Waterproof controller integrated with injection-molded conductive bridge and stretch heat dissipation

Abstract

The application discloses a waterproof controller integrated with injection-molded conductive bridging and tensile heat dissipation, and belongs to the technical field of controllers, which comprises a tensile aluminum waterproof shell, a front cover, a PCBA board, a MOS tube, a rear cover, a compression spring and a screw head. The outer side of the tensile aluminum waterproof shell is provided with heat dissipation fins, and the lower part is tensilely formed into a thick heat dissipation step, one end of which is sealed with the front cover to form a closed space; one end of the leading-out copper sheets of two power supply lines and three phase lines is integrally molded and pressed with the front cover, and the other end is welded to the PCBA board in the closed space; the MOS tube is press-connected to the heat dissipation step through the compression spring; the wire leading-out hole of the front cover is sealed with the wire leading-out hole through the screw head and the conical sealing ring, and the front cover, the rear cover and the aluminum shell are provided with waterproof silica gel rings and waterproof pads and are fixed by bolts. The waterproof controller solves the problems of poor waterproof performance, low heat dissipation and complex structure of the existing controller, improves the waterproof and heat dissipation efficiency, simplifies the structure, reduces the cost, and is suitable for complex working conditions such as humidity and outdoor environment.

Description

Technical Field

[0001] This application relates to the field of controller technology, specifically to an integrated waterproof controller with one-piece injection-molded conductive bridging and stretch heat dissipation. Background Technology

[0002] As the core control unit of various electronic devices, controllers often face complex operating conditions. Therefore, waterproof sealing and efficient heat dissipation are key technical indicators for ensuring long-term stable operation and extending the service life of controllers. Existing controller structures still have many problems that urgently need to be solved regarding waterproofing, heat dissipation, and assembly processes.

[0003] Firstly, in the design of the power cord and phase wire lead-out structure, existing technologies generally adopt a "step-by-step assembly" mode: the power cord, phase wire, and lead-out copper plate are pre-connected, and then the lead-out copper plate is fixed to the controller front cover using bolts, clips, and other connectors. This process not only increases the assembly steps and raises labor and time costs, but more importantly, the connection between the lead-out copper plate and the front cover is prone to gaps due to assembly gaps, loose bolts, or long-term vibration. External moisture can easily seep into the controller through these gaps, leading to short circuits, component corrosion, and other malfunctions, seriously affecting waterproof performance and controller reliability.

[0004] Secondly, in terms of heat dissipation structure design, existing controllers typically employ an "aluminum strip transition" heat dissipation solution for the core heat-generating components, the MOSFET. This involves adding an independent aluminum strip between the MOSFET and the controller's aluminum housing to transfer heat from the MOSFET to the housing. This solution has significant drawbacks: firstly, the addition of the aluminum strip increases the number of components, raising material costs and assembly complexity; secondly, heat must be transferred through three stages: "MOSFET → aluminum strip → aluminum housing," resulting in a long path and gaps at the contact interface due to assembly errors, leading to increased thermal resistance and low heat dissipation efficiency. Especially under high-power conditions, the MOSFET is prone to overheating due to excessive heat accumulation, triggering overheat protection and affecting the normal operation of the controller.

[0005] Thirdly, regarding the waterproofing and securing of the functional leads, existing technologies mostly employ simple sealing ring connections or tape wrapping methods, lacking a reliable locking structure. During long-term use, the sealing rings are prone to aging and deformation, and the tape is prone to falling off due to vibration, temperature cycling, or external pulling forces. This leads to the failure of the waterproofing structure, allowing moisture to seep into the controller along the functional leads, further exacerbating the controller's failure risk.

[0006] In summary, existing controllers have significant shortcomings in terms of waterproof sealing of power lines and phase lines, heat dissipation efficiency of MOSFETs, and waterproof reliability of functional leads. Furthermore, they are complex in structure and expensive, making it difficult to meet the current application requirements of electronic devices for controllers with high integration, high reliability, and low cost. Therefore, developing a new controller that can simultaneously solve the above problems, achieving improved waterproof performance, optimized heat dissipation efficiency, and simplified structure, has significant practical importance and market value. Utility Model Content

[0007] In view of the shortcomings of the existing technology, the purpose of this application is to provide an integrated waterproof controller with integrated injection molding conductive bridging and stretching heat dissipation to solve the problems mentioned in the background art.

[0008] According to one aspect of this application, an integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller includes a stretched aluminum waterproof shell, a front cover, a PCBA board, a MOSFET, a rear cover, a waterproof pad, a compression spring, and a spiral head. Both ends of the stretched aluminum waterproof shell are open, and a plurality of heat dissipation fins are uniformly stretched along its circumference on its outer side wall. One end opening of the stretched aluminum waterproof shell is fixedly and sealed to the front cover to form a closed installation space. One end of the copper leads for two power lines and three phase lines is integrally molded and fixed to the inner side of the front cover. The PCBA board is installed within the closed installation space, and the MOSFET is fixed to the PCBA board. The other ends of the copper leads for the two power lines and three phase lines are soldered to the PCBA board within the closed installation space using copper wire. Two thick heat dissipation steps are integrally formed at the lower part of the stretched aluminum waterproof shell through a stretching process. The PCBA board is disposed between the two thick heat dissipation steps. The MOSFET is pressed against the surface of the thick heat dissipation steps by a compression spring. The rear cover is fixedly and sealed to the other end opening of the stretched aluminum waterproof shell by a waterproof pad.

[0009] Preferably, the front cover has a through-hole for cable exit, a spiral head is fitted at the cable exit, a conical sealing ring is fitted inside the cable exit, the conical sealing ring is threadedly connected to the spiral head, the controller function lead wire passes through the cable exit and the spiral head, and the conical sealing ring is pressed against the outer wall of the function lead wire to form a seal by tightening the spiral head.

[0010] Preferably, annular sealing grooves are provided at the connection surfaces of the front cover and the rear cover with the openings at both ends of the stretched aluminum waterproof shell, and waterproof silicone rings are embedded in the annular sealing grooves.

[0011] Preferably, the front cover and the rear cover are sealed and fixed to the openings at both ends of the stretched aluminum waterproof shell by bolts.

[0012] Preferably, one end of the copper strip leading out of the two power lines and three phase lines is integrally formed with the front cover using a molding press.

[0013] The advantages of this application compared to existing technologies are as follows: This integrated injection-molded conductive bridging and stretching heat dissipation waterproof controller uses a molding press to integrally mold the copper leads of two power lines and three phase lines with the inner side of the front cover. This completely eliminates the gaps caused by bolt connections, assembly gaps, or long-term vibration between the copper leads and the front cover in the traditional "step-by-step assembly" mode, preventing moisture from seeping in from the lead-out parts at the source. Simultaneously, the other end of the copper lead is soldered to the PCBA board with copper wire within the enclosed installation space, completely isolating the solder joint from external moisture and dust environments. This avoids poor circuit contact caused by solder joint corrosion and further enhances the waterproofness and circuit stability of the lead-out structure. Furthermore, by using... The locking sealing structure of "spiral head + conical sealing ring" allows the conical sealing ring to fit tightly against the outer wall of the functional lead by tightening the spiral head, forming an adaptive sealing pressure. Compared with the traditional simple sealing ring sleeve or tape wrapping, it can effectively resist the sealing failure caused by vibration, temperature cycle and external force pulling, ensuring a long-term stable waterproof effect at the functional lead. Two thick heat dissipation steps are integrally formed at the bottom of the waterproof shell through a stretching process, and the MOSFET is pressed against the surface of the thick heat dissipation steps by a compression spring. The elastic force of the compression spring can always maintain a tight contact between the two, eliminating the traditional three-stage heat dissipation path of "MOSFET → aluminum strip → aluminum shell", ensuring that the heat generated by the MOSFET is quickly dissipated, and the heat transfer is more direct and efficient. Attached Figure Description

[0014] Figure 1 This is a perspective view of an integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to an embodiment of this application.

[0015] Figure 2 This is a schematic diagram of the internal structure of an integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to an embodiment of this application.

[0016] Figure 3 This is a perspective view of a stretched aluminum waterproof housing of an integrated injection-molded conductive bridging and stretched heat dissipation waterproof controller according to an embodiment of this application.

[0017] Figure 4 This is a perspective view of the front cover of an integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to an embodiment of this application.

[0018] Figure 5 This is a perspective view of the back cover of an integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to an embodiment of this application.

[0019] Figure 6This is a perspective view of the spiral head of an integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to an embodiment of this application.

[0020] Figure 7 This is a perspective view of a waterproof pad of an integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to an embodiment of this application.

[0021] Figure 8 This is a perspective view of the compression spring of an integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to an embodiment of this application.

[0022] Reference numerals: 1. Stretched aluminum waterproof shell; 2. Front cover; 3. PCBA board; 4. MOSFET; 5. Rear cover; 6. Waterproof pad; 7. Compression spring; 8. Spiral head; 9. Thick heat dissipation step; 10. Cable outlet hole; 11. Conical sealing ring; 12. Functional lead wire. Detailed Implementation

[0023] To make the content of this application easier to understand, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to the accompanying drawings. Figure 2 In the context of direction, the terms "inside" and "outside" refer to directions toward or away from the geometric center of a specific component, respectively.

[0024] like Figures 1 to 8 As shown, the integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller includes a stretched aluminum waterproof shell 1, a front cover 2, a PCBA board 3, a MOSFET 4, a rear cover 5, a waterproof pad 6, a compression spring 7, and a spiral head 8. Both ends of the stretched aluminum waterproof shell 1 are open, and several heat dissipation fins are evenly stretched along its circumference on its outer wall. One end of the stretched aluminum waterproof shell 1 is fixedly and sealed to the front cover 2 to form a closed installation space. The copper leads of the two power lines and three phase lines are integrally formed on the inner side of the front cover 2 using a molding press. The PCBA board 3 is installed in the closed installation space, and the MOSFET 4 is fixed on the PCBA board 3. The leads of the two power lines and three phase lines... The other end of the copper strip is soldered to the PCBA board 3 via copper wire within a closed installation space. In this design, the copper strips for the two power lines and three phase lines are integrally formed with the inner side of the front cover 2 using a molding press, completely eliminating the gaps between the copper strips and the front cover 2 caused by bolt connections, assembly gaps, or long-term vibration in the traditional "step-by-step assembly" mode, thus preventing moisture from seeping in from the lead-out part. At the same time, the other end of the copper strip is soldered to the PCBA board 3 via copper wire within a closed installation space, completely isolating the solder joint from the external humid and dusty environment. This not only avoids poor circuit contact caused by solder joint corrosion, but also further enhances the waterproofness and circuit stability of the lead-out structure.

[0025] A cable outlet hole 10 is provided through the front cover 2. A spiral head 8 is installed at the cable outlet hole 10, and a conical sealing ring 11 is installed inside the cable outlet hole 10. The conical sealing ring 11 is threadedly connected to the spiral head 8. The controller function lead wire 12 passes through the cable outlet hole 10 and the spiral head 8. By tightening the spiral head 8, the conical sealing ring 11 is pressed against the outer wall of the function lead wire 12 to form a seal. In this design, the cable outlet hole 10 of the front cover 2 adopts a locking sealing structure of "spiral head 8 + conical sealing ring 11". By tightening the spiral head 8, the conical sealing ring 11 can fit tightly against the outer wall of the function lead wire 12 to form an adaptive sealing pressure. Compared with the traditional simple sealing ring sleeve or tape wrapping, it can effectively resist the sealing failure caused by vibration, temperature cycle and external force pulling, ensure the long-term stable waterproof effect of the function lead wire 12, and greatly reduce the risk of water seeping into the interior along the lead wire.

[0026] The lower part of the stretched aluminum waterproof shell 1 has two thick heat dissipation steps 9 integrally formed through a stretching process. The PCBA board 3 is placed between the two thick heat dissipation steps 9. The MOSFET 4 is pressed against the surface of the thick heat dissipation steps 9 by a compression spring 7. In this design, the lower part of the waterproof shell has two thick heat dissipation steps 9 integrally formed through a stretching process, and the MOSFET 4 is pressed against the surface of the thick heat dissipation steps 9 by a compression spring 7. The elastic force of the compression spring 7 can always maintain close contact between the two, eliminating the traditional three-stage heat dissipation path of "MOSFET 4 → aluminum strip → aluminum shell", ensuring that the heat generated by the MOSFET 4 is quickly dissipated, and the heat transfer is more direct and efficient.

[0027] The rear cover 5 is fixedly and sealed to the other end opening of the stretched aluminum waterproof shell 1 by a waterproof gasket 6. The front cover 2 and the rear cover 5 are provided with annular sealing grooves at the connection surfaces with the openings at both ends of the stretched aluminum waterproof shell 1. Waterproof silicone rings are embedded in the annular sealing grooves. The front cover 2 and the rear cover 5 are fixedly and sealed to the openings at both ends of the stretched aluminum waterproof shell 1 by bolts. In this design, by setting an annular sealing groove and embedding a waterproof silicone ring at the connection surface of the front cover 2 and the stretched aluminum waterproof shell 1, and sealing the rear cover 5 with the stretched aluminum waterproof shell 1 by a waterproof gasket 6, and fixing both with bolts, the tightness of the sealing at the splicing part is ensured, and gaps caused by loosening of the shell during long-term use are avoided.

[0028] The above embodiments are only used to illustrate the technical solutions of the embodiments of this application, and are not intended to limit them. Although the embodiments of this application have been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features, without departing from the spirit and scope defined by the claims of this application.

Claims

1. An integrated waterproof controller with one-piece injection-molded conductive bridging and stretching heat dissipation, characterized in that, The system includes a stretched aluminum waterproof shell (1), a front cover (2), a PCBA board (3), a MOSFET (4), a rear cover (5), a waterproof pad (6), and a compression spring (7). Both ends of the stretched aluminum waterproof shell (1) are open, and several heat dissipation fins are evenly stretched along its circumference on its outer side wall. One end of the stretched aluminum waterproof shell (1) is fixedly and sealed to the front cover (2) to form a closed installation space. Two power lines and three phase lines are integrally molded and fixed to the inner side of the front cover (2). The PCBA board (3) is installed within the closed installation space. The S-tube (4) is fixed on the PCBA board (3). The other ends of the copper strips of the two power lines and three phase lines are soldered to the PCBA board (3) by copper wire in the enclosed installation space. The lower part of the stretched aluminum waterproof shell (1) is integrally formed with two thick heat dissipation steps (9) by stretching process. The PCBA board (3) is set between the two thick heat dissipation steps (9). The MOS tube (4) is pressed against the surface of the thick heat dissipation steps (9) by compression spring (7). The back cover (5) is fixedly and sealed to the other end opening of the stretched aluminum waterproof shell (1) by waterproof pad (6).

2. The integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to claim 1, characterized in that, The front cover (2) has a through hole (10) with a screw head (8) installed at the through hole (10). A conical sealing ring (11) is installed inside the through hole (10). The conical sealing ring (11) is threadedly connected to the screw head (8). The controller function lead wire (12) passes through the through hole (10) and the screw head (8). By tightening the screw head (8), the conical sealing ring (11) presses against the outer wall of the function lead wire (12) to form a seal.

3. The integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to claim 1, characterized in that, An annular sealing groove is provided at the connection surfaces of the front cover (2) and the rear cover (5) with the openings at both ends of the stretched aluminum waterproof shell (1), and a waterproof silicone ring is embedded in the annular sealing groove.

4. The integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to claim 1, characterized in that, The front cover (2) and the rear cover (5) are sealed and fixed to the openings at both ends of the stretched aluminum waterproof shell (1) by bolts.

5. The integrated injection-molded conductive bridging and stretch heat dissipation waterproof controller according to claim 1, characterized in that, The copper strips leading out from the two power lines and three phase lines are integrally formed with the front cover (2) by a plastic press.

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