A sealed housing for an electric vehicle controller

Abstract

This utility model discloses a sealed housing for an electric vehicle controller, belonging to the field of controller technology. It includes a heat sink, end caps, an extension cylinder, and a clamping member. The heat sink is hollow inside, with open ends. A front end cap and a rear end cap are respectively sealed and installed at the front and rear ends of the heat sink. The front end cap has a cable outlet hole. The extension cylinder is sealed and installed in the cable outlet hole of the front end cap. The clamping member is used to fix the wire harness passing through the cable outlet hole. The heat sink's front and rear ends are sealed by the front and rear end caps, forming a seal at both ends. The cable outlet hole on the front end cap is sealed to the extension cylinder by a first sealing ring. The inner side of the extension cylinder is designed with a clamping member, which allows the annular body to cooperate with the plug to clamp the wire harness. Sealant is poured into the potting groove to achieve a seal between the wire harness and the inner wall of the extension cylinder, ultimately achieving an overall seal for the electric vehicle controller, effectively preventing external moisture and dust from entering the electric vehicle controller through gaps.

Description

Technical Field

[0001] This utility model relates to the field of controller technology, specifically to a sealed housing for an electric vehicle controller. Background Technology

[0002] As the core control component of an electric vehicle, the reliability of the controller directly affects the overall performance and safety of the vehicle. Depending on the installation location and usage scenario, some electric vehicle controller models require good sealing to withstand complex environments such as humidity, dust, and severe vibration. Electric vehicle controller housings are generally made of die-cast aluminum alloy and sealed with front and rear covers. A single rubber sealing ring is typically used at the cable outlet of the end cover, relying on the axial compression of the rubber ring by a tightening nut to radially deform and hold the wiring harness. This method is sensitive to the dimensional tolerances of the wiring harness; too loose and the seal is poor, too tight and the insulation layer is easily damaged. After long-term use, the rubber is prone to aging, cracking, and loss of elasticity, reducing sealing reliability, and making it difficult to evenly and reliably hold multiple strands of wire. Overall potting completely fills the entire internal circuit board and wiring harness connections of the controller with epoxy resin or other potting compounds. While this sealing method provides good sealing, it leads to poor heat dissipation and extremely poor maintainability. Utility Model Content

[0003] In view of the above-mentioned technical deficiencies, the purpose of this utility model is to provide a sealed housing for an electric vehicle controller, which can seal the front and rear ends of the heat sink and the wiring hole.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: The present invention provides a sealed housing for an electric vehicle controller, comprising:

[0005] A heat dissipation shell, wherein the heat dissipation shell is hollow inside and open at both the front and rear ends;

[0006] The front cover and the rear cover are respectively sealed and installed at the front and rear ends of the heat sink, and the front cover is provided with a cable outlet hole;

[0007] An extension tube is sealed and installed in the outlet hole of the front end cover;

[0008] A clamping member is provided inside the extension tube to fix the wire harness passing through the outlet hole. The clamping member is provided with a glue-filling groove, and the extension tube is provided with a glue-filling hole that cooperates with the glue-filling groove.

[0009] Preferably, the extension tube is inserted into the outlet hole, and an external protruding ring is provided at one end of the extension tube located inside the heat sink housing. A threaded limiting sleeve is fitted on the extension tube on the side of the front end cover away from the heat sink housing, and a first sealing ring is fitted on the extension tube between the limiting sleeve and the front end cover.

[0010] Preferably, an inner protruding ring is provided on the inner sidewall of the end of the extension cylinder near the outer protruding ring, and the abutting member includes:

[0011] An annular body, one end of which abuts against an inner convex ring, and a plurality of first grooves are provided on the inner side of the annular body;

[0012] A plug is located on the side of the annular body away from the inner convex ring. Multiple second grooves are provided on the outer side of the plug, and the glue-filling groove is located in the middle of the plug.

[0013] After the wire harness passes through the first wire groove, the second wire groove and the glue-filling groove in sequence, it extends out from the end of the extension tube away from the outer convex ring.

[0014] Preferably, the annular body has a conical transition portion at one end near the block, and the block has a conical portion at one end near the annular body that cooperates with the conical transition portion.

[0015] Preferably, a fastening sleeve is threaded onto the end of the extension tube away from the front end cover, and an inner abutment ring is fixed to the end of the fastening sleeve away from the front end cover and inserted into the extension tube. The inner abutment ring is used to push the block towards the annular body.

[0016] Preferably, an annular folding cap is fixed to the end of the fastening sleeve away from the front end cover, and the inner diameter of the folding cap is smaller than the inner diameter of the inner abutment ring.

[0017] Preferably, the front cover and the rear cover are fixed to the front and rear ends of the heat sink shell by bolts, and a sealing gasket is provided between the front cover and the rear cover and the heat sink shell.

[0018] Preferably, a second sealing ring is fitted onto the bolt, the second sealing ring being used to seal the bolt hole opened on the front end cover or the rear end cover.

[0019] Preferably, both the front cover and the rear cover are provided with steps protruding into the heat sink housing, and the steps are inserted into the inside of the heat sink housing; the sealing gasket is fitted onto the steps.

[0020] Preferably, the heat sink has multiple heat dissipation grooves.

[0021] The beneficial effects of this utility model are as follows:

[0022] The heat sink of this utility model is sealed at both ends by a front cover and a rear cover, respectively. The steps of the front cover and the rear cover are inserted into the inside of the heat sink and a sealing gasket is installed to form a seal at both ends of the heat sink, effectively preventing external moisture and dust from entering from the interface gaps. The cable outlet on the front cover is sealed with the extension tube by a first sealing ring. The inside of the extension tube is designed with a clamping member so that the annular body and the plug can cooperate to clamp the wire harness. The glue filling groove is filled with sealant to achieve a seal between the wire harness and the inner wall of the extension tube, and finally achieves the overall sealing of the electric vehicle controller, effectively preventing external moisture and dust from entering the electric vehicle controller from the gaps.

[0023] This invention features a first groove on a ring-shaped body and a second groove on a plug. The wire harness passes through the first and second grooves in sequence. Simultaneously, the conical transition portion of the ring-shaped body matches the conical portion of the plug, generating a radial contraction force under pressure to further tighten the cable and firmly fix the wire harness. During the glue-filling process, glue enters between the wire harness and the second groove. Due to the small gap between the second groove and the wire harness, glue overflow is effectively prevented, reducing the amount of glue used. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a perspective view of the overall structure of a sealed housing for an electric vehicle controller, provided as an embodiment of the present invention.

[0026] Figure 2 This is a top view of the present invention.

[0027] Figure 3 for Figure 2 Sectional view at point AA.

[0028] Figure 4 for Figure 3 A magnified view of a portion of point A in the middle.

[0029] Figure 5 for Figure 2 Sectional view at point BB.

[0030] Figure 6 This is a perspective view of the front end cap, extension cylinder, and clamping member in this utility model.

[0031] Figure 7 This is a three-dimensional view of the annular body in this utility model.

[0032] Explanation of reference numerals in the attached figures:

[0033] 1. Heat sink housing; 2. Front end cover; 3. Rear end cover; 4. Extension tube; 5. Glue filling groove; 6. Glue filling hole; 7. Outer convex ring; 8. Limiting sleeve; 9. First sealing ring; 10. Inner convex ring; 11. Annular body; 12. First groove; 13. Block; 14. Second groove; 15. Conical transition part; 16. Conical part; 17. Fastening sleeve; 18. Inner abutment ring; 19. Closing cover; 20. Sealing gasket; 21. Second sealing ring; 22. Step; 23. Heat dissipation groove. Detailed Implementation

[0034] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0035] Example 1

[0036] like Figures 1 to 7 As shown, Embodiment 1 of this utility model provides a sealed housing for an electric vehicle controller, including a heat dissipation shell 1, a front cover 2, a rear cover 3, an extension cylinder 4, and a clamping member. The heat dissipation shell 1 is generally rectangular in shape, and its interior forms a cavity for accommodating electronic components such as the controller circuit board. Both the front and rear ends of the heat dissipation shell 1 are open structures. To enhance the heat dissipation effect, multiple heat dissipation grooves 23 are formed on the outer surface of the heat dissipation shell 1 along its length. These heat dissipation grooves 23 increase the heat dissipation surface area, which is beneficial for the heat generated by the controller to dissipate into the surrounding air.

[0037] The front cover 2 is used to seal the front opening of the heat sink 1. The main body shape of the front cover 2 matches the front opening of the heat sink 1, and a step 22 protruding into the heat sink 1 is provided on the side facing the interior of the heat sink 1. The outer contour of the step 22 is slightly smaller than the contour of the front opening of the heat sink 1, so that the step 22 can be inserted into the interior of the heat sink 1. During installation, an annular sealing gasket 20 is fitted onto the step 22. The front cover 2 is fastened to the front face of the heat sink 1 by multiple bolts. The bolts pass through bolt holes on the front cover 2 and are screwed into the corresponding threaded holes at the front of the heat sink 1. To ensure the sealing of the bolt connection and prevent moisture or dust from seeping in along the bolt holes, a second sealing ring 21 (e.g., an O-ring) is fitted on each bolt, between the bolt head and the outer surface of the front cover 2. When the bolt is tightened, the second sealing ring 21 is compressed, effectively sealing the bolt hole. A cable exit hole for the wire harness to pass through is provided in the central area of ​​the front cover 2. The bottom of the front cover 2 is fixed with an ear plate, and the ear plate has a long slot hole to facilitate fixing the front cover 2 to the electric vehicle.

[0038] The rear end cover 3 is used to seal the rear opening of the heat sink 1. The structure and installation method of the rear end cover 3 are similar to those of the front end cover 2. It also has a step 22 protruding into the heat sink 1, and a sealing gasket 20 is fitted on the step 22. The rear end cover 3 is also fastened to the rear end face of the heat sink 1 by multiple bolts, and a second sealing ring 21 is fitted on each bolt to seal the bolt hole.

[0039] The extension tube 4 is used to seal the cable outlet of the front cover 2 and provide a passage for the wire harness. The extension tube 4 is inserted into the cable outlet of the front cover 2. One end of the extension tube 4 located inside the heat sink 1 has an outwardly protruding radially projecting outer ring 7. A limiting sleeve 8 with a threaded fit is fitted on the portion of the extension tube 4 located outside the heat sink 1. A first sealing ring 9 (e.g., an O-ring) is fitted on the extension tube 4 between the limiting sleeve 8 and the outer surface of the front cover 2. When the limiting sleeve 8 is tightened on the extension tube 4, it pushes the first sealing ring 9 towards the heat sink 1, pressing it tightly against the outer surface of the front cover 2, thereby achieving radial and end-face sealing between the extension tube 4 and the cable outlet of the front cover 2.

[0040] The clamping element is located inside the extension tube 4, and its main function is to fix the wire harness passing through the outlet hole and provide space for glue filling and sealing. An inwardly protruding inner ring 10 is provided on the inner sidewall of the extension tube 4 near its outer ring 7. The clamping element includes an annular body 11 and a plug 13. The annular body 11 is located inside the extension tube 4, with its end near the outer ring 7 abutting against the inner ring 10 of the extension tube 4. Multiple first wire grooves 12 are circumferentially formed on the inner sidewall of the annular body 11 to accommodate and initially position the wire harness. The plug 13 is located on the side of the annular body 11 away from the inner ring 10. Multiple second wire grooves 14 are circumferentially formed on the outer sidewall of the plug 13, their number and position corresponding to the first wire grooves 12. A ring of glue filling groove 5 is formed on the central circumferential surface of the plug 13. During installation, the wiring harness led out from the controller passes sequentially through the first wire groove 12 of the annular body 11, the second wire groove 14 of the block 13, and the glue-filling groove 5 of the block 13, and finally extends out of the housing from the end of the extension tube 4 away from the outer convex ring 7.

[0041] A fastening sleeve 17 is threaded onto the end of the extension tube 4 furthest from the front end cover 2. An inner abutment ring 18 is fixed to the end of the fastening sleeve 17 furthest from the front end cover 2. When the fastening sleeve 17 is tightened onto the outer surface of the extension tube 4, the inner abutment ring 18 pushes the plug 13 towards the heat sink 1 (i.e., inwards) from inside the extension tube 4. The plug 13, under this pushing force, presses against the annular body 11. Under the fastening action of the fastening sleeve 17, the plug 13 and the annular body 11 work together to clamp and fix the wire harness passing between them.

[0042] An injection hole 6 is provided on the wall of the extension tube 4, and the position of the injection hole 6 corresponds to the injection groove 5 on the plug block 13. During the injection operation, sealant (such as epoxy resin or silicone rubber) is injected into the injection groove 5 of the plug block 13 through the injection hole 6 on the extension tube 4, filling the gaps between the wire harness and the inner wall of the injection groove 5, as well as the gaps between the wire harnesses. After the sealant cures, a reliable seal is achieved between the wire harness and the inner wall of the extension tube 4, preventing moisture and dust from entering the controller through the gap between the wire harness and the housing.

[0043] Example 2

[0044] Based on Embodiment 1, Embodiment 2 optimizes the structure of the clamping member to enhance the wire harness fixing and sealing effect. A tapered transition portion 15 is designed at the end of the annular body 11 near the plug 13 (i.e., the end away from the inner convex ring 10). The outer diameter of the tapered transition portion 15 remains constant, while the inner diameter gradually increases from the end near the inner convex ring 10 towards the plug 13 (i.e., an inner tapered surface). Correspondingly, the end of the plug 13 near the annular body 11 is provided with a tapered portion 16 that matches the tapered transition portion 15 of the annular body 11. The outer diameter of the tapered portion 16 gradually increases from the end near the annular body 11 towards the end away from the annular body 11 (i.e., an outer tapered surface).

[0045] During the installation and tightening of the wire harness, the wire harness first passes through the first groove 12 of the annular body 11, and then through the second groove 14 and the glue-filling groove 5 of the plug 13. When the fastening sleeve 17 is tightened, its inner abutment ring 18 pushes the plug 13 towards the annular body 11. Since the conical portion 16 of the plug 13 and the conical transition portion 15 of the annular body 11 cooperate with each other, the movement of the plug 13 towards the annular body 11 forces the conical transition portion 15 of the annular body 11 (due to its limited outer space) to generate a radially inward contraction force. At the same time, the plug 13 itself may also be subject to a certain radial constraint. This conical surface fit design allows the annular body 11 and the plug 13 to generate a stronger radial clamping force on the wire harness passing between them when axially compressed, thereby more firmly fixing the wire harness and reducing the shaking of the wire harness in a vibration environment.

[0046] like Figure 4 As shown, since there are second grooves 14 at both ends of the glue-filling tank 5, when glue is poured into the glue-filling tank 5, the glue will naturally flow into and fill the glue-filling tank 5 and the tiny gaps between the wire harness and the second grooves 14. Because the gaps are small, the glue is less likely to overflow from the glue-filling tank 5 into the second grooves 14 at both ends. This not only improves the reliability of the seal but also reduces the amount of sealant used.

[0047] Example 3

[0048] Based on Embodiment 1 or Embodiment 2, this embodiment optimizes the design of the wire harness outlet on the outside of the extension tube 4 to provide additional wire harness protection and sealing.

[0049] like Figure 4 As shown, an annular retractable cover 19 is fixedly connected to the end of the fastening sleeve 17 away from the front end cover 2 (i.e., the outermost end). The inner diameter of the retractable cover 19 is smaller than the inner diameter of the inner abutment ring 18 inside the fastening sleeve 17. When the wire harness passes through the second wire groove 14 and the inner abutment ring 18, it will enter and pass through the center hole of this retractable cover 19.

[0050] The smaller inner diameter of the folding cover 19 can gather and guide multiple wire harnesses, ensuring that the wire harnesses remain in a relatively neat bundle after leaving the housing, preventing them from becoming scattered and facilitating subsequent installation and protection.

[0051] Obviously, those skilled in the art can make various modifications and variations to this utility model without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this utility model and their equivalents, this utility model also intends to include these modifications and variations.

Claims

1. An electric vehicle controller sealed housing, characterized by, include: A heat dissipation shell, wherein the heat dissipation shell is hollow inside and open at both the front and rear ends; The front cover and the rear cover are respectively sealed and installed at the front and rear ends of the heat sink, and the front cover is provided with a cable outlet hole; An extension tube is sealed and installed in the outlet hole of the front end cover; A clamping member is provided inside the extension tube to fix the wire harness passing through the outlet hole. The clamping member is provided with a glue-filling groove, and the extension tube is provided with a glue-filling hole that cooperates with the glue-filling groove.

2. An electric vehicle controller sealed housing as claimed in claim 1, wherein, The extension tube is inserted into the outlet hole. One end of the extension tube located inside the heat sink is provided with an external protruding ring. A threaded limiting sleeve is fitted on the extension tube on the side of the front end cover away from the heat sink. A first sealing ring is fitted on the extension tube between the limiting sleeve and the front end cover.

3. An electric vehicle controller sealed housing as claimed in claim 1, wherein, An inner protruding ring is provided on the inner sidewall of the end of the extension cylinder near the outer protruding ring, and the abutting member includes: An annular body, one end of which abuts against an inner convex ring, and a plurality of first grooves are provided on the inner side of the annular body; A plug is located on the side of the annular body away from the inner convex ring. Multiple second grooves are provided on the outer side of the plug, and the glue-filling groove is located in the middle of the plug. After the wire harness passes through the first wire groove, the second wire groove and the glue-filling groove in sequence, it extends out from the end of the extension tube away from the outer convex ring.

4. An electric vehicle controller sealed housing as claimed in claim 3, wherein, The annular body has a conical transition portion at one end near the block, and the block has a conical portion at one end near the annular body that cooperates with the conical transition portion.

5. An electric vehicle controller sealed housing as claimed in claim 3, wherein, The end of the extension tube away from the front end cover is threaded with a fastening sleeve, and the end of the fastening sleeve away from the front end cover is fixed with an inner abutment ring inserted into the extension tube. The inner abutment ring is used to push the block towards the annular body.

6. An electric vehicle controller sealed housing as claimed in claim 5, wherein, The end of the fastening sleeve furthest from the front end cover is fixed with an annular folding cap, the inner diameter of which is smaller than the inner diameter of the inner abutment ring.

7. An electric vehicle controller sealed housing as claimed in claim 1, wherein, The front cover and the rear cover are fixed to the front and rear ends of the heat sink shell by bolts, respectively, and a sealing gasket is provided between the front cover and the rear cover and the heat sink shell.

8. The sealed housing for an electric vehicle controller as described in claim 7, characterized in that, A second sealing ring is fitted onto the bolt, which is used to seal the bolt hole on the front or rear cover.

9. The sealed housing for an electric vehicle controller as described in claim 7, characterized in that, Both the front and rear covers are provided with steps protruding into the heat sink housing, and the steps are inserted into the inside of the heat sink housing; the sealing gasket is fitted onto the steps.

10. The sealed housing for an electric vehicle controller as described in claim 1, characterized in that, The heat sink has multiple heat dissipation grooves.

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