Electronic brake housing and method of manufacture

Abstract

The application discloses an electronic brake shell and a processing method, and relates to the technical field of electronic brakes, which comprises a plastic shell, a signal terminal, a power terminal and two kinds of sealing glue. The signal terminal and the power terminal are directly injection molded on the plastic shell, and the signal terminal and the power terminal are designed with three different specifications, a total of 38. The plastic shell further comprises a motor phase lead frame and a resolver lead frame, which are installed inside the plastic shell. The plastic shell further comprises a stroke sensor terminal and a grounding terminal. The grounding terminal specifically comprises a mechanical holding terminal and a grounding spring. In the application, the resolver lead frame adopts a pre-injection molding and cutting method, which greatly improves the pin efficiency, stabilizes the product quality, not only meets the production capacity demand of customers, but also reduces the manufacturing cost of products, and has obvious cost advantage in stamping, electroplating and inlay injection molding, and can greatly shorten the molding cycle.

Description

Technical Field

[0001] This invention relates to the field of electronic braking technology, and in particular to an electronic brake housing and its processing method. Background Technology

[0002] An Electronic Braking Housing (ECU housing) is a protective cover and mounting point for printed circuit board (PCB) electronic controllers, coils, sensors, and terminals. The housing is an injection-molded part with integrated compression-limiting bushings and positioning functions for connecting the ECU housing to the Hydraulic Unit (HU), ECU cover, and cover-and-connector (BCC assembly). The ECU housing assembly connects to the HU to ensure proper mating of the hydraulic and electrical connectors during connection. The housing, provided during ECU assembly, prevents debris, dust, liquids, and other objects from degrading the ECU assembly and entering it. The tightly molded ECU housing provides positioning and connection functions for the lead frame structure and terminals.

[0003] Currently, the electronic control units (ECUs) used in new energy vehicles are mostly produced through stamping, electroplating, one-time injection molding, injection molding, hot riveting, welding, and assembly. This process is lengthy, lacks functional integration, has high manufacturing costs, and suffers from poor stability. In existing technologies, the number of metal parts in injection-molded components is large and their distribution is concentrated, leading to low production efficiency, high defect rates in mass production, and inability to meet customer positioning requirements. The Motor Phase LeadFrame and Resolver Lead Frame in the ECU are long and irregularly shaped, making it difficult to guarantee their position after assembly. Furthermore, the CIPG gasket seal on the ECU housing requires precise height and width at each designated location; otherwise, the final product delivered to the customer will fail to meet sealing performance requirements. Summary of the Invention

[0004] The purpose of this invention is to provide an electronic brake housing and its processing method in order to solve the above-mentioned problems.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] An electronic brake housing, characterized in that it comprises a plastic housing, signal terminals, power terminals, and two types of sealant, wherein the signal terminals and power terminals are directly injection molded onto the plastic housing; the signal terminals and power terminals are designed with three different specifications, totaling 38 terminals;

[0007] The plastic housing also includes a motor phase lead frame and a resolver lead frame, which are installed inside the plastic housing. The housing also includes a stroke sensor terminal and a grounding terminal, which specifically includes a mechanical holding terminal and a grounding spring. The resolver lead frame has three bends, which are L-shaped. Two of the bends are inside the plastic housing, and the third bend extends to the outside of the plastic housing.

[0008] A method for manufacturing an electronic brake housing includes the following steps:

[0009] Step 1: The 38 terminals of the signal terminals and power terminals are injection molded using one-time pin injection molding.

[0010] Step 2, the semi-finished forming process of the resolver lead frame in the plastic housing is as follows: metal needle stamping - electroplating - stamping - pre-injection molding - cutting - assembly; the resolver lead frame is designed to fix the metal needles by pre-injection molding. First, the metal needles are arranged by stamping the material strip (including two bends inside the plastic); then the metal needles are arranged by injection molding. Then, the bends extending to the outside of the plastic housing are processed and shaped. Finally, the connecting areas of each metal needle are cut to ensure that each metal part cannot be short-circuited.

[0011] Step 3: The motor phase lead frame adopts the conventional process: stamping-electroplating-stamping-pin injection molding. There are three different terminals injection molded together, so positioning notches need to be punched out at the designated positions when the first stamping is rolled into a roll. Then, different plating types are applied to different areas according to the product's functional requirements. After the second stamping, it is cut into loose parts and then inserted into the mold together. At the same time, the process notches from the first stamping are used for positioning and pre-injection molding.

[0012] Step 4: Based on the deformation of the product after mold flow analysis, different dispensing heights are used in different areas of the sealant to compensate for different deformation amounts.

[0013] Step 5: Assemble the stroke sensor terminals, mechanical holding terminals, grounding spring, and the above-mentioned components together. Finally, apply UV adhesive and weld the breathable membrane to complete the finished product.

[0014] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0015] 1. In this invention, the signal terminals and power terminals are fed from rolls, and 38 terminals are injection molded in one go, which ensures the consistency and dimensional stability between terminals, avoids errors caused by multiple injections, and improves the product yield.

[0016] 2. In this invention, the resolver lead frame adopts a pre-injection molding and then cutting method, which will greatly improve the pin insertion efficiency and ensure stable product quality. It can not only meet the customer's production capacity requirements, but also reduce the product manufacturing cost. Furthermore, it has obvious cost advantages in stamping, electroplating, and inlay injection molding, and can greatly shorten the molding cycle.

[0017] 3. In this invention, a positioning notch is added to the motor phase lead frame during the first stamping production to ensure the stability of the product dimensions after pre-injection molding, and to ensure the relative position on the final product, thereby improving the stability of the product dimensions; the sealant is applied at different heights according to the height differences of different positions on the product to compensate for the height difference, avoiding adjustments on the product, while also meeting the customer's performance requirements and effectively improving the first-pass yield of the product. Attached Figure Description

[0018] Figure 1 This diagram illustrates the structural schematic of step one of the signal terminal and power terminal connection method provided by the present invention;

[0019] Figure 2 This diagram illustrates the second step of the signal terminal and power terminal connection method provided by the present invention.

[0020] Figure 3 This diagram illustrates step three of the connection method between signal terminals and power terminals provided by the present invention.

[0021] Figure 4 A schematic diagram of the electroplating step one of the signal terminals and power terminals provided according to the present invention is shown;

[0022] Figure 5 A schematic diagram of the second electroplating step of the signal terminals and power terminals provided according to the present invention is shown;

[0023] Figure 6 This diagram illustrates the structure of step three in the electroplating process of the signal terminals and power terminals provided by the present invention.

[0024] Figure 7 A schematic diagram of the metal component connection method of the resolver lead frame provided according to the present invention is shown.

[0025] Figure 8 A schematic diagram of the electroplating structure of the resolver lead frame provided according to the present invention is shown.

[0026] Figure 9A schematic diagram of the pre-molded structure of the resolver lead frame provided according to the present invention is shown;

[0027] Figure 10 This diagram illustrates the structure of step one of the process notch arrangement steps for the motor phase lead frame according to the present invention.

[0028] Figure 11 This diagram illustrates the structure of step two in the process notch arrangement of the motor phase lead frame according to the present invention.

[0029] Figure 12 This diagram illustrates the structure of step three in the process notch arrangement of the motor phase lead frame according to the present invention.

[0030] Figure 13 A schematic diagram of the sealant difference compensation parameter structure provided according to the present invention is shown.

[0031] Figure 14 A schematic diagram of the finished product structure provided according to the present invention is shown. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Please see Figure 13 The present invention provides a technical solution: an electronic brake housing, comprising a plastic housing, signal terminals, power terminals, and two types of sealant, wherein the signal terminals and power terminals are directly injection molded onto the plastic housing; the signal terminals and power terminals are designed with three different specifications, totaling 38 terminals;

[0034] The plastic housing also includes a motor phase lead frame and a resolver lead frame, which are installed inside the plastic housing. The plastic housing also includes a stroke sensor terminal and a grounding terminal, which specifically includes a mechanical holding terminal and a grounding spring. The resolver lead frame has three bends, which are L-shaped. Two of the bends are inside the plastic housing, and the third bend extends to the outside of the plastic housing.

[0035] The processing method for the electronic brake housing includes the following steps:

[0036] Step 1: Signal terminals and power terminals are injection molded using disposable pins. The roll of material is supplied to the next process, then cut and inserted into the mold for injection molding. This fully ensures the relative position of the terminals, guarantees the consistency and dimensional stability of the terminals, avoids errors caused by multiple insertions, and improves the product yield.

[0037] Signal terminals and power terminals: First, they are stamped into a roll, and then the pins are arranged as follows. Figure 1-3 The design incorporates various plating types for different areas of the terminals, tailored to the product's function, and includes the design of the tape roll (e.g., ...). Figures 1-3 After designing the roll, the electroplating inlet and outlet methods need to be confirmed (e.g., ...). Figures 4-6 The discharge method determines the feeding method of the subsequent cutting mold. An incorrect discharge method will cause the strip to fail to enter the mold synchronously for cutting and forming. After electroplating, the strip is cut on the automatic line and then inserted into a carrier. Then, a robot arm inserts it into the mold for injection molding.

[0038] Step two, the semi-finished forming process of the resolver lead frame in the plastic housing is as follows: metal needle stamping - electroplating - stamping - pre-injection molding - cutting - assembly; the resolver lead frame is designed to use pre-injection molding to fix the metal needles. First, the metal needles are arranged by stamping the material strip (including two bends inside the plastic); then they are arranged by injection molding, and then bent and cut into individual semi-finished components; the main requirement of this structure is to ensure that the relative position of the entire terminal assembly does not change during the production process and injection molding, and it can also serve as an injection molding positioning structure; after pre-injection molding, the bends extending to the outside of the plastic housing are first processed and shaped, and then the connecting areas of each metal needle are cut to ensure that each metal part cannot be short-circuited and conduction is achieved;

[0039] The resolver lead frame takes into account that the two bends need to be enclosed in plastic. Therefore, during the first stamping, these two bends need to be formed first, while reserving sufficient connecting material, such as... Figure 7 As shown, the manufacturing process of this component is: one-time stamping - electroplating (e.g.) Figure 8 - Pre-injection molding (e.g.) Figure 9 - Secondary stamping: During the secondary stamping process, the remaining part is bent and shaped, and finally cut into a semi-finished product, which is then packaged and transferred to the next process.

[0040] Step 3: The motor phase lead frame uses a conventional process: stamping-electroplating-stamping-pin injection molding; since three different terminals are injection molded together, positioning notches need to be punched out at designated locations during the first stamping into a roll (e.g., Figure 10 Then, depending on the product's functional requirements, different plating types are applied to different areas. After a second stamping process, the parts are cut into individual components and then inserted into the mold together. Simultaneously, the process gap from the first stamping is used for positioning and pre-injection molding (e.g., Figures 11-12This process, using notch positioning during pre-injection molding, ensures the accuracy of the product's position after injection molding.

[0041] Step four: Based on the deformation of the product after mold flow analysis, different dispensing heights are used in different areas of the sealant to compensate for varying deformation amounts and ensure the final sealing effect of the entire product's sealing area. The sealant requires prior surface scanning analysis of the actual product, combined with mold flow analysis to determine the differences in shrinkage and deformation in different areas of the product, and the data on these differences is compiled. Finally, when designing CIPG dispensing parameters, the differences are compensated based on the summarized data (e.g., ...). Figure 13 ).

[0042] Step five, then assemble the stroke sensor terminals, mechanical holding terminals, grounding spring, and the above components together. Finally, apply UV adhesive and weld the breathable membrane to complete the entire finished product (e.g., Figure 14 ).

[0043] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for processing an electronic brake housing, characterized in that, The electronic brake housing includes a plastic housing, signal terminals, power terminals, and two types of sealant. The signal terminals and power terminals are directly injection molded onto the plastic housing. The signal terminals and power terminals are designed in three different specifications, totaling 38 terminals. The plastic housing also includes a motor phase lead frame and a resolver lead frame, which are installed inside the plastic housing. The plastic housing also includes a stroke sensor terminal and a grounding terminal, specifically including a mechanical holding terminal and a grounding spring. The processing method includes the following steps: Step 1: The 38 terminals of the signal terminals and power terminals are injection molded using one-time pin injection molding. Step 2, the semi-finished product forming process of the resolver lead frame in the plastic shell is as follows: metal needle stamping - electroplating - stamping - pre-injection molding - cutting - assembly; the resolver lead frame adopts the method of pre-injection molding to fix the metal needles, firstly by stamping the material strip; then by injection molding, then first bending and forming the extension outside the plastic shell, and then cutting the connecting area of ​​each metal needle to ensure that each metal part cannot be short-circuited and conduction. Step 3, the process used for the motor phase lead frame: stamping-electroplating-stamping-pin injection molding; three different terminals are injection molded together, including signal terminals, power terminals and ground terminals, so positioning notches need to be punched out at designated positions when the first stamping is rolled into a roll, and then different plating types are applied to different areas according to the product's functional requirements. After the second stamping, the parts are cut into individual pieces and then inserted into the mold together. At the same time, the process notches from the first stamping are used for positioning and pre-injection molding. Step 4: Based on the deformation of the product after mold flow analysis, different dispensing heights are used in different areas of the sealant to compensate for different deformation amounts. Step 5: Assemble the stroke sensor terminals, mechanical holding terminals, grounding spring, resolver lead frame in the plastic housing, and motor phase lead frame together. Finally, apply UV adhesive and weld the breathable membrane to complete the finished product.

2. The processing method of an electronic brake housing according to claim 1, characterized in that, The resolver lead frame has three bends, and the bends are L-shaped.

3. The processing method of an electronic brake housing according to claim 2, characterized in that, Two of the bends are inside the plastic housing, and the other bend extends to the outside of the plastic housing.

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