Manufacturing method of a filter structure

Abstract

Disclosed are a filter structure, a welding fixture, and a manufacturing method of the filter structure. The filter structure includes: a box having a cavity; coil components installed in the cavity; and wiring components, each having a positive wiring pin and a negative wiring pin fixed to the box. The conductive wire has conductive wires coupled to both ends of the coil component and welded with the positive and negative wiring pins respectively. After a wiring section of the pins is embedded into a side of a wire latch slot, the conductive wire of the coil is latched into the wire latch slot and welded with the pins by spot welding without the need of manually winding the conductive wire and the pins, so as to reduce labor, expedite assembling, improve production efficiency and save material cost of the conductive wire.

Claims

1. A manufacturing method of a filter structure, the filter structure comprising: a box, having a cavity; a plurality of coil components, installed in the cavity; and a plurality of wiring components, each having a positive wiring pin and a negative wiring pin fixed to the box; conductive wires coupled to both ends of each coil component being welded and fixed to the positive wiring pin and the negative wiring pin respectively, wherein the manufacturing method comprises the steps of: (A) embedding a plurality of wiring components into both sides of the box respectively; (B) installing a coil component into a chamber of a welding fixture, and latching the conductive wires at both ends of the coil component into a latch slot of the welding fixture tightly; (C) installing a welding fixture to a top of the box, pressing the conductive wire by a protruding portion, so that the conductive wire is contacted with the positive wiring pin or the negative wiring pin; (D) using a spot welding machine to sequentially weld the conductive wire and the positive wiring pin or the negative wiring pin; and (E) packaging the filter structure.

2. The manufacturing method of a filter structure according to claim 1, wherein each of the positive and negative wiring pins has a connecting plate installed at the rear end thereof, and the step D further comprises the steps of: (D1) connecting a negative electric level of the spot welding machine to the connecting plate; (D2) passing a positive electrode of the spot welding machine through the welding slot of the welding fixture and electrically coupled to the conductive wire, so that the spot welding machine can weld and fix the conductive wires at both ends of the coil component with the positive wiring pin and the negative wiring pin respectively; (D3) bending the positive and negative wiring pins of the wiring component downwardly and then bending the positive and negative wiring pins of the wiring component horizontally; and (D4) cutting off the connecting plates at the rear ends of the positive and negative wiring pins respectively.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a top view showing the internal structure of a filter structure of the present invention;

(2) FIG. 2 is a perspective view showing the internal structure of a filter structure of the present invention;

(3) FIG. 3 is a blowup view of Section A of FIG. 2;

(4) FIG. 4 is a perspective view of a positive wiring pin of the present invention;

(5) FIG. 5 is a sectional view of a filter structure of the present invention;

(6) FIG. 6 is a cross-sectional view of a welding fixture situated in a welding status in accordance with the present invention; and

(7) FIG. 7 is a flow chart of a manufacturing method of a filter structure in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(8) The invention discloses a filter structure comprising: a box having a cavity; a plurality of coil components installed in the cavity; and a plurality of wiring components. Each wiring component has a positive wiring pin and a negative wiring pin fixed to the box; wherein the conductive wire has conductive wires coupled to both ends of the coil component and welded and fixed to the positive and negative wiring pins respectively by spot welding or melting.

(9) With reference to FIGS. 1, 2, and 3 for a filter structure 10 in accordance with the present invention, the filter structure 10 comprises a box 1 having a cavity 11, and a coil component 2 and a wiring component 3 installed in the cavity 11. Specifically, there are eight groups of coil components 2, and 24 groups of wiring components 3, and each group of coil components 2 has three conductive wires 22.

(10) The wiring component 3 includes a positive wiring pin 31 and a negative wiring pin 32 fixed to the box 1, and conductive wires 22 at both ends of the coil component 2 fixed to the positive and negative wiring pins 31, 32 respectively by spot welding.

(11) The coil component 2 includes two winding parts serially connected to each other, and the winding part includes a hollow magnetic ring 21, and a conductive wire 22 wound around the magnetic ring 21, wherein the center axis of the magnetic rings 21 of the two coils is configured vertically.

(12) The box 1 has a plurality of wire latch slots 12 arranged equidistantly with one another, wherein the box 1 is made of an insulating plastic material. The positive wiring pin 31 and the negative wiring pin 32 are embedded into the lateral sides of the wire latch slot 12 of the box 1 respectively.

(13) In FIGS. 4 and 5, the positive wiring pin 31 includes a wiring section 311 and a connecting section 312. The positive wiring pin 31 and the negative wiring pin 32 have the same structure. An end of the wiring section 311 is disposed in the wire latch slot 12, and the conductive wire at the input end of the coil component 2 is welded and fixed to the wiring section 311 by spot welding, and the connecting section 312 is extended to the outer side of the box 1.

(14) The box 1 further comprises a wire input slot 12 formed on a side of the cavity 11 and communicated to the wire latch slot 12, and the conductive wire 22 is passed through the wire input slot 13 and extended to and latched tightly with the wire latch slot 12. Before the conductive wires 22 are welded to the positive wiring pin 31 and the negative wiring pin 32, the conductive wire 22 is latched and connected to the wire latch slot 12 to facilitate positioning the conductive wire 22 for future spot welding. During the assembling process, the wire input slot 13 is provide for guiding the conductive wire 22 of the coil component 2 to the wire latch slot 12.

(15) After the wiring section 311 is bent into the hook shape, the head portion of the connecting section 312 is bent obliquely to facilitate embedding the wiring section 311 into the wire latch slot 12 of the box 1. Specifically, the wire latch slots 12 formed on both sides of the box 1 are arranged equidistantly from one another in order to provide a compact structure of the filter structure 10 and facilitate the automated production. Therefore, the head portion of the connecting section 312 is tilted to facilitate installing an end of the wiring section 311 into the wire latch slot 12.

(16) The end of the wiring component 3 has a connecting plate 33 for fixing the positive wiring pin 31. In the production process, the positive wiring pin 31 and the connecting plate 33 are manufactured integrally with each other, and the head portion of the positive wiring pin 31 is bent obliquely and then further bent into a hook shape.

(17) The rear portion of the connecting section 312 is bent downwardly and then horizontally. After the assembling process is completed, the connecting plates 33 at the rear ends of the positive wiring pin 31 and the negative wiring pin 32 are cut off.

(18) With reference to FIG. 6 for a welding fixture 4 in accordance with the present invention, the welding fixture 4 is used for welding the aforementioned filter structure 10. The welding fixture 4 comprises a main body 41. Arranged sequentially from the inside to the outside, the main body 41 comprises a chamber 411, a protruding portion 412, a welding slot 413 for passing an electrode 5 of a spot welding machine, and a latch slot 414. When the conductive wire of the filter structure 10 is welded with the positive wiring pin 31 or the negative wiring pin 32, the coil component 2 is accommodated in the chamber 411, and the conductive wire is passed through the protruding portion 412, and the welding slot 413 is latched into the latch slot 414, and the protruding portion 412 presses the conductive wire 22, so that the conductive wire is contacted with an end of the positive wiring pin 31 or the negative wiring pin 32.

(19) With reference to FIG. 7 for a manufacturing method of a filter structure in accordance with the present invention, the method is used for manufacturing the aforementioned filter structure and comprises the following steps:

(20) A. Embed a plurality of wiring components into both sides of the box respectively.

(21) B. Install a coil component into a chamber of a welding fixture, and latch the conductive wires at both ends of the coil component into a latch slot of the welding fixture tightly.

(22) C. Install the welding fixture to the top of the box, and press the conductive wire by the protruding portion, so that the conductive wire is contacted with the positive wiring pin or the negative wiring pin. Specifically, the protruding portion presses the conductive wire into the wire latch slot of the box.

(23) D. Use a spot welding machine to sequentially weld the conductive wire and the positive wiring pin or the negative wiring pin. Wherein, each of the positive and negative wiring pins has a connecting plate installed at the rear end thereof, and the step D further comprises the following steps:

(24) D1. Connect a negative electric level of the spot welding machine to the connecting plate.

(25) D2. Pass a positive electrode of the spot welding machine through the welding slot of the welding fixture and electrically connect the positive electrode of the spot welding machine to the conductive wire, so that the spot welding machine can weld and fix the conductive wires at both ends of the coil component with the positive and negative wiring pins respectively.

(26) D3. Bend the positive and negative wiring pins of the wiring component downwardly and then horizontally.

(27) D4. Cut off the connecting plates at the rear ends of the positive and negative wiring pins respectively.

(28) E. Package the filter structure.

(29) Before the step A takes place, the manufacturing method further comprises the steps of manufacturing positive and negative wiring pins, and a plastic box with a cavity, wherein the rear end of each of the positive and negative wiring pins has a connecting plate fixed to the positive wiring pin, and bending the head portions of the positive and negative wiring pins obliquely and then further bending the head portions of the positive and negative wiring pins into a hook shape.

(30) While the invention has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the invention set forth in the claims.