic diagram of the external structure of the electric valve provided in Embodiment 1 of this application when the connector is fixedly connected to the waterproof cover by injection molding;

[0033] Figure 2 shows a schematic diagram of the internal structure in Figure 1;

[0034] Figure 3 shows a partial structural schematic diagram of the connector provided in Embodiment 1 of this application when it is fixedly connected to the waterproof cover by injection molding;

[0035] Figure 4 shows a schematic diagram of the internal structure in Figure 3;

[0036] Figure 5 shows a schematic diagram of the specific structure of the connector provided in Embodiment 1 of this application;

[0037] Figure 6 shows a schematic diagram of the specific structure of the connector provided in Embodiment 2 of this application;

[0038] Figure 7 shows a partial structural schematic diagram of the connector provided in Embodiment 3 of this application when it is fixedly connected to the waterproof cover by injection molding;

[0039] Figure 8 shows a schematic diagram of the internal structure in Figure 7;

[0040] Figure 9 shows a schematic diagram of the specific structure of the connector provided in Embodiment 3 of this application;

[0041] Figure 10 shows a schematic diagram of the external structure of the electric valve provided in Embodiment 4 of this application when the connector is riveted and fixed to the waterproof cover;

[0042] Figure 11 shows a schematic diagram of the internal structure in Figure 10;

[0043] Figure 12 shows a schematic diagram of the specific structure of the connector provided in Embodiment 4 of this application;

[0044] Figure 13 shows a schematic diagram of the external structure of the electric valve provided in Embodiment 5 of this application when the connector is riveted and fixedly connected to the waterproof cover;

[0045] Figure 14 shows a schematic diagram of the specific structure of the connector provided in Embodiment 5 of this application.

[0046] The above-mentioned figures include the following reference numerals: 100, stator assembly; 200, waterproof cover; 210, upper waterproof shell; 220, lower waterproof shell; 230, fixing protrusion; 300, connector; 31, through hole; 32, boss; 33, fixing hole; 34, fixing piece; 35, connecting piece; 351, limiting protrusion; 400, encapsulation structure. Detailed Implementation

[0047] 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 some embodiments of this application, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit this application or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0048] As shown in Figures 1 to 14, an embodiment of this application provides a coil component, including a stator assembly 100, a waterproof cover 200, and a connector 300. The waterproof cover 200 surrounds at least a portion of the stator assembly 100. One end of the connector 300 is fixedly connected to the waterproof cover 200, and the other end is used to cooperate with other structures so that the stator assembly 100 is relatively fixed to other structures.

[0049] This application effectively prevents external foreign objects from entering the stator assembly 100 by setting a waterproof cover 200 around at least a portion of the stator assembly 100, thereby ensuring the reliable operation of the coil structure inside the stator assembly 100. By fixing one end of a connector 300 to the waterproof cover 200, compared to existing technologies where the connector 300 is directly connected to the stator housing of the stator assembly 100, the connector 300 in this application does not need to be fixed to the stator housing by welding or potting. This not only effectively avoids the weld points from loosening or falling off over time, but also avoids loosening due to a decrease in the strength of the fixing adhesive layer, thus ensuring the reliable operation of the stator assembly 100. The stable fixation of the stator assembly 100 to other structures ensures the long-term reliable operation of the stator assembly 100 and subsequent electric valves. Furthermore, by providing a connector 300 fixedly connected to the waterproof cover 200, this application allows the connector 300 to be connected to the waterproof cover 200 by welding, snap-fitting, riveting, or injection molding, thus increasing the selectivity of the fixing method for the connector 300. This enables the connector 300 to adapt to the usage requirements of different models of electric valves, facilitating the efficient assembly of the connector 300 onto the waterproof cover 200, effectively improving assembly efficiency, and facilitating subsequent large-scale standardized production. This application has a simple structure and low cost, is easy to assemble and maintain, and is suitable for large-scale promotion and use.

[0050] It should be noted that in one specific embodiment of this application, the stator assembly 100 does not include the encapsulation structure 400. The stator assembly 100 includes a skeleton, a coil structure formed by winding, a stator shell, and stator plates, etc. The encapsulation structure 400 (e.g., encapsulation layer) is an independent structure from the stator assembly 100.

[0051] As shown in Figures 1, 2, 10, 11 and 13, the waterproof cover 200 includes an upper waterproof shell 210 and a lower waterproof shell 220, which are respectively disposed on two axial parts of the stator assembly 100; the interior of the upper waterproof shell 210 and the interior of the lower waterproof shell 220 together form at least a part of a waterproof cavity; wherein at least a part of the stator assembly 100 is located inside the waterproof cavity; one end of the connector 300 is fixedly connected to the lower waterproof shell 220.

[0052] It is worth noting that in one specific embodiment of this application, the upper waterproof shell 210 and the lower waterproof shell 220 can be either an integral or separate structures. When the upper waterproof shell 210 and the lower waterproof shell 220 are an integral structure, they can be integrally injection molded with the stator assembly 100 as an insert. When the upper waterproof shell 210 and the lower waterproof shell 220 are separate structures, they can be injection molded separately and then wrapped around the outside of the stator assembly 100 by welding, snap-fitting, gluing, or other methods. Alternatively, one of the waterproof shells can be pre-formed, and then the waterproof shell and the stator assembly 100 can be assembled to form an assembly. The other waterproof shell can then be injection molded with the assembly as an insert to form the coil component. Alternatively, the coil component may also have an encapsulation structure 400 (e.g., an encapsulation layer), which encapsulates at least a portion of the outer peripheral surface of the stator assembly 100, with the upper waterproof housing 210 and / or the lower waterproof housing 220 sealingly engaged with the encapsulation structure 400 (e.g., the encapsulation layer).

[0053] The combination of the upper waterproof shell 210 and the lower waterproof shell 220 forms a complete waterproof cavity, which further enhances the waterproof effect and ensures the long-term stable operation of the internal coil structure. The fixed connection between the connector 300 and the lower waterproof shell 220 allows the connector 300 to more firmly fix the coil components during the assembly of the electric valve, avoiding the performance degradation of the electric valve caused by the loosening of the connector 300.

[0054] Specifically, as shown in Figures 3, 4, 5, 6, 7, 8 and 9, the waterproof cover 200 is formed by injection molding and is fixedly connected to the connector 300 by injection molding.

[0055] The injection-molded waterproof cover 200 can precisely match the shape of the stator assembly 100 to form a tight waterproof seal. At the same time, fixing the connector 300 to the waterproof cover 200 by injection molding can improve the connection strength, simplify the assembly process, reduce production costs, and improve the production efficiency and quality of the electric valve.

[0056] Furthermore, it is worth noting that: as shown in Figures 1 to 9, in Embodiments 1, 2, and 3 of this application, the connector 300 and the waterproof cover 200 are fixedly connected by injection molding; as shown in Figures 10 to 14, in Embodiments 4 and 5 of this application, the connector 300 and the waterproof cover 200 are fixedly connected by riveting or snap-fitting; the above-mentioned injection molding method and riveting or snap-fitting method are parallel methods, thus forming a total of five embodiments;

[0057] More specifically, in Embodiments 1, 2, and 3 of this application, the connector 300 and the lower waterproof shell 220 of the waterproof cover 200 are fixedly connected by injection molding; in Embodiments 4 and 5 of this application, the connector 300 and the lower waterproof shell 220 of the waterproof cover 200 are fixedly connected by riveting or snap-fitting.

[0058] As shown in Figures 5, 6, 9, 12 and 13, the connector 300 includes a fixing piece 34 and a connecting piece 35. One end of the fixing piece 34 is fixedly connected to the outer wall of the waterproof cover 200, and the other end of the fixing piece 34 is connected to one end of the connecting piece 35. The other end of the connecting piece 35 is used to cooperate with other structures. The extending direction of the fixing piece 34 and the extending direction of the connecting piece 35 form an angle.

[0059] It is worth noting that, in a specific embodiment of this application, the process of molding the waterproof cover 200 and the connector 300 by injection molding is as follows: 1. Preparation stage: Design and manufacture a high-precision mold, which includes the shape of the lower waterproof shell 220 and the reserved installation position of the connector 300; the reserved position of the connector 300 needs to be precisely matched with its shape to ensure a good fit during injection molding; the metal connector 300 is pre-placed in the designated position in the mold, ensuring that the other end of its fixing piece 34 can be accurately aligned and leaving space for cooperation with other structures for subsequent assembly; 2. Injection molding process: Heat the plastic raw material to a molten state to ensure that the plastic can flow fully and fill all detailed areas of the mold, especially the surrounding area of ​​the connector 300; inject the molten plastic into the mold through the nozzle of the injection molding machine, and the plastic will surround the pre-placed connector 300. The plastic flows and fills every detail of the mold, including the outer periphery of the fixing piece 34 of the connector 300. After the plastic is filled, a certain pressure needs to be maintained to ensure that the plastic and the connector 300 are tightly bonded. Subsequently, the mold and the plastic inside gradually cool and solidify to form the structure of the lower waterproof shell 220, which is tightly bonded to the connector 300 to form an integrated structure. 3. Post-processing and inspection: After the plastic is completely cured, the mold is opened and the molded lower waterproof shell 220 and the connector 300 integrally formed part are taken out. The integrally formed part is strictly inspected to ensure that there are no defects in the bonding between the plastic and the connector 300, such as bubbles, cracks or areas that are not fully fused. At the same time, the overall dimensions are checked to ensure that they meet the design requirements and to ensure the accuracy of the waterproof shell and the connector. After the initial molding is completed, secondary processing may be required, such as trimming and hole processing, to meet specific assembly requirements.

[0060] The advantages of the above embodiments are as follows: 1. Improved stability: Through injection molding, a strong mechanical bond is formed between the connector 300 and the lower waterproof shell 220, avoiding problems such as loosening and corrosion that may be caused by traditional welding or adhesive fixing methods; 2. Simplified assembly: The integrally molded connector 300 and lower waterproof shell 220 reduce subsequent assembly steps, improve production efficiency, and reduce production costs; 3. Enhanced waterproof performance: The injection-molded waterproof shell is tightly integrated with the connector, forming a seamless waterproof cavity, effectively protecting the internal stator assembly 100 and improving the waterproof performance of the electric valve; 4. Improved standardization: The application of injection molding technology enables the assembly of the connector 300 and the lower waterproof shell 220 to achieve standardized and large-scale production, facilitating subsequent mass production and maintenance.

[0061] Through the above-described injection molding process, the connector 300 and the lower waterproof shell 220 form a new type of component with stable structure, good waterproof performance, and easy assembly, which significantly improves the reliability of the electric valve and the level of industrial production.

[0062] As shown in Figures 5 and 6, the connector 300 has a through hole 31, a portion of the waterproof cover 200 extends into the through hole 31 and is limited to fit the through hole 31 to fix the connector 300; and / or, as shown in Figure 9, the connector 300 includes a boss 32, the waterproof cover 200 covers the outer periphery of the boss 32 and is limited to fit the boss 32 to fix the connector 300.

[0063] The design of the through hole 31 and the boss 32 increases the fixing strength between the connector 300 and the waterproof cover 200 during the integral injection molding process, making the fixing between the connector 300 and the waterproof cover 200 more reliable. Through the limiting fit, not only is the fixing strength of the connector 300 improved, but its durability in complex environments is also enhanced. The above design also enables the connector 300 to be positioned more accurately during the assembly of the electric valve, simplifying the assembly steps and improving the assembly efficiency.

[0064] Specifically, as shown in Figures 7, 8, and 9, in Embodiment 3 of this application, when the connector 300 and the waterproof cover 200 are fixedly connected by injection molding, a portion of the structure of the connector 300 passes through the waterproof cover 200 and abuts against the stator housing of the stator assembly 100, so that the stator housing is grounded. This arrangement ensures the electrical connection between the stator housing and other structures of the electric valve, helps to form a complete electromagnetic circuit, and improves the electromagnetic performance and stability of the electric valve. At the same time, through the structural cooperation between the connector 300 and the waterproof cover 200, the connector 300 can withstand greater mechanical stress during the operation of the electric valve, avoiding loosening of the connector 300 due to mechanical vibration.

[0065] More specifically: As shown in Figures 7, 8, and 9, the boss 32 provided on the connector 300 can be configured to protrude from the inner wall of the waterproof cover 200. After the waterproof cover 200 is installed on the stator assembly 100, the boss 32 and the stator housing of the stator assembly 100 are brought into contact to achieve grounding of the coil component.

[0066] As shown in Figures 10, 11, 12, 13 and 14, the connector 300 is fixedly connected to the outer wall of the waterproof cover 200 by riveting or snap-fitting.

[0067] Using riveting or snap-fit ​​methods can avoid the heat effects that welding may cause and the strength problems that glue fixation may have, thereby improving the fixing strength and stability between the connector 300 and the waterproof cover 200, ensuring the stable performance of the electric valve during long-term operation; at the same time, it also facilitates the rapid assembly of the connector 300 and the waterproof cover 200, thereby improving the efficiency of subsequent standardized processing.

[0068] As shown in Figures 12 and 14, the outer wall of the waterproof cover 200 includes a fixing protrusion 230, and the connector 300 has a fixing hole 33. The fixing protrusion 230 is fixedly connected to the fixing hole 33 by riveting or snap-fitting.

[0069] The fixing protrusion 230 and the fixing hole 33 are connected by riveting or snapping, which not only achieves a stable connection between the connector 300 and the waterproof cover 200, but also avoids the thermal stress caused by welding and the possible reduction in strength due to glue fixation, thereby improving the reliability and service life of the electric valve. At the same time, this design simplifies the structure of the connector 300 and the waterproof cover 200, making it easier to process and reduce costs.

[0070] As shown in Figures 10, 11 and 13, the fixing protrusion 230 is made of plastic. When the connector 300 is fixedly connected to the waterproof cover 200 by riveting, the fixing protrusion 230 passes through the fixing hole 33. One end of the fixing protrusion 230 undergoes plastic deformation by thermoplasticization so that the fixing protrusion 230 is fixedly connected to the fixing hole 33.

[0071] The plastic fixing protrusion 230 forms a plastic deformation connection with the fixing hole 33 through thermoplastic method, which not only improves the stability of the connection, but also avoids the electrochemical corrosion that may occur in the metal connection, thus improving the corrosion resistance and long-term stability of the electric valve. In addition, the above-mentioned hot riveting processing design based on plastic material also facilitates rapid processing and molding.

[0072] It should be noted that, in one specific embodiment of this application, the hot riveting integral molding process is a method combining heating and shaping with riveting fixing technology, used to firmly bond the connector 300 to the plastic waterproof cover 200; the process of hot riveting integral molding of the connector 300 and the lower waterproof shell 220 is as follows: 1. Preparation: Preheat the mold used for hot riveting to a suitable value below the plastic melting temperature to ensure that the plastic does not melt prematurely before molding; confirm that the fixing hole 33 of the fixing piece 34 is aligned with the fixing protrusion 230 to ensure the accuracy and stability of subsequent hot riveting; 2. Hot riveting process: Use a heating tool to heat the fixing protrusion 230 on the plastic outer wall of the lower waterproof shell 220 to a plastic state, and then apply pressure to the heated fixing protrusion 230... The portion passing through the fixing hole 33 forms an enlarged nut shape or other fixing shape, thereby forming a hot riveting structure to ensure a stable connection between the connector 300 and the waterproof cover 200; 3. Cooling and curing: After the thermoplastic deformation is completed, the fixing protrusion 230 cools and solidifies under pressure to form a firm riveting point, at which the connector 300 and the lower waterproof shell 220 are fixedly connected; 4. Post-processing and inspection: Take out the formed part, that is, the structure of the connector 300 and the lower waterproof shell 220 integrally formed; inspect the integrally formed part to ensure that the hot riveting point is free of defects and the connection strength meets the design requirements, and at the same time check the overall dimensional accuracy to ensure that it conforms to the design drawings; perform necessary post-processing on the integrally formed structure, such as removing burrs and grinding, to meet the final assembly requirements.

[0073] Through the hot riveting integrated processing steps described in the above embodiments, a connection structure with high mechanical strength and good waterproof performance is formed between the connector 300 and the lower waterproof shell 220, avoiding the corrosion problems that may be caused by traditional welding and the problem of the strength of glue fixation decreasing over time. In addition, the hot riveting integrated molding technology simplifies the assembly process, improves production efficiency, and reduces maintenance costs caused by weld point or glue failure. It is an effective means to improve assembly efficiency and product stability in the field of electric valve manufacturing.

[0074] As shown in Figures 1, 2, 10, 11 and 13, the coil component also includes an encapsulation structure 400, which covers at least a portion of the outer periphery of the stator assembly 100, and the encapsulation structure 400 and the waterproof cover 200 are sealed together.

[0075] The encapsulation structure 400 further enhances the protection of the stator assembly 100. Through its sealing cooperation with the waterproof cover 200, it forms a double waterproof and isolation barrier, improving the waterproof performance and durability of the electric valve and ensuring stable operation in harsh environments.

[0076] Specifically, as shown in Figures 1, 2, 10, 11, and 13, the waterproof cover 200 includes an upper waterproof shell 210 and a lower waterproof shell 220, which are respectively disposed on two axial parts of the stator assembly 100; the encapsulation structure 400 is fixedly connected to the upper waterproof shell 210 by welding, snap-fitting, or injection molding, and the encapsulation structure 400 is fixedly connected to the lower waterproof shell 220 by welding, snap-fitting, or injection molding.

[0077] The upper waterproof housing 210 and the lower waterproof housing 220 enable the waterproof cover 200 to cover the stator assembly 100. Through multiple fixed connections with the encapsulation structure 400, the assembly flexibility and production efficiency of the electric valve are improved. At the same time, the connection strength between the waterproof cover 200 and the encapsulation structure 400 is enhanced, thereby improving the overall performance and reliability of the electric valve.

[0078] It is worth noting that the connector 300 and the lower waterproof shell 220 can be fixedly connected by one of the following methods: injection molding, riveting, and snap-fit.

[0079] Preferably, the connector 300 is connected to the lower waterproof shell 220 by injection molding; the encapsulation structure 400 is connected to the upper waterproof shell 210 and the lower waterproof shell 220 by injection molding; the upper waterproof shell 210 and the lower waterproof shell 220 are respectively covered at both ends of the stator assembly 100 along the axial direction, and the upper waterproof shell 210 and the lower waterproof shell 220 are spaced apart along the axial direction of the stator assembly 100; an accommodating space is formed between the upper waterproof shell 210 and the lower waterproof shell 220 extending in the circumferential direction of the outer surface of the stator assembly 100, at least a portion of the encapsulation structure 400 is located in the accommodating space, and is sealed to the upper waterproof shell 210 and the lower waterproof shell 220 respectively.

[0080] This configuration allows the upper waterproof shell 210 and the lower waterproof shell 220, which is injection molded with the connector 300 as an insert, to be pre-processed and molded. Furthermore, the assembly of the upper waterproof shell 210 and the lower waterproof shell 220 can be carried out on separate production lines, thereby improving the overall assembly efficiency of the coil components. By setting the encapsulation structure 400 (i.e., the encapsulation layer) to be sealed and connected to the upper waterproof shell 210 and the lower waterproof shell 220, the insulation performance of the coil components is effectively improved.

[0081] As shown in Figures 5, 6, 9, 12, and 13, the connector 300 includes a fixing piece 34 and a connecting piece 35. One end of the fixing piece 34 is fixedly connected to the waterproof cover 200, and the other end of the fixing piece 34 is connected to one end of the connecting piece 35. The other end of the connecting piece 35 is used to cooperate with other structures. The extending direction of the fixing piece 34 and the extending direction of the connecting piece 35 form an angle. And / or, the connector 300 is made of metal, and the waterproof cover 200 is made of plastic.

[0082] The design of the fixing piece 34 and the connecting piece 35 allows the connector 300 to be more securely fixed to the waterproof cover 200. At the same time, the combination of the metal connector 300 and the plastic waterproof cover 200 not only improves the connection strength but also avoids the risk of electrochemical corrosion, thereby improving the corrosion resistance and service life of the electric valve.

[0083] As shown in Figures 1, 2, 10, 11 and 13, the connecting piece 35 and the waterproof cover 200 are spaced apart from each other on one end face along the axial direction of the stator assembly 100; the extending direction of the fixing piece 34 is arranged along the axial direction of the stator assembly 100, and the extending direction of the connecting piece 35 is arranged along the radial direction of the stator assembly 100.

[0084] As shown in Figures 1, 2, 10, 11 and 13, the fixing plate 34 has a fixing hole 33 that passes through the fixing plate 34, and the outer wall of the waterproof cover 200 includes a fixing protrusion 230 extending radially along the stator assembly 100. The fixing protrusion 230 is fixedly connected to the fixing hole 33 by riveting or snap-fitting, so that the connecting piece 35 is fixed on the outer periphery of the waterproof cover 200.

[0085] The specific arrangement of the connecting piece 35 and the fixing piece 34, as well as the cooperation between the fixing hole 33 and the fixing protrusion 230, allows the connector 300 to be more securely fixed on the waterproof cover 200, improving the stability of the electric valve during operation and avoiding performance degradation caused by loosening of the connector 300.

[0086] Specifically, there are multiple fixing holes 33, which are spaced apart, and there are multiple fixing protrusions 230, which are arranged in a one-to-one correspondence with the multiple fixing holes 33.

[0087] The aforementioned multiple fixing holes 33 and fixing protrusions 230 make the connection between the connector 300 and the waterproof cover 200 more stable, improve the stability of the electric valve during operation, and avoid the risk of loosening that may be caused by a single-point connection; at the same time, the one-to-one correspondence setting also simplifies the assembly process and improves assembly efficiency.

[0088] It should be noted that: the waterproof cover 200 is formed by injection molding and is fixedly connected to the fixing piece 34 of the connector 300 by injection molding; optionally, the fixing piece 34 has a through hole 31, a portion of the waterproof cover 200 extends into the through hole 31 and is limited and engaged with the through hole 31 to fix the connector 300; and / or, the fixing piece 34 has a boss 32, the waterproof cover 200 covers the outer periphery of the boss 32 and is limited and engaged with the boss 32 to fix the connector 300. Through the above design, the connection strength between the waterproof cover 200 and the fixing piece 34 is further improved after injection molding.

[0089] As shown in Figures 1, 2, 10, 11 and 13, the connecting piece 35 has a limiting protrusion 351, and other structures include a plate-like structure with limiting holes or limiting grooves. When the connecting piece 35 is fixedly connected to other structures, a portion of the plate-like structure is located between one end face of the connecting piece 35 and the waterproof cover 200 along the axial direction of the stator assembly 100. At least a portion of the limiting protrusion 351 is located in the limiting hole or limiting groove and is limited and engaged with the inner wall of the limiting hole or limiting groove to fix the connecting piece 35 relative to the plate-like structure.

[0090] The design of the limiting protrusion 351 allows the connecting piece 35 to be positioned more precisely when fixed with other structures, avoiding positional deviations during assembly and improving the assembly accuracy and performance stability of the electric valve. At the same time, the limiting fit also improves the fixing strength between the connecting piece 300 and other structures of the electric valve, ensuring the performance stability of the electric valve during long-term operation. It allows other structures to be fixedly connected to the valve body of the electric valve to fix the coil components and the valve body of the electric valve.

[0091] This application also provides a method for processing coil components, which is used to process the aforementioned coil components; the coil components further include an encapsulation structure 400; the waterproof cover 200 includes an upper waterproof shell 210 and a lower waterproof shell 220; the method for processing coil components includes: assembling the stator assembly 100, pre-processing the upper waterproof shell 210 and the lower waterproof shell 220 carrying the connector 300; injection molding the lower waterproof shell 220 with the connector 300 as an insert; and assembling the upper waterproof shell 210 and the lower waterproof shell 220 onto the stator respectively. The upper waterproof shell 210 and the lower waterproof shell 220 are spaced apart along the axial direction of the stator assembly 100 at both ends of the component 100, and a receiving space is formed between the upper waterproof shell 210 and the lower waterproof shell 220 extending in the circumferential direction of the outer surface of the stator assembly 100. At this time, an assembly is formed. Using the assembly as an insert, an encapsulation structure 400 is formed by injection molding. The encapsulation structure 400 is filled into the receiving space and into the stator assembly 100 so that the encapsulation structure 400 is sealed and connected to the upper waterproof shell 210 and the lower waterproof shell 220 respectively.

[0092] The use of a pre-processed, separate upper waterproof shell 210 and a lower waterproof shell 220 injection-molded with a connector 300 as an insert allows the assembly of the stator assembly 100 and the coil component to be processed on separate production lines, thereby improving the assembly efficiency of the coil component. At the same time, an encapsulation structure 400 is injection-molded with the shell-stator assembly as an insert. After injection molding, the encapsulation structure 400 finally achieves a sealed connection with the upper and lower shells, effectively improving the insulation performance of the coil component.

[0093] Specifically, the lower waterproof shell 220 carrying the connector 300 is pre-processed by injection molding the lower waterproof shell 220 with the connector 300 as an insert. This arrangement further improves the connection strength between the lower waterproof shell 220 and the connector 300.

[0094] This application also provides an electric valve, which includes a valve body and a valve body fixing structure. The electric valve includes the above-mentioned coil component, and the connector 300 and the valve body fixing structure are mutually limiting and cooperating to connect the coil component and the valve body.

[0095] The electric valve proposed in this application, through the above-mentioned optimized structural design, significantly improves the performance stability, corrosion resistance and service life of the electric valve, can adapt to a wider range of use environments, and enhances the market competitiveness and user satisfaction of the electric valve.

[0096] The specific working process and principles of this application will now be explained in detail as follows:

[0097] Figure 1 shows a schematic diagram of the external structure of the electric valve provided in Embodiment 1 of this application when the connector and the waterproof cover are fixedly connected by injection molding. It illustrates the structure of the waterproof cover 200 surrounding the stator assembly 100, and the fixed connection method between the connector 300 and the waterproof cover 200, demonstrating the improved structural design and fixing strength of this application. The stator assembly 100 is centrally located and tightly surrounded by the waterproof cover 200, which consists of an upper waterproof shell 210 and a lower waterproof shell 220, distributed along the axial direction of the stator assembly 100. Notably, the interiors of the upper waterproof shell 210 and the lower waterproof shell 220 together form a waterproof cavity, which ensures that at least a portion of the stator assembly 100 is protected from external moisture and impurities, thereby protecting its electrical performance from damage. One end of the connector 300 is fixedly connected to the outer wall of the lower waterproof shell 220, while the other end is reserved for cooperation with other structures to achieve the fixation of the stator assembly 100.

[0098] Figure 2 shows a schematic diagram of the internal structure in Figure 1, further revealing the waterproof cavity structure inside the waterproof cover 200, and the way the stator assembly 100 and the waterproof cover 200 are fitted together, demonstrating the waterproof performance and protection effect on the internal coil structure of this application. Figures 3 and 4 show partial structural schematic diagrams of the connector provided in Embodiment 1 of this application when it is fixedly connected to the waterproof cover by injection molding, showing in detail the injection molding connection details between the connector 300 and the waterproof cover 200. Specifically, it can be combined with structures such as the through hole 31 or the boss 32, and the way it is fitted with the waterproof cover 200 to achieve improved structural design and fixing strength. Figures 5 to 9 show specific structural schematic diagrams of the connector in different embodiments, showing the design of the connector 300 including the fixing piece 34 and the connecting piece 35, and the different shapes of the through hole 31.

[0099] Figures 10 to 14 show the external structural schematic diagram and the specific structural schematic diagram of the electric valve provided in Embodiments 4 and 5 of this application when the connector is riveted and fixed to the waterproof cover. They detail the riveting and fixing connection between the connector 300 and the waterproof cover 200, including the matching method between the fixing hole 33 and the fixing protrusion 230, demonstrating the structural design and improved fixing strength of this application under different fixing methods. The connector 300 includes a fixing piece 34 and a connecting piece 35. One end of the fixing piece 34 is fixedly connected to the outer wall of the waterproof cover 200, and the other end is connected to one end of the connecting piece 35. The fixing piece 34 extends axially along the stator assembly 100, while the connecting piece 35 extends radially along the stator assembly 100, forming a right-angled structure. The fixing plate 34 is provided with fixing holes 33, and the outer wall of the waterproof cover 200 is equipped with fixing protrusions 230 extending radially along the stator assembly 100. The fixing protrusions 230 are fixedly connected to the fixing holes 33 by riveting or snap-fitting. This connection method is not only stable, but also simplifies the assembly process and reduces production costs. It is worth noting that there can be multiple fixing holes 33, arranged at intervals, corresponding one-to-one with multiple fixing protrusions 230, which enhances the reliability of the connection.

[0100] The coil component, electric valve, and coil component processing method of this application not only solve the problems existing in the fastening methods of the connectors in the prior art, such as welding corrosion and loosening caused by reduced glue strength, but also significantly improve the fixing strength, corrosion resistance and standardization of the coil component through optimized structural design, reduce production costs, ensure the stable operation of the electric valve coil in various working environments, and improve the overall performance and service life of the equipment.

[0101] In summary, this application provides a coil component, an electric valve, and a method for processing the coil component. By providing a waterproof cover 200 surrounding at least a portion of the stator assembly 100, this application effectively prevents external foreign objects from entering the stator assembly 100, thereby ensuring the reliable operation of the coil structure within the stator assembly 100. By providing a connector 300 with one end fixedly connected to the waterproof cover 200, compared to existing technical solutions where the connector 300 is directly connected to the stator housing of the stator assembly 100, the connector 300 in this application does not need to be fixed to the stator housing by welding or potting. This not only effectively avoids the weld points from loosening or falling off over time, but also avoids the problem of reduced strength of the fixing adhesive layer. The loosening of the connection ensures the stable fixation of the stator assembly 100 to other structures, guaranteeing the long-term reliable operation of the stator assembly 100 and subsequent electric valves. Furthermore, by providing a connector 300 fixedly connected to the waterproof cover 200, this application allows the connector 300 to be connected to the waterproof cover 200 via welding, snap-fitting, riveting, or injection molding, increasing the selectivity of the fixing method and enabling the connector 300 to adapt to the usage requirements of different models of electric valves. This facilitates efficient assembly of the connector 300 onto the waterproof cover 200, effectively improving assembly efficiency and facilitating subsequent large-scale standardized production. The application features a simple structure and low cost, is easy to assemble and maintain, and is suitable for large-scale promotion and use.

[0102] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A coil component, characterized in that, It includes a stator assembly (100), a waterproof cover (200), and a connector (300), the waterproof cover (200) surrounding at least a portion of the stator assembly (100); one end of the connector (300) is fixedly connected to the waterproof cover (200), and the other end is used to cooperate with other structures to fix the stator assembly (100) relative to the other structures.

2. The coil component according to claim 1, characterized in that, The waterproof cover (200) includes an upper waterproof shell (210) and a lower waterproof shell (220), the upper waterproof shell (210) and the lower waterproof shell (220) being respectively disposed on two axial portions of the stator assembly (100); the interior of the upper waterproof shell (210) and the interior of the lower waterproof shell (220) together form at least a portion of a waterproof cavity; wherein at least a portion of the stator assembly (100) is located within the waterproof cavity; one end of the connector (300) is fixedly connected to the lower waterproof shell (220).

3. The coil component according to claim 1, characterized in that, The waterproof cover (200) is formed by injection molding and is fixedly connected to the connector (300) by injection molding.

4. The coil component according to claim 3, characterized in that, A portion of the structure of the connector (300) passes through the waterproof cover (200) and abuts against the stator housing of the stator assembly (100) to ground the stator housing.

5. The coil component according to claim 3, characterized in that, The connector (300) has a through hole (31), a portion of the waterproof cover (200) extends into the through hole (31) and is limited to fit the through hole (31) to fix the connector (300). And / or, the connector (300) includes a boss (32), the waterproof cover (200) covers the outer periphery of the boss (32) and is limited to the boss (32) to fix the connector (300).

6. The coil component according to claim 1, characterized in that, The connector (300) is fixedly connected to the outer wall of the waterproof cover (200) by riveting or snap-fitting.

7. The coil component according to claim 6, characterized in that, The outer wall of the waterproof cover (200) includes a fixing protrusion (230), and the connector (300) has a fixing hole (33). The fixing protrusion (230) is fixedly connected to the fixing hole (33) by riveting or snap-fitting.

8. The coil component according to claim 7, characterized in that, The fixing protrusion (230) is made of plastic. When the connector (300) is fixedly connected to the waterproof cover (200) by riveting, the fixing protrusion (230) passes through the fixing hole (33). One end of the fixing protrusion (230) undergoes plastic deformation by thermoplasticization so that the fixing protrusion (230) is fixedly connected to the fixing hole (33).

9. The coil component according to claim 1, characterized in that, The coil component further includes an encapsulation structure (400) that covers at least a portion of the outer periphery of the stator assembly (100) and is sealed to the waterproof cover (200).

10. The coil component according to claim 9, characterized in that, The waterproof cover (200) includes an upper waterproof shell (210) and a lower waterproof shell (220), the upper waterproof shell (210) and the lower waterproof shell (220) being respectively disposed on two axial parts of the stator assembly (100); the encapsulation structure (400) is fixedly connected to the upper waterproof shell (210) by welding, snap-fitting or injection molding, and the encapsulation structure (400) is fixedly connected to the lower waterproof shell (220) by welding, snap-fitting or injection molding.

11. The coil component according to claim 10, characterized in that, The connector (300) is fixedly connected to the lower waterproof shell (220) by one of the following methods: injection molding, riveting, and snap-fitting.

12. The coil component according to claim 10, characterized in that, The connector (300) is connected to the lower waterproof shell (220) by injection molding; the encapsulation structure (400) is connected to the upper waterproof shell (210) and the lower waterproof shell (220) by injection molding; the upper waterproof shell (210) and the lower waterproof shell (220) are respectively covered at both ends of the stator assembly (100) along the axial direction, and the upper waterproof shell (210) and the lower waterproof shell (220) are spaced apart along the axial direction of the stator assembly (100); an accommodating space is formed between the upper waterproof shell (210) and the lower waterproof shell (220) extending along the circumferential direction of the outer surface of the stator assembly (100), at least a portion of the encapsulation structure (400) is located in the accommodating space, and is sealed to the upper waterproof shell (210) and the lower waterproof shell (220) respectively.

13. The coil component according to claim 1, characterized in that, The connector (300) includes a fixing piece (34) and a connecting piece (35). One end of the fixing piece (34) is fixedly connected to the waterproof cover (200), and the other end of the fixing piece (34) is connected to one end of the connecting piece (35). The other end of the connecting piece (35) is used to cooperate with the other structures. The extending direction of the fixing piece (34) and the extending direction of the connecting piece (35) form an angle. And / or, the connector (300) is made of metal, and the waterproof cover (200) is made of plastic.

14. The coil component according to claim 13, characterized in that, The connecting piece (35) and the waterproof cover (200) are spaced apart from each other along one end face of the stator assembly (100) along the axial direction; the extending direction of the fixing piece (34) is arranged along the axial direction of the stator assembly (100), and the extending direction of the connecting piece (35) is arranged along the radial direction of the stator assembly (100).

15. The coil component according to claim 14, characterized in that, The fixing plate (34) has a fixing hole (33) that penetrates the fixing plate (34), and the outer wall of the waterproof cover (200) includes a fixing protrusion (230) extending radially along the stator assembly (100). The fixing protrusion (230) is fixedly connected to the fixing hole (33) by riveting or snap-fitting, so that the connecting piece (35) is fixed on the outer periphery of the waterproof cover (200).

16. The coil component according to claim 15, characterized in that, There are multiple fixing holes (33), which are spaced apart. There are multiple fixing protrusions (230), which correspond one-to-one with the multiple fixing holes (33).

17. The coil component according to claim 14, characterized in that, The waterproof cover (200) is formed by injection molding and is fixedly connected to the fixing piece (34) of the connector (300) by injection molding.

18. The coil component according to claim 17, characterized in that, The fixing piece (34) has a through hole (31), a part of the waterproof cover (200) extends into the through hole (31) and is limited to the through hole (31) to fix the connector (300); And / or, the fixing piece (34) has a boss (32), the waterproof cover (200) covers the outer periphery of the boss (32) and is limited to the boss (32) to fix the connector (300).

19. The coil component according to claim 14, characterized in that, The connecting piece (35) has a limiting protrusion (351), and the other structure includes a plate-like structure with a limiting hole or a limiting groove. When the connecting piece (35) is fixedly connected to the other structure, a portion of the plate-like structure is located between one end face of the connecting piece (35) and the waterproof cover (200) along the axial direction of the stator assembly (100). At least a portion of the limiting protrusion (351) is located in the limiting hole or the limiting groove and is limited and engaged with the inner wall of the limiting hole or the limiting groove so that the connecting piece (35) is relatively fixed to the plate-like structure.

20. An electric valve, comprising a valve body and a valve body fixing structure, characterized in that, The electric valve includes a coil component as described in any one of claims 1 to 19, wherein the connector (300) and the valve body fixing structure are mutually limiting and engaged to connect the coil component and the valve body.

21. A method for processing a coil component, characterized in that, The coil component processing method is used to process the coil component according to any one of claims 1 to 19; the coil component further includes an encapsulation structure (400); the waterproof cover (200) includes an upper waterproof shell (210) and a lower waterproof shell (220); the coil component processing method includes: Assemble the stator assembly (100), pre-process the upper waterproof shell (210) and the lower waterproof shell (220) carrying the connector (300); assemble the upper waterproof shell (210) and the lower waterproof shell (220) to the two ends of the stator assembly (100) along the axial direction, such that the upper waterproof shell (210) and the lower waterproof shell (220) are spaced apart along the axial direction of the stator assembly (100), and a receiving space extending along the circumferential direction of the outer surface of the stator assembly (100) is formed between the upper waterproof shell (210) and the lower waterproof shell (220), thus forming an assembly. Using the assembly as an insert, an encapsulation structure (400) is formed by injection molding. The encapsulation structure (400) is filled into the receiving space and the stator assembly (100) so that the encapsulation structure (400) is sealed to the upper waterproof shell (210) and the lower waterproof shell (220) respectively.

22. The coil component processing method according to claim 21, characterized in that, The method of pre-processing the lower waterproof shell (220) carrying the connector (300) is as follows: the lower waterproof shell (220) is injection molded with the connector (300) as an insert.

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