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CN-121989408-A - Integrated manufacturing method of vehicle-mounted filter and vehicle-mounted filter

CN121989408ACN 121989408 ACN121989408 ACN 121989408ACN-121989408-A

Abstract

The application discloses an integrated manufacturing method of a vehicle-mounted filter, which comprises the steps of providing at least one conductor and at least one connecting structure for conducting with an external circuit, forming an integrated injection molding framework by injection molding insulating materials outside the conductor and the connecting structure, forming a reserved bin and an installation part for installing electronic components integrally by the integrated injection molding framework, fixedly installing at least one magnetic core assembly on the installation part, enabling one section of the conductor to penetrate through the magnetic core assembly, fixedly installing at least one capacitor in the reserved bin, enabling pins of the capacitor to be electrically connected with the conductor, and providing at least one circuit board, and fixing the circuit board on the integrated injection molding framework and electrically connected with the conductor and a grounding end of the capacitor respectively. Through the design, the application provides an integrated vehicle-mounted filter manufacturing scheme which can meet the requirements of high reliability and high performance of the vehicle gauge and is suitable for large-scale production.

Inventors

  • Zhu yongjia
  • ZENG HAIFENG
  • ZHOU ZHENGGUO
  • WANG YANGYANG
  • XIAO KENG
  • JIA XILING

Assignees

  • 惠州市可立克电子有限公司
  • 惠州市可立克科技有限公司
  • 深圳可立克科技股份有限公司
  • 信丰可立克科技有限公司
  • 安徽可立克科技有限公司

Dates

Publication Date
20260508
Application Date
20251229

Claims (10)

  1. 1. An integrated manufacturing method of a vehicle-mounted filter, comprising the steps of: s1, providing at least one conductor (1) and at least one connecting structure (2) for conducting with an external circuit; S2, an insulating material is coated outside the conductor (1) and the connecting structure (2) in an injection molding mode, so that an integrated injection molding framework (3) is formed, and a reserved bin (31) and a mounting part (32) for mounting electronic components are formed integrally with the integrated injection molding framework (3); S3, fixedly mounting at least one magnetic core assembly (4) on the mounting part (32), and enabling one section of the conductor (1) to penetrate through the magnetic core assembly (4) so as to form an inductor; S4, fixedly mounting at least one capacitor (5) in the reserved bin (31), and electrically connecting pins of the capacitor (5) with the conductor (1); s5, providing at least one circuit board (6), fixing the circuit board (6) on the integrated injection molding framework (3), and electrically connecting the circuit board with the conductor (1) and the grounding end of the capacitor (5) respectively.
  2. 2. The integrated manufacturing method of an in-vehicle filter according to claim 1, characterized in that the conductor (1) is provided with preformed holes and/or grooves into which the insulating material flows during injection molding to achieve a mechanical interlocking of the insulating material with the conductor (1).
  3. 3. The integrated manufacturing method of the in-vehicle filter according to claim 1, wherein the step S5 further includes the steps of: the circuit board (6) is arranged above the reserved bin (31), and a plurality of welding ports (61) penetrating the circuit board (6) are formed in the circuit board; and penetrating pins of the capacitor (5) into the welding openings (61) so as to realize the electrical connection between the capacitor (5) and the circuit board (6).
  4. 4. The integrated manufacturing method of the in-vehicle filter according to claim 1, wherein the step S5 further includes the steps of: a plurality of welding ports (61) penetrating the circuit board (6) are formed in the circuit board; the conductor (1) is provided with a connecting part (11) in a protruding mode at a position corresponding to the welding opening (61); When the insulating material is coated on the conductor (1) in an injection molding way, the connecting part (11) is exposed out of the integrated injection molding framework (3); the connection part (11) is inserted into the soldering joint (61) to electrically connect the conductor (1) to the circuit board (6).
  5. 5. The integrated manufacturing method of the vehicle-mounted filter according to claim 1, wherein the magnetic core assembly (4) includes a first magnetic core (41) and a second magnetic core (42), and the first magnetic core (41) is sleeved outside the second magnetic core (42) so that the second magnetic core (42) is disposed in a magnetic circuit of the first magnetic core (41).
  6. 6. The integrated manufacturing method of the in-vehicle filter according to claim 1, wherein the step S3 further includes the step of performing a high voltage insulation test and an electrical performance test on the integrated injection-molded skeleton (3) after the installation of the magnetic core assembly (4) and before the installation of the capacitor (5).
  7. 7. The integrated manufacturing method of the in-vehicle filter according to claim 1, wherein the step S1 further includes the steps of: -connecting the connection structure (2) with an electrical contact of the conductor (1) by welding or riveting; and electroplating the conductor (1) and the connecting structure (2).
  8. 8. The integrated manufacturing method of an in-vehicle filter according to claim 7, characterized in that the conductor (1) comprises a copper bar, the connection structure (2) comprises a nut and/or a stud, and the electrical contact comprises an input and/or an output and/or a shunt of the copper bar.
  9. 9. The integrated manufacturing method of an in-vehicle filter according to claim 1, further comprising a bushing (7), the bushing (7) being integrally formed with the integrated injection-molded skeleton (3) by an injection molding process.
  10. 10. An in-vehicle filter made by the method of any one of claims 1 to 9.

Description

Integrated manufacturing method of vehicle-mounted filter and vehicle-mounted filter Technical Field The invention relates to the technical field of vehicle-mounted filtering, in particular to an integrated manufacturing method of a vehicle-mounted filter and the vehicle-mounted filter. Background With the popularization of electric vehicles and hybrid vehicles, vehicle-mounted power electronic devices (such as vehicle-mounted chargers, DC-DC converters, and the like) face increasingly severe electromagnetic compatibility (EMC) challenges. The power switching devices in these devices can generate strong electromagnetic interference (EMI) during the high frequency switching process, and if not suppressed, can interfere with the normal operation of other electronic devices within the vehicle, even affecting the safe operation of the vehicle. Conventional in-vehicle filters are typically assembled from discrete components including individual inductors, capacitors, connecting copper bars, insulating brackets, and various fasteners. The assembly mode has the following problems and disadvantages that firstly, parasitic inductance is larger due to the fact that a plurality of discrete components are connected through cables, high-frequency filtering effect is reduced, secondly, mechanical connection points are numerous, loosening is easy to occur under a vehicle vibration environment, reliability is insufficient, assembly procedures are complex, production efficiency is low, cost is high, in addition, the structure is loose, power density is low, occupied space is large, and finally, safety isolation and insulation protection often depend on additional insulation pieces, so that cost and assembly complexity are increased. Therefore, there is an urgent need in the art for a solution for a vehicle-mounted filter with higher integration level, better reliability and better filtering performance. It should be noted that the information disclosed in the above background section is only for understanding the background of the application and thus may include information that does not form the prior art that is already known to those of ordinary skill in the art. Disclosure of Invention The top-level technical problem to be solved by the invention is how to provide an integrated vehicle-mounted filter manufacturing scheme which can meet the requirements of high reliability and high performance of the vehicle-mounted filter and is suitable for large-scale production, and the method can be embodied in how to provide the vehicle-mounted filter with higher integration level, better reliability and better filtering performance so as to solve the defects of high parasitic inductance, poor shock resistance, complex assembly, low power density, insufficient safety and the like of the existing vehicle-mounted filter. To this end, the invention provides an integrated manufacturing method of an in-vehicle filter and the in-vehicle filter. In order to achieve the above purpose, the present invention adopts the following technical scheme: The first aspect of the present application provides an integrated manufacturing method of a vehicle-mounted filter, comprising the steps of: S1, providing at least one conductor and at least one connecting structure for conducting with an external circuit; S2, injection molding and wrapping the insulating material outside the conductor and the connecting structure through an injection molding process, so that an integrated injection molding framework is formed, wherein a reserved bin for installing electronic components and an installation part are formed integrally with the integrated injection molding framework; S3, fixedly mounting at least one magnetic core assembly on the mounting part, and enabling one section of the conductor piece to penetrate through the magnetic core assembly to form an inductor; S4, fixedly mounting at least one capacitor in the reserved bin, and electrically connecting pins of the capacitor with the conductor; s5, providing at least one circuit board, fixing the circuit board on the integrated injection molding framework, and electrically connecting the circuit board with the conductor piece and the grounding end of the capacitor respectively. In some embodiments, the conductor is provided with preformed holes and/or grooves into which the insulating material flows during the injection molding process to achieve a mechanical interlock of the insulating material with the conductor. In some embodiments, step S5 further comprises the steps of: the circuit board is arranged above the reserved bin, and a plurality of welding ports penetrating the circuit board are formed in the circuit board; and penetrating pins of the capacitor into the welding ports to realize the electrical connection between the capacitor and the circuit board. In some embodiments, step S5 further comprises the steps of: a plurality of welding ports penetrating the circuit board are formed in the circu