Power Module Clamp With Ejector for Magnetic Core Gluing
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Solution Overview
Problem
The conventional clamp structure for assembling DC power modules is complicated, leading to inefficiencies and increased costs in large-scale production, and there is a need for a simplified design that ensures uniform glue application and structural stability of magnetic cores during assembly.
Innovation Solution
An auxiliary production clamp using high-temperature-resistant metal clips with an ejector assembly to simultaneously press and clamp the magnetic cores, ensuring uniform glue application and maintaining structural stability before high-temperature curing, and allowing easy removal after curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional clamp structure with multiple spring loaded pins and metal bases is used, then the magnetic cores can be assembled and clamped, but the clamp structure becomes complicated and manual operation becomes inefficient
Solution Approach 1:
The clamp is divided into an upper clamp body and a lower clamp body that can separate from each other. The ejector assembly is integrated into the lower clamp body, allowing the magnetic core to be ejected after gluing. This segmentation simplifies the overall structure compared to the conventional single-piece clamp with multiple spring loaded pins.
Solution Approach 2:
The elastic component automatically provides pressing force to press the magnetic core against the circuit board during assembly. The ejector assembly uses the elastic component's stored energy to automatically eject the magnetic core after gluing, eliminating the need for complex manual operation sequences.
2Reliability
If conventional manual assembly operations are used, then the magnetic cores can be assembled, but the production efficiency and cost are reduced
Solution Approach 1:
The elastic component is pre-compressed between the upper and lower clamp bodies, storing energy that is automatically released during assembly. This preliminary action ensures consistent pressing force for uniform glue application without requiring complex control systems.
Solution Approach 2:
The clamp transitions from a static structure to a dynamic one where the upper and lower clamp bodies can move relative to each other. The ejector assembly enables automatic ejection of the magnetic core after gluing, reducing manual intervention and improving production efficiency.
3Productivity
If the clamp structure is simplified, then the production efficiency is improved, but the ability to ensure structural stability before glue curing may be compromised
Solution Approach 1:
The elastic component acts as an intermediary that automatically provides the necessary pressing force to stabilize the magnetic core structure during assembly and glue curing. This eliminates the need for complex mechanical restraint systems while maintaining structural stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The clamp facilitates efficient assembly by ensuring uniform glue distribution and structural stability, simplifying the process while maintaining magnetic core integrity, and enabling easy removal post-curing.
Implementation Method 1
an elastic component sleeved on an outer periphery of the pivot shaft and abutted between the first clamp element and the second clamp element to provide a pressing force
Implementation Method 2
a compression spring accommodated in the metal tube and arranged between the limiting portion and a bottom of the metal tube
Implementation Method 3
After the power module and the auxiliary production clamp are processed through the high-temperature furnace, the glue between the two magnetic cores and the glue between the upper magnetic core and the upper circuit board are completely cured
Data Source
AI summary
An auxiliary production clamp including a first clamp element, a second clamp element, a pivot shaft, an elastic component and an ejector assembly for a power module and a using method thereof are disclosed. The second clamp element includes a through opening running through a second pressing end and spatially corresponding to a first pressing end of the first clamp element. The pivot shaft is pivotally connected between the first clamp element and the second clamp element. The elastic component is sleeved on the pivot shaft to provide a pressing force. The ejector assembly is provided on the second pressing end and spatially corresponding to the through opening. In a working state, the first pressing end presses against a upper first magnetic core of the power module, and an abutting end of the ejector assembly is driven to run through the through opening and push against the second magnetic core.