CN116315973A - DCDC high-voltage converter and manufacturing process thereof - Google Patents
DCDC high-voltage converter and manufacturing process thereof Download PDFInfo
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- CN116315973A CN116315973A CN202310158667.3A CN202310158667A CN116315973A CN 116315973 A CN116315973 A CN 116315973A CN 202310158667 A CN202310158667 A CN 202310158667A CN 116315973 A CN116315973 A CN 116315973A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 30
- HEZMWWAKWCSUCB-PHDIDXHHSA-N (3R,4R)-3,4-dihydroxycyclohexa-1,5-diene-1-carboxylic acid Chemical compound O[C@@H]1C=CC(C(O)=O)=C[C@H]1O HEZMWWAKWCSUCB-PHDIDXHHSA-N 0.000 title claims abstract description 18
- 238000001746 injection moulding Methods 0.000 claims abstract description 66
- 239000002184 metal Substances 0.000 claims abstract description 43
- 229910052751 metal Inorganic materials 0.000 claims abstract description 43
- 238000009713 electroplating Methods 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 13
- 239000003990 capacitor Substances 0.000 claims abstract description 7
- 238000012545 processing Methods 0.000 claims abstract description 6
- 238000004080 punching Methods 0.000 claims description 28
- 239000000463 material Substances 0.000 claims description 19
- 238000002347 injection Methods 0.000 claims description 16
- 239000007924 injection Substances 0.000 claims description 16
- 238000013461 design Methods 0.000 claims description 7
- 239000000109 continuous material Substances 0.000 claims description 6
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 4
- 239000000956 alloy Substances 0.000 claims description 4
- 230000005288 electromagnetic effect Effects 0.000 claims description 4
- 239000000565 sealant Substances 0.000 claims description 3
- 238000004804 winding Methods 0.000 claims description 3
- 239000002131 composite material Substances 0.000 claims description 2
- 230000000694 effects Effects 0.000 abstract description 4
- 238000010586 diagram Methods 0.000 description 11
- 238000005520 cutting process Methods 0.000 description 10
- 238000000465 moulding Methods 0.000 description 5
- 239000000243 solution Substances 0.000 description 4
- 239000003292 glue Substances 0.000 description 3
- 238000007789 sealing Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 238000004382 potting Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000000275 quality assurance Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000002194 synthesizing effect Effects 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
- H01R12/70—Coupling devices
- H01R12/71—Coupling devices for rigid printing circuits or like structures
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
- H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
- H01R13/5216—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases characterised by the sealing material, e.g. gels or resins
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
- H01R13/5219—Sealing means between coupling parts, e.g. interfacial seal
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
Abstract
The invention discloses a DCDC high-voltage converter, which relates to the technical field of DCDC converters and comprises a shell, a lead frame and a U/V/W phase bus, wherein the lead frame specifically comprises a signal terminal and a power terminal, a main board is fixedly arranged on the shell, a hole metal needle and a central processing unit are arranged in the shell, the main board is communicated with the hole metal needle, and the U/V/W phase bus comprises a 48V connector, a GND connector, a 12V connector and an electromagnetic compatibility capacitor pin. In the invention, the hole metal needles in the lead frame area are cut off after pre-injection molding, so that the efficiency of the contact pins is improved, the product quality is stable, the manufacturing cost of the product is reduced, the cost advantages are obvious during stamping, electroplating and embedded injection molding, the needles formed by two side by side are assembled into a whole in the pre-injection molding mode, the integrated forming process of upper and lower needle arrangement is realized, and the product quality and the size are stable; can avoid staff to take single needle for injection molding, has lower efficiency, is suitable for more and complex needle arrangement, and has high productivity and obvious effect.
Description
Technical Field
The invention relates to the technical field of DCDC converters, in particular to a DCDC high-voltage converter and a manufacturing process thereof.
Background
The DCDC converter is the core of a modern electronic power supply, and provides conversion from one voltage electric frequency to a plurality of other voltage electric frequencies, and the control converter which has the advantages of simple structure, complete functions, high output precision and low power consumption is higher and higher in manufacturing precision; a signal terminal, a power Can line terminal and the like, and two areas of U/V/W high-voltage Basbar are arranged; the U/V/W high-voltage Basbar is used as a conduction component of the whole converter, and is formed by synthesizing electromagnetic effect by high-performance copper alloy materials and magnetic coils, so that the electrical connection between the lead-out end of the internal circuit of the chip and the outer lead is realized, a key structural member of an electrical loop is formed, and the bridge connected with an external lead is realized; the bus bar (laminated bus bar is also called as a composite bus bar, a laminated bus bar, a bus bar and a bus bar) is used for replacing the traditional copper bar and lead wires and realizing high-efficiency low-loss current conduction and current division.
At present, most DCDC converter control systems used in the automobile industry are stamping, electroplating, injection molding and assembling, and in the injection molding process, the metal parts are more complicated in process, the processing production cost is high, the size and position degree are poor, and the production stability is poor; the main purpose is to be used as an electrical connection or transmission signal; in the prior art, because the proportion of the metal needles relative to the whole injection molding product is large and the metal needles are distributed more, the production efficiency of the pin assembly is low, the reject ratio in mass production is high, and the position degree requirement cannot be met; the U/V/W high-voltage phase bus bar material is thick and wide, the metal pins in the signal pin area are widely distributed, the space is small, the forming thickness is thin, and the glue feeding forming is difficult.
Disclosure of Invention
The invention aims at: in order to solve the problems of difficult thin forming processing and high reject ratio of a plurality of metal parts, the DCDC high-voltage converter and the manufacturing process thereof are provided.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
the utility model provides a DCDC high voltage converter, includes casing, lead frame and U/V/W phase busbar (laminated busbar), and lead frame and U/V/W phase busbar are all installed inside the casing, and wherein lead frame specifically includes signal terminal and power supply terminal, signal terminal and power supply terminal specifically are cave mouth metallic needle, still fixed mounting has the mainboard on the casing, the inside cave mouth metallic needle and the central processing unit of being equipped with of casing, the mainboard switches on with cave mouth metallic needle, and wherein U/V/W phase busbar specifically includes 48V connector, GND connector, 12V connector and electromagnetic compatibility condenser pin.
As a further description of the above technical solution:
the shell is specifically made of plastic materials, sealing glue is further injected on the surface of the shell, the distance between the signal terminal and the power terminal is 2.54mm, the signal terminal and the power terminal are arranged side by side up and down, 4 signal terminals and 4 power terminals are respectively arranged, and the U/V/W phase bar is specifically made of high-performance copper alloy materials and is in electromagnetic effect synthesized by magnetic rings.
A manufacturing process of a DCDC high-voltage converter specifically comprises the following steps:
s1: lead frame: firstly stamping a lead frame into a coil mode, then electroplating the lead frame, then conducting secondary stamping, stamping into parallel metal needles with continuous materials, and then conducting pre-injection molding treatment on the lead frame, wherein the pre-injection molding is conducted in a disposable contact pin injection molding mode, then conducting cutting treatment on the continuous material position of the lead frame after injection molding, conducting clockwise winding after electroplating of the lead frame, and guaranteeing that burrs face downwards and face a coil core S2:48V connector: firstly punching into parts, then assembling riveting bolts and bushings, and then punching injection molding process holes of finished products;
s2:48V connector: firstly punching into parts, then assembling riveting bolts and bushings, and then punching injection molding process holes of finished products;
s3: GND connector: firstly punching into parts, then assembling riveting bolts, then punching injection molding process holes of finished products, and finally performing pre-injection molding treatment;
s4: the 12V connector is punched into parts, then the riveting bolts and the bushings are assembled, and finally punching holes is performed;
s5: the electromagnetic compatible capacitor pin is punched firstly, then is subjected to electroplating treatment, and finally is punched secondarily into a required shape;
s6: placing the laminated busbar, the hole metal needle and the components into an injection mold together for injection molding to complete injection molding of the parts, and then performing ultraviolet curing by dispensing and assembling the magnetic ring to basically complete the finished product;
as a further description of the above technical solution:
after the signal terminal, the power terminal and the U/V/W phase bus are processed, the U/V/W phase bus, the signal terminal and the power terminal assembly are put into a die together for high-pressure injection molding.
As a further description of the above technical solution:
the magnet ring assembly adopts automatic line positioning to assemble the clamping position in the design structure of the converter, finally, the magnet ring assembly is assembled and fixed by a manipulator, and then the magnet ring assembly enters a tunnel oven for curing, wherein the temperature of the tunnel oven is set to be 150 ℃, and the curing connection between the magnet ring and the converter lasts for 15 minutes.
In summary, due to the adoption of the technical scheme, the beneficial effects of the invention are as follows:
in the invention, the hole metal needle in the lead frame area adopts a cutting mode after pre-injection molding, so that the efficiency of the contact pin is greatly improved, the product quality is stable, the manufacturing cost of the product is reduced, the cost advantages are obvious during stamping, electroplating and embedding injection molding, and the molding period can be greatly shortened; in the scheme, the needles formed by two side by side are assembled into a whole in a pre-injection mode, so that an upper needle arranging and lower needle arranging integrated forming process is realized, and the product quality and the size are stable; through the process, six needle bars can be integrally formed, staff is prevented from taking single needles for injection molding, the efficiency is low, the process is suitable for multiple and complex needle bars, the productivity is high, and the effect is obvious.
Drawings
Fig. 1 shows a schematic diagram of a leadframe stamping structure provided in accordance with the present invention;
fig. 2 shows a schematic view of a leadframe plating structure provided in accordance with the present invention;
fig. 3 shows a schematic diagram of a secondary stamping structure of a lead frame provided according to the present invention;
fig. 4 shows a schematic diagram of a pre-injection structure of a lead frame provided according to the present invention;
fig. 5 shows a schematic diagram of a lead frame connection cutting structure provided according to the present invention;
FIG. 6 shows a schematic view of a 48V connector assembly provided in accordance with the present invention;
FIG. 7 shows a schematic diagram of a 48V connector staking structure provided in accordance with the present invention;
FIG. 8 illustrates a schematic diagram of a 48V connector die-cut structure provided in accordance with the present invention;
fig. 9 shows a schematic diagram of GND connector parts provided according to the present invention;
fig. 10 shows a schematic diagram of a GND connector riveted structure provided according to the present invention;
fig. 11 shows a schematic diagram of a GND connector punching structure provided according to the present invention;
fig. 12 shows a schematic diagram of a GND connector pre-injection structure provided according to the present invention;
FIG. 13 shows a schematic view of a 12V connector assembly provided in accordance with the present invention;
FIG. 14 shows a schematic illustration of a 12V connector staking structure provided in accordance with the present invention;
FIG. 15 illustrates a 12V connector die-cut structure schematic provided in accordance with the present invention;
FIG. 16 shows a schematic view of the external structure of a housing provided in accordance with the present invention;
fig. 17 shows a schematic view of a dispensing and potting structure for a housing provided in accordance with the present invention;
FIG. 18 illustrates a schematic side view of FIG. 17 provided in accordance with the present invention;
FIG. 19 shows a schematic view of the external structure of a laminated busbar provided according to the present invention;
fig. 20 shows a schematic view of the external structure of a lead frame provided according to the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 19-20, the present invention provides a technical solution: the DCDC high-voltage converter comprises a shell, a lead frame and a U/V/W phase busbar (laminated busbar), wherein the lead frame and the U/V/W phase busbar are both arranged inside the shell, the lead frame particularly comprises a signal terminal and a power terminal, the signal terminal and the power terminal are particularly pocket metal pins, a main board is fixedly arranged on the shell, the pocket metal pins and a central processing unit are arranged inside the shell, the main board is communicated with the pocket metal pins, and the U/V/W phase busbar particularly comprises a 48V connector, a GND connector, a 12V connector and electromagnetic compatibility capacitor pins;
the shell is made of plastic material, the surface of the shell is also injection-molded with sealant, the interval between the signal terminal and the power terminal is 2.54mm, the signal terminal and the power terminal are arranged up and down side by side, 4 signal terminals and 4 power terminals are respectively arranged, the U/V/W phase bus is made of high-performance copper alloy material and magnetic ring to synthesize electromagnetic effect,
a manufacturing process of a DCDC high-voltage converter specifically comprises the following steps:
s1: lead frame: firstly stamping a lead frame into a coil material mode, then electroplating the lead frame, then conducting secondary stamping, stamping into parallel metal needles with continuous material, and then conducting pre-injection molding on the lead frame, wherein the pre-injection molding is conducted in a disposable contact pin injection molding mode, then conducting cutting-off treatment on the continuous material position of the lead frame after injection molding, conducting clockwise winding after electroplating of the lead frame, and guaranteeing that burrs face downwards to face a coil core;
the manufacturing design of the lead frame is a mode of pre-injection molding and fixing hole metal needles, and electroplating arrangement is carried out in a stamping material belt mode; cutting into a row of metal needles for connecting materials; then carrying out product structural design on the pre-injection molding, wherein the structural requirement is mainly that the relative positions of the whole row of metal needles are ensured not to be deformed in the production process and the injection molding process, and the injection molding positioning structure can be also realized; after pre-injection molding, cutting off the material connecting areas of the metal pins to confirm that the metal pieces cannot be conducted in a short circuit manner; because two rows of metal needles are needed to be designed into two separated rows of pre-injection needles, the two rows of pre-injection needles are combined into a whole after cutting off the material connecting positions, the signal terminals and the power terminals are subjected to injection molding by adopting disposable contact pins and are supplied to the following procedure, and then the two rows of pre-injection needles are cut off and inserted into a mold for injection molding, so that the relative position degree between the terminals is fully ensured, and the molding efficiency is high;
the signal terminals and the power terminals are fed by adopting coiled materials and are designed in an upper row and a lower row, so that after the pre-injection molding, the integration of the terminals is ensured, the consistency among the terminals and the dimensional stability are ensured, errors caused by the multiple contact pins are avoided, and the production yield of products is improved; simultaneously, the integrated punching and bending disassembly ensures the production efficiency
Because the stamping roll-to-roll production is required, the product flattening design is required, the secondary stamping is required to bend and shape the metal needles into a row of metal needles, then the pre-injection molding/cutting/assembling is carried out to meet the requirements of the finished product in the lead frame area, and after the production is carried out, the metal needles are formed into a whole, so that the operation of staff is convenient, and the manufacturing difficulty is reduced;
the metal piece material connection mode is shown in fig. 1, the material connection positions are respectively arranged among the metal needles, and the metal needles of the pre-injection part are required to be buried in plastic at last; and each metal needle is required to reach a certain strength, so that deformation can not occur in the process of carrying and production; the material connecting position is required to be avoided in the pre-injection molding process and cannot be wrapped in plastic, so that the material connecting position is cut off to avoid conduction as shown in fig. 5;
s2:48V connector: firstly punching into parts, then assembling riveting bolts and bushings, and then punching injection molding process holes of finished products; punching to form the required shape of the 48V connector, sequentially riveting the bolt and the bushing together as shown in FIG. 7, and punching holes as shown in FIG. 8;
s3: GND connector: firstly punching into parts, then assembling riveting bolts, then punching injection molding process holes of finished products, and finally performing pre-injection molding treatment; manufacturing the GND connector, namely firstly punching the GND bus into a shape required by the GND bus as shown in fig. 9, sequentially riveting bolts together as shown in fig. 10, punching holes, and performing pre-injection molding as shown in fig. 11;
s4: the 12V connector is punched into parts, then the riveting bolts and the bushings are assembled, and finally punching holes is performed; the 12V connector is shown in FIG. 12, punched into a shape required by a 12V bus, then sequentially riveted together the bolt and the bushing as shown in FIG. 13, and then punched Over moulding process holes as shown in FIG. 14;
the 8 hole metal needles can be integrally formed by arranging the needles up and down, so that the phenomenon that a worker takes single needles for injection molding, the efficiency is low, the strength of the single needles is weak, and the single needles are pinched and deformed to cause a pressing die is avoided. The process is suitable for long, thin, multiple and complex pin header structure, and has high quality assurance efficiency and obvious effect
S5: the electromagnetic compatible capacitor pin is punched firstly, then is subjected to electroplating treatment, and finally is punched secondarily into a required shape;
the pin working procedure of the electromagnetic compatibility capacitor is specifically stamping-electroplating-secondary stamping to form the required shape; the working procedures of the 48V connector, the GND connector and the 12V connector are stamping-electroplating-secondary stamping until the required shape is obtained;
s6: and then placing the laminated busbar, the hole metal needle and the components into an injection mold together for injection molding to complete injection molding of the parts, and finally, performing ultraviolet curing by dispensing and assembling the magnetic ring to basically complete the finished product.
After the signal terminal, the power terminal and the U/V/W phase bus bar are processed, the U/V/W phase bus bar, the signal terminal and the power terminal assembly are put into a mold together for high-pressure injection molding, a high-pressure molding injection molding mode is adopted, gaps and air holes between a metal piece and an injection molding piece can be reduced, and a product hole is sealed by adopting a Mickey diagram and a Wake glue;
the magnet ring assembly adopts automatic line positioning to assemble clamping positions in a converter design structure, finally, the clamping positions are assembled and fixed by a manipulator, and then the clamping positions enter a tunnel oven for curing, wherein the temperature of the tunnel oven is set to be 150 ℃, the curing connection between the magnet ring and the converter lasts for 15 minutes, the leakage current requirement is less than 3mA within 0.28 cubic centimeters under 200mbar +/-10 air pressure, 100% automatic resistance value test is required, and no breakdown is required under 500V +/-50 under 50 Hz;
the sealant in the shell performs area sealing according to the functional requirements of different positions of the product, bonds the magnetic ring, and has good vibration-proof effect and heat dissipation function on the magnetic ring;
through the above manufacturing process flow, the component is basically molded, and then the Busbar (laminated Busbar) is put into an injection mold together with the hole metal needle to be injection molded, so as to complete the injection molding of the component as shown in fig. 16; and then the finished product shown in figure 17 is basically finished through dispensing and ultraviolet curing of the assembled magnetic ring.
Working principle: when the electroplating device is used, each part is sequentially processed, and electroplating arrangement is carried out in a stamping material belt mode; cutting into a row of metal needles for connecting materials; then carrying out product structural design on the pre-injection molding, wherein the structural requirement is mainly that the relative positions of the whole row of metal needles are ensured not to be deformed in the production process and the injection molding process, and the injection molding positioning structure can be also realized; after pre-injection molding, cutting off the material connecting areas of the metal pins to confirm that the metal pieces cannot be conducted in a short circuit manner; because of two rows of metal needles, two rows of separated pre-injection needles are needed to be designed, the two rows of pre-injection needles are combined into a whole after cutting off the material connecting positions, parts are punched, riveting bolts and bushings are assembled, and then finished injection molding process holes are punched; punching to form the required shape of the 48V connector, sequentially riveting the bolt and the bushing together, and punching a hole;
firstly punching into parts, then assembling riveting bolts, then punching injection molding process holes of finished products, and finally performing pre-injection molding treatment; firstly stamping a GND bus into a shape required by the GND bus, sequentially riveting bolts together, punching holes, and performing pre-injection molding; the 12V connector is punched into a shape required by 12Vbus, then a bolt and a bushing are riveted together in sequence, then Over moulding process holes are punched, through the manufacturing process flow, the part is basically molded, and then the bus (laminated Busbar), a hole metal needle and the part are put into an injection mold together for injection molding, so that injection molding of the part is completed; and then the finished product is basically finished by dispensing and assembling the magnetic ring and ultraviolet curing.
The foregoing is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art, who is within the scope of the present invention, should make equivalent substitutions or modifications according to the technical scheme of the present invention and the inventive concept thereof, and should be covered by the scope of the present invention.
Claims (9)
1. The DCDC high-voltage converter is characterized by comprising a shell, a lead frame and a U/V/W phase bus bar (laminated busbar), wherein the lead frame and the U/V/W phase bus bar are both installed inside the shell, the lead frame specifically comprises a signal terminal and a power terminal, the signal terminal and the power terminal specifically are hole metal pins, a main board is fixedly installed on the shell, the hole metal pins and a central processing unit are arranged inside the shell, the main board is communicated with the hole metal pins, and the U/V/W phase bus bar specifically comprises a 48V connector, a GND connector, a 12V connector and electromagnetic compatibility capacitor pins.
2. The DCDC high voltage converter of claim 1, wherein the housing is made of plastic material, and the surface of the housing is further injection molded with sealant.
3. A DCDC high voltage converter according to claim 1, wherein the distance between the signal terminals and the power terminals is 2.54mm, and the signal terminals and the power terminals are arranged side by side up and down, and the signal terminals and the power terminals are respectively provided with 4.
4. The DCDC high voltage converter of claim 1, wherein the U/V/W phase bus is specifically a high performance copper alloy material and a magnetic coil composite electromagnetic effect.
5. A process for manufacturing a DCDC high voltage converter according to claim 1, comprising the steps of:
s1: lead frame: firstly stamping a lead frame into a coil material mode, then electroplating the lead frame, then conducting secondary stamping, stamping into parallel metal needles with continuous material, and then conducting pre-injection molding on the lead frame, wherein the pre-injection molding is conducted in a disposable contact pin injection molding mode, then conducting cutting-off treatment on the continuous material position of the lead frame after injection molding, conducting clockwise winding after electroplating of the lead frame, and guaranteeing that burrs face downwards and face a coil core.
6. The manufacturing process of claim 5, further comprising the steps of:
s2:48V connector: firstly punching into parts, then assembling riveting bolts and bushings, and then punching injection molding process holes of finished products;
s3: GND connector: firstly punching into parts, then assembling riveting bolts, then punching injection molding process holes of finished products, and finally performing pre-injection molding treatment; s4: the 12V connector is punched into parts, then the riveting bolts and the bushings are assembled, and finally punching holes is performed;
s5: the electromagnetic compatible capacitor pin is punched firstly, then is subjected to electroplating treatment, and finally is punched secondarily into a required shape;
s6: and then placing the laminated busbar, the hole metal needle and the components into an injection mold together for injection molding to complete injection molding of the parts, and finally, performing ultraviolet curing by dispensing and assembling the magnetic ring to basically complete the finished product.
7. The manufacturing process according to claim 5, wherein after the signal terminal, the power terminal and the U/V/W phase bus are processed, the U/V/W phase bus is put into a mold together with the signal terminal and the power terminal assembly for high-pressure injection molding.
8. The manufacturing process of claim 5, wherein the magnet assembly is assembled into a fixture in the converter design using an automated line fixture, and finally assembled into a fixture by a robot, and then cured in a tunnel oven.
9. The manufacturing process of claim 8, wherein the tunnel oven temperature is set to 150 ℃ for 15 minutes for the cured connection between the magnet coil and the transducer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310158667.3A CN116315973A (en) | 2023-02-21 | 2023-02-21 | DCDC high-voltage converter and manufacturing process thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310158667.3A CN116315973A (en) | 2023-02-21 | 2023-02-21 | DCDC high-voltage converter and manufacturing process thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN116315973A true CN116315973A (en) | 2023-06-23 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202310158667.3A Pending CN116315973A (en) | 2023-02-21 | 2023-02-21 | DCDC high-voltage converter and manufacturing process thereof |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116759833A (en) * | 2023-08-17 | 2023-09-15 | 宁波精成电机有限公司 | Motor connector, manufacturing method thereof, car window driving motor and car |
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2023
- 2023-02-21 CN CN202310158667.3A patent/CN116315973A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116759833A (en) * | 2023-08-17 | 2023-09-15 | 宁波精成电机有限公司 | Motor connector, manufacturing method thereof, car window driving motor and car |
| CN116759833B (en) * | 2023-08-17 | 2023-12-26 | 宁波精成电机有限公司 | Motor connector, manufacturing method thereof, car window driving motor and car |
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