Insert, electrical device and method for producing an electrical device

Description

[0001] The invention relates to an electrical device according to claim 1 and a method for producing such an electrical device according to claim 8.

[0002] Various designs for cable feedthroughs in housings are known. One challenge here is making the cable feedthrough fluid-tight. Especially for cable feedthroughs in housings, such as those located in the engine compartment of a motor vehicle, the cable feedthrough is particularly important to prevent various liquids from entering the housing. Furthermore, particularly high temperature differences occur here, which can lead to the cable feedthrough becoming leaky.

[0003] Furthermore, various cable bushings are known from DE 20 2015 106 891 U1, US 5 422 436 A and CN 1 04 810 768 A.

[0004] A multiple sealing plug for electrical fittings is known from DE 34 03 387 A1.

[0005] A cable sealing element is known from WO 2005 / 101603 A1.

[0006] It is therefore an object of the invention to provide an improved electrical device and an improved method for producing an electrical device.

[0007] This object is achieved by means of an electrical device, in particular a control device, according to claim 1 and a method for producing such an electrical device according to claim 8. Advantageous embodiments are specified in the dependent claims.

[0008] An improved electrical device, in particular an improved control device, can be provided in that the electrical device has an insert, at least one power transmission component and a housing wall of a housing with an inner wall and an outer wall arranged at a distance from the inner wall with respect to the axis. The insert has a first wall and a second wall arranged offset along an axis at a distance from the first wall and has a first chamber. The first wall has a first through-opening and the second wall has a second through-opening, wherein the first through-opening and the second through-opening are aligned with respect to the axis. The first wall is designed to bear against the first through-opening and the second wall is designed to bear against the second through-opening on a power transmission component of the electrical device.The insert has a first chamber arranged between the first wall and the second wall. The first through-opening and the second through-opening open at the first chamber. The first chamber is designed to receive a potting compound. The outer wall has a third through-opening and the inner wall has a fourth through-opening into which the insert engages. The inner wall and the outer wall delimit a housing chamber, wherein the housing chamber and the first chamber open into one another. The first chamber and the housing chamber are filled with a potting compound, wherein the current transmission component extends through at least the first and second through-opening and is embedded in the potting compound between the first wall and the second wall.

[0009] This design has the advantage that the first wall abuts the first through-opening and the second wall abuts the second through-opening, preventing the potting compound from escaping from the first chamber. Furthermore, the arrangement of the first chamber in the insert allows the power transmission component to be particularly well encapsulated by the potting compound in the insert. As a result, the power transmission component is completely embedded in the potting compound in the area of the insert.

[0010] The embedding completely encloses the power transmission component on its periphery with the potting compound, ensuring a particularly good and fluid-tight seal between the housing's interior and the surrounding environment. This protects the electronic components of the electrical device inside the housing from corrosive media. Particularly when the electrical device is located in the engine compartment of a motor vehicle, embedding the power transmission component in the potting compound prevents corrosive media from penetrating the housing's interior.

[0011] In addition, no injection mold is required to cast the power transmission component, since the shaping function is fulfilled by the insert with the first and second walls.

[0012] In a further embodiment, the first chamber extends in a main extension direction, wherein the main extension direction is inclined, preferably perpendicular, to the axis. A maximum first extension of the first chamber in the main extension direction is at least twice as large as a maximum second extension of the first through-opening, inclined, preferably perpendicular, to the axis and along the main extension direction. This ensures that the first chamber has sufficient volume to accommodate the potting compound to ensure complete circumferential flow around the current transmission component.

[0013] In a further embodiment, the insert has a second chamber between the first wall and the second wall, wherein the second chamber is formed in a groove-like manner on the insert and is designed to accommodate the potting compound and / or a housing wall of a housing of an electrical device. This configuration ensures a good, materially bonded connection of the insert to a housing wall via the potting compound arranged in the second chamber.

[0014] In a further embodiment, the insert has a connecting web, wherein the connecting web extends between the first wall and the second wall and connects the first wall to the second wall. This configuration has the advantage that the insert is particularly rigid and the volume of the first and second chambers is particularly large.

[0015] In a further embodiment, the insert has a plug-in slot for a contact device on a side facing away from the first chamber, wherein the plug-in slot is formed circumferentially around the power transmission component. This configuration has the advantage that the power transmission component can be easily contacted with a further contact device, wherein a contact housing of the further contact device can be guided through the plug-in slot and can be mechanically fastened to the insert.

[0016] In a further embodiment, the housing has a further insert, wherein the insert is connected to the further insert to form a collective insert, wherein the housing wall engages between the insert and the further insert, wherein the collective insert is positively secured to the housing wall. This configuration has the advantage that the positively locking fastening essentially prevents the potting compound from escaping during the pouring of the potting compound into the first chamber and into the housing chamber.

[0017] The potting compound is prevented from escaping from the first chamber and / or the housing chamber by the housing wall and the first wall and / or the second wall being arranged in an overlapping manner.

[0018] In a further embodiment, the housing wall and / or the insert comprises at least one of the following first materials: plastic, thermoplastic, polyethylene, silicone, polyurethane, foam, closed-cell foam. It is particularly advantageous if the potting compound comprises at least one of the following second materials: plastic, thermoplastic, polyethylene, polyurethane, silicone. It is also advantageous if the first material and the second material are identical. This ensures that the bond between the first material and the second material is particularly good and that particularly good cross-linking occurs between the potting compound and the insert.

[0019] In another embodiment, the potting compound firmly bonds the insert to the housing wall and the power transmission component. This design has the advantage of preventing accidental detachment of the insert. Furthermore, a positive and / or frictional connection between the insert and the housing wall prevents damage to the bonded connection. Particularly when a tensile force acts on the power transmission component, the positive and frictional connection between the insert and the housing wall allows the tensile force to be particularly well supported in the housing wall.

[0020] In a method for producing the electrical device, an insert as described above, at least one power transmission component, and a housing are provided. The power transmission component is guided through the first and second through-openings. The insert is inserted into the housing wall such that the first chamber of the insert and the housing chamber of the housing wall are fluidically connected to one another, wherein a precursor of a potting compound or a liquid potting compound is introduced into the first chamber of the insert and the housing chamber of the housing wall. The precursor is cured to form the potting compound, or the liquid potting compound is cured. This configuration has the advantage of ensuring a fluid-tight seal between the insert and the housing wall, on the one hand, and the power transmission component and the potting compound, on the other.

[0021] In another embodiment, the potting compound flows around the power transmission component in the first chamber. It is particularly advantageous if the potting compound precursor foams during curing. This configuration has the advantage that, due to the foaming, the potting compound in the first chamber and in the housing chamber is locally pressurized, allowing it to penetrate particularly well into cracks and corners of the power transmission component, thus enclosing the power transmission component particularly well within the potting compound.

[0022] It is also advantageous if the housing wall and the first wall and / or second wall are arranged overlapping.

[0023] The invention is explained in more detail below with reference to the figures. These show: Figure 1 a schematic representation of an electrical device according to a first embodiment; Figure 2 a first side view of a Figure 1first insert shown; Figure 3 a top view of the Figures 1 and 2 first insert shown; Figure 4 a second side view of the Figures 1 to 3 first insert shown; Figure 5 a perspective view of a housing with a housing wall of the Figures 1 to 4 electrical device shown; Figure 6 a perspective view of a Figure 1 shown second insert; Figure 7 a perspective view of a Figure 1 shown third insert; Figure 8 a perspective view of the Figure 1 electrical device shown; Figure 9 a perspective view of an electrical device according to a second embodiment; Figure 10 a perspective view of a first insert of the Figure 9 electrical device shown; Figure 11 a perspective view of a second insert of the Figure 9electrical device shown; Figure 12 a perspective view of a Figure 9 shown third insert of the Figure 9 electrical device shown; Figure 13 a perspective view of the housing and the housing wall of the Figure 9 electrical device shown; Figure 14 a perspective view of an electrical device according to a third embodiment; Figure 15 a perspective view of an electrical device according to a fourth embodiment; Figure 16 a perspective view of an electrical device according to a fifth embodiment; Figure 1 shows a section of a schematic representation of an electrical device 10, for example a control unit 15 of a motor vehicle.

[0024] The electrical device 10 has a housing 25 with a cable feedthrough 20. The housing 25 defines a housing interior 30, which is fluid-tight with respect to an environment 35 of the electrical device 10. The housing 25 has a housing part 40, which is, for example, bowl-shaped, and a housing cover 45. The housing cover 45 is in Figure 1 Illustrated schematically by dashed lines, for example, to allow visibility of the cable feedthrough 20 and a view into the housing interior 30. The housing cover 45 can, for example, be plate-shaped and close the housing interior 30 at the top of the housing part 40. In addition, a sealing element (not shown) can be provided between the housing part 40 and the housing cover 45 to ensure the fluid-tightness of the housing interior 30 with respect to the environment 35.

[0025] Due to its fluid-tight design, the Figure 1The electrical device 10 shown, in particular the control unit 15, is designed for installation in thermal and / or humid environmental conditions. For example, due to the fluid-tight design, the electrical device 10 can be arranged in an engine compartment or on the underside of the motor vehicle and be exposed to moisture influences, such as splash water and / or thermal heat from an internal combustion engine of the motor vehicle.

[0026] The cable feedthrough 20 has at least one first insert 50 and at least one first power transmission component 60. The housing part 40 has a first housing wall 55. For example, Figure 1 the first housing wall 55 perpendicular to a housing bottom 65 of the housing part 40.

[0027] The first housing wall 55 can extend in a yz-plane. The first housing wall 55 connects the second housing wall 70 of the housing part 40, arranged in the transverse direction, with a third housing wall 75 arranged opposite the second housing wall 70, which, for example, run parallel to each other in xz-planes. It is particularly advantageous if the housing part 40 is manufactured in one piece and from the same material, preferably in a single casting process.

[0028] The first power transmission component 60 is, for example, a first electrical cable having an electrical conductor 85 embedded on the inside in a sheath 80. In the embodiment, the sheath 80 is designed as a cable sheath. The electrical conductor 85 is completely enclosed circumferentially by the sheath 80. The sheath 80 has, for example, a circular configuration on a first outer circumferential side 90. Another configuration of the sheath 80 would also be conceivable. It is particularly advantageous here if the use of release agents is dispensed with during the production of the sheath 80 and the first outer circumferential side 90 is substantially free of release agent.

[0029] The electrical conductor 85 can be fine-stranded or ultra-fine-stranded and is designed to transmit an electrical current for power transmission (in a range from 0.1 amperes to 1,000 amperes). The first power transmission component 60 extends, for example, through the cable feedthrough 20 and is arranged to extend both in the housing interior 30 and in the surrounding area 35 of the electrical device 10. The first power transmission component 60 can, for example, supply the electrical control unit 15 with electrical energy for operating the electrical control unit 15.

[0030] Additionally or alternatively, in addition to the first insert 50 and the first power transmission component 60, the electrical device 10 can have a second insert 95 and a second power transmission component 100, additionally or alternatively a third insert 105 and a third power transmission component 110, and additionally or alternatively a fourth insert 115 and a fourth power transmission component 120. The second power transmission component 100 can, for example, be a multi-pole electrical contact element, for example a pin contact. Individual pins 125 of the second power transmission component 100 can be arranged in a row. The pins 125 are electrically insulated from one another and serve, for example, to transmit a data signal.The data signal can be differentiated from the power transmission by means of the first current transmission component 60 in that the data signal has an electrical current of less than 0.1 amperes.

[0031] The third power transmission component 110 can, for example, be an electrically conductive rail, such as a busbar. Another configuration of the third power transmission component 110 is also possible. The third power transmission component 110 differs from the first power transmission component 60 in that the rail is essentially formed in one piece and made of the same material and extends along the x-axis with a substantially constant cross-section. The rail is not sheathed on the periphery.

[0032] The fourth power transmission component 120 is substantially identical to the first power transmission component 60.

[0033] Figure 2 shows a first side view of the Figure 1 shown first insert 50.

[0034] The first insert 50 has a first wall 130 on a side facing the viewer and the surroundings 35. The first wall 130 is, for example, essentially plate-shaped and extends, for example, in a yz-plane spanned by the x-axis and the y-axis. The first wall 130 is arranged on a side of the insert 50 facing away from the housing interior 30.

[0035] In plan view, the first insert 50 has a first outer contour 135. The first outer contour 135 is essentially trapezoidal. On a first upper side 140, which in the assembled state is arranged on a side facing the housing cover 45, the first insert 50 is essentially flat. Furthermore, the first insert 50 has a first through-opening 150. The first through-opening 150 extends from a side of the first wall 130 facing away from the housing interior 30 to the first chamber 150. In the unassembled state, the first through-opening 150 fluidically connects the first chamber 130 to the environment 35 towards the side facing away from the housing interior 30. The first through-opening 150 is arranged in the z-direction between the first upper side 140 and a first underside 145 of the first insert 50, for example centrally in the transverse direction. The first through-opening 150 is, for example, designed in the manner of a bore.A contour of the first through-opening 150 is configured to correspond, at least in some areas, to the first outer circumferential side 90 of the casing 80 of the first power transmission component 60. A radius of the first through-opening 150 can be selected to be slightly smaller than an outer radius of the first outer circumferential side 90 (for example, between 1 percent and 4 percent).

[0036] On the rear side facing away from the viewer, the first insert 50 can have a first connecting web 155 and / or a second connecting web 160, wherein the first connecting web 155 and the second connecting web 160 are arranged spaced apart from one another in the transverse direction. The first and second connecting webs 155, 160 are in Figure 2 indicated by a dashed line. The first connecting web 155 and the second connecting web 160 can extend substantially parallel to the x-axis and the z-axis.

[0037] The first outer contour 135 further has a first side 165 and a second side 170 arranged opposite the first side 165 in the y-direction, wherein the first side 165 and the second side 170 connect the first upper side 140 to the first lower side 145. The first side 165 and the second side 170 are arranged at an angle to one another and to the z-axis. The first side 165 and the second side 170 converge from the first upper side 140 to the first lower side 145. At a first transition 175 between the first side 165 and the first lower side 145, the first transition 175 can be rounded. A second transition 180 between the first lower side 145 and the second side 170 can likewise be rounded. A third transition 185 between the first side 165 and the first top side 140 can be pointed.Due to an exemplary axially symmetrical design of the first insert 50 with respect to a plane of symmetry 190, which is arranged, for example, centrally in the transverse direction of the first insert 50 and extends substantially in an xz plane, a fourth transition 195 between the second side 170 and the first upper side 140, as well as the third transition 185, is designed to taper to a point.

[0038] Figure 3 shows a top view of the Figures 1 and 2 shown first insert 50.

[0039] The first insert 50 further has a second wall 200, wherein the second wall 200 is arranged at a distance a from the first wall 130 in the longitudinal direction (x-direction). The second wall 200 is plate-shaped and runs, for example, parallel to the first wall 130. The second wall 200 is arranged on a side of the insert 50 facing the housing interior 30. The second wall 200 is mechanically connected to the first wall 130 by means of the first connecting web 155 and the second connecting web 160. The first insert 50 is preferably formed in one piece and from the same material. For example, the first insert 50 can be produced using an injection molding process.

[0040] The first wall 130, together with the second wall 200, defines a first chamber 205 arranged between the first wall 130 and the second wall 200 in the longitudinal direction. The first chamber 205 extends from the first upper side 140 to the first lower side 145. Laterally in the transverse direction, the first chamber 205 can be defined by the first connecting web 155 and the second connecting web 160. The first through-opening 150 opens into the first chamber 205.

[0041] Between the first connecting web 155 and the first side 165 (in the transverse direction), the first insert 50 can have a second chamber 206. The second chamber 206 is groove-shaped and open toward the first side 165. Likewise, the second chamber 206 is open at the top and extends to the first underside 145. The second chamber 206 can also be open at the first underside 145.

[0042] Between the second connecting web 160 and the second side 170 (in the transverse direction), the second insert 95 can have a third chamber 207. The third chamber 207 is mirror-symmetrical to the second chamber 206 with respect to the plane of symmetry 190. The third chamber 207 is open towards the first upper side 140. The third chamber 207 extends from the first upper side 140 to the first lower side 145 and is groove-shaped with respect to the second side 170. The third chamber 207 is thus open towards the second side 170. Likewise, the third chamber 207 is open towards the first lower side 145.

[0043] Figure 4 shows a second side view of the Figures 1 to 3 shown first insert 50.

[0044] The second wall 200 has a second outer contour 210, wherein the second outer contour 210 is preferably identical to the first outer contour 135. The second wall 200 has a second through-opening 215, wherein the second through-opening 215 is preferably identical to the first through-opening 150. The first through-opening 150 and the second through-opening 215 are aligned with respect to the x-axis. The second through-opening 150 extends from a side of the second wall 200 facing the housing interior 30 to the first chamber 150. In the unassembled state, the second through-opening 215 fluidically connects the first chamber 130 to the housing interior 30. Opposite the first through-opening 150, the second through-opening 215 opens, for example, into the first chamber 205.

[0045] The first chamber 205 has a first maximum extension b, which is in the Figures 1 to 4runs along the z-axis. The z-direction is the main extension direction of the first chamber 205. The first maximum extension b is significantly greater, at least twice to fifteen times as large, than the minimum distance a of the first wall 130 to the second wall 200. Furthermore, a second maximum extension l of the first through-opening 150 perpendicular to the x-axis is selected to be significantly smaller than the first maximum extension b. The maximum first extension b of the first chamber 205 in the main extension direction (z-direction) is at least twice as large as the maximum second extension l of the first through-opening 150 perpendicular to the x-axis.

[0046] It is particularly advantageous if the first insert 50 comprises at least one of the following first materials: plastic, thermoplastic, polyethylene.

[0047] Figure 5 shows a perspective view of the housing 25 with the first housing wall 55.

[0048] The first housing wall 55 has an inner wall 225 and an outer wall 230. The inner wall 225 is arranged on a side facing the housing interior 30. The outer wall 230 is arranged on a side facing away from the housing interior 30 and facing the environment 35. The first wall 130 can have a first wall thickness in the x-direction, which essentially corresponds to a second wall thickness in the x-direction of the outer wall 230. The second wall 200 can have a third wall thickness in the x-direction, which essentially corresponds to a fourth wall thickness in the x-direction of the inner wall 225.

[0049] The inner wall 225 and the outer wall 230 are arranged at a distance from one another in the x-direction with a maximum outer distance b. The maximum outer distance refers to a distance from an inner side of the inner wall 225 to the outer side of the outer wall 230. The outer distance b corresponds to the distance a or is smaller than the distance a. Both the inner wall 225 and the outer wall 230 each extend in a yz-plane. Between the inner wall and the outer wall 225, 230, the first housing wall 55 has a housing chamber 235. The housing chamber 235 can be formed in one piece and continuously between the second housing wall 70 and the third housing wall 75. A third connecting web 240 can also be arranged between the inner wall 225 and the outer wall 230, wherein the third connecting web 240 mechanically connects the inner wall 225 to the outer wall 230.The outer wall 230 has a third through-opening 245 and the inner wall 225 has a fourth through-opening 250.

[0050] The third through-opening 245 and the fourth through-opening 250 together delimit a first receptacle 255. The third and fourth through-openings 245, 250 have, for example, the same outer contour as that of the first insert 50, but the third and fourth through-openings 245, 250 are smaller than the outer contour 135, 210 of the first insert 50.

[0051] In the embodiment, a plurality of first receptacles 255 are arranged in the first housing wall 55, wherein between each two adjacent first receptacles 255 arranged in the y-direction, a third connecting web 240 extends at least partially between the second upper side 285 and the housing base 65.

[0052] Figure 6 shows a perspective view of the second insert 95.

[0053] The second insert 95 is essentially identical to that shown in the Figures 1 to 4 shown first insert 50. In the following, only the differences of the Figure 6 shown second insert 95 compared to the one shown in the Figures 1 to 4 shown first depositor 50 received.

[0054] In contrast to the first insert 50, the first and second through-openings 150, 215 of the second insert 95 are formed corresponding to a second outer circumferential side of the second power transmission component 100.

[0055] Figure 7 shows a perspective view of the third insert 105.

[0056] The third insert 105 is essentially identical to that shown in the Figures 1 to 4 The following section focuses exclusively on the differences between the Figure 7 shown third insert 105 compared to the one shown in the Figures 1 to 4shown first depositor 50 received.

[0057] The first through-opening 150 and the second through-opening 215 of the third insert 105 are configured to correspond to a circumferential configuration of the third power transmission component 110. The first and / or second through-opening 150, 215 is configured such that, in the assembled state of the third power transmission component 110, the first and / or second through-opening 150, 215 essentially seals against the third power transmission component 110 on the circumferential side. It is particularly advantageous if the first and second through-openings 150, 215 are configured as a transition fit or interference fit with the third power transmission component 110 on the circumferential side.

[0058] With regard to the fourth insert 115 and the fourth power transmission component 120, reference is made to the first insert 50 and the first power transmission component 60, since the first power transmission component 60 and the fourth power transmission component 120 are identical to one another in the embodiment. As a result, the fourth insert 115 is also identical to the first insert 50. A different design of the fourth power transmission component 120 and the first power transmission component 60 would also be possible.

[0059] Figure 8 shows the Figure 1 shown perspective view of the electrical device 10. In the following, the electrical device 10 is described in connection with the Figures 1 to 8 explained.

[0060] The first insert 50 is inserted into the first receptacle 255 in the assembled state of the electrical device 10. If the second and / or third and / or fourth insert 95, 105, 115 is provided, the second insert 95 is inserted into the second receptacle 265 formed in the first housing wall 55. Likewise, the third insert 105 can be inserted into a third receptacle 270 formed in the first housing wall 55, and the fourth insert 115 can be inserted into a fourth receptacle 275 formed therein.

[0061] The inserts 50, 95, 105, 115 are each positioned, for example, such that the first wall 130 and the inner wall 225 overlap in the y-direction. Likewise, the inserts 50, 95, 105, 115 are positioned such that the second wall 200 and the outer wall 230 overlap in the y-direction. An overlap in the y-direction is understood to mean that when two components, for example, the first wall 130 and the inner wall 225, are projected into a projection plane in the y-direction, which runs perpendicular to the y-axis and is configured, for example, as an xz-plane, the two components overlap in the projection plane.

[0062] In the assembled state of the electrical device 10, the first power transmission component 60 is guided through the first through-opening 150 and the second through-opening 215. The casing 80 preferably bears circumferentially against a contour of the first through-opening 150 and the second through-opening 215 in a sealing manner. Analogous to the first insert 50, the respective second to fourth power transmission components 100, 110, 120 are guided through the first and second through-openings 150, 215 of the respective second to fourth inserts 95, 105, 115.

[0063] When the respective insert 50, 95, 105, 115 is mounted in the associated receptacle 255, 265, 270, 275, the first to third chambers 205, 206, 207 adjoin the housing chamber 235 and are thus fluidically connected to the housing chamber 235. The housing chamber 235 fluidically connects the first chamber 205 and / or the second chamber 206 and / or the third chamber 207 to one another.

[0064] As in Figure 1 and Figure 8 As can be seen, the first to third chambers 205, 206, 207 and the housing chamber 235 are open at the first upper side 140. The first to third chambers 205, 206, 207 and the housing chamber 235 form a casting chamber. In the fully assembled state, the casting chamber is filled with a casting compound 280.

[0065] The potting compound 280 comprises at least one of the following second materials: plastic, thermoplastic, polyethylene. It is particularly advantageous if the first material and the second material are identical. As a result, the potting compound 280 is particularly well bonded to the insert 50, 95, 105, 115 and the first housing wall 55. It is particularly advantageous if the first to third chambers 205, 206, 207 and the housing chamber 235 are completely filled with the potting compound 280, so that essentially no cavities or voids are enclosed in the potting compound 280.

[0066] In the first chamber 205, the first power transmission component 60 is completely enclosed by the potting compound 280 in the first insert 50 and thus embedded in the potting compound 280. The potting compound 280 is integrally bonded to the first outer circumferential side 90 of the casing 80 of the first power transmission component 60. As a result, the potting compound 280 fluid-tightly seals the first power transmission component 60 within the first insert 50. Through the transition of the first to third chambers 205, 206, 207 and the housing chamber 235, the first insert 50 is fluid-tightly sealed to the first housing wall 55 by the potting compound 280 filled into the chambers 205, 206, 207 and is mechanically secured by a fluid-tight bond.

[0067] By making the first receptacle 255 smaller than the first insert 50, the first housing wall 55 engages in sections of the first to third chambers 205, 206, 207. The inner wall 225 rests on the inside against the second wall 200, and the outer wall 240 rests on the outside against the first wall 130 in sections, so that the first housing wall 55 and the first insert 50 overlap in sections.

[0068] Analogous to the first insert 50 and the first power transmission component 60 guided through the first insert 50 into the housing interior 30, the second insert 95 and the second power transmission component 100 inserted into the second insert 95 are also guided. Analogous to the first insert 50, the third power transmission component 110 is sealed fluid-tight on the third insert 105 and the fourth power transmission component 120 on the fourth insert 115 by the potting compound 280.

[0069] The Figures 1 to 8The configuration shown has the advantage that additional contact devices for the housing feedthrough of the power transmission component 60, 100, 110, 120 can be dispensed with. Furthermore, by using the Figures 1 to 8 shown insert 50, 95, 105, 115, a complicated tool for casting the respective associated power transmission components 60, 100, 110, 120 guided through the insert 50, 95, 105, 115 can be dispensed with, so that a production plant for producing the electrical device 10 is particularly cost-effective.

[0070] This can be done particularly easily and cost-effectively in Figure 1 and 8The electrical device 10 shown can be manufactured by the method described below. It should be noted that, unless otherwise stated, what is described below for the first insert 50 also applies to the second to fourth inserts 95, 105, 115 and the power transmission components 100, 110, 120 guided through the second to fourth inserts 95, 105, 115, respectively.

[0071] In a first process step, the insert 50, 95, 105, 115 is manufactured in a first injection molding process. It is particularly advantageous if the use of release agents is omitted when casting the insert 50, 95, 105, 115. It is particularly advantageous if the insert 50, 95, 105, 115 is cast from the first material.

[0072] In a second process step, the first housing wall 55 is cast together with the housing 25 in a second injection molding process, separately from the insert 50, 95, 105, 115, from the first material.

[0073] In a third method step, the associated power transmission component 60, 100, 110, 120 is guided through the first and second through-openings 150, 215. For example, the first power transmission component 60 is inserted through the first and second through-openings 150, 215 of the first insert 50.

[0074] Furthermore, in the third process step, the insert 50, 95, 105, 115 with the power transmission component 60, 100, 110, 120 is inserted into the respective associated receptacle 255, 265, 270, 275. Insertion can be accomplished, for example, by a simple, linear movement along the z-axis.

[0075] In a fourth method step following the third method step, the liquid potting compound 280 and / or a first precursor of the potting compound 280 in the liquid state is poured into at least one of the chambers 205, 206, 207 and / or into the housing chamber 235 by means of an injection mold (not shown). Alternatively, it would also be possible to pour a mixture of the first precursor and a second precursor in the liquid state into at least one of the chambers 205, 206, 207 and / or the housing chamber 235 by means of the injection mold, instead of the first precursor. Due to the fluidic connection of the first and / or second and / or third chambers 205, 206, 207 with the housing chamber 235, the first precursor and / or the mixture of the first precursor and the second precursor, or the liquid potting compound 280, is distributed throughout the chambers 205, 206, 207 and the housing chamber 235.The liquid potting compound 280 and / or the liquid first precursor and / or the liquid mixture of the first and second precursor flows around the current transmission component 60, 100, 110, 120 in the first chamber 205 such that the current transmission component 60, 100, 110, 120 is embedded in the liquid potting compound 280 and / or the liquid first precursor and / or the mixture of the first and second precursor and is completely enclosed in the first chamber 205.

[0076] The sealing closure of the first and second through-openings 150, 215 on the outer circumferential side of the power transmission component 60, 100, 110, 120 and the engagement with a housing section of the first housing wall 55 into the chamber 205, 206, 207 prevent the liquid potting compound 280 and / or the liquid first precursor and / or the liquid mixture of the first and second precursor from escaping from the first chamber 205.

[0077] Filling of the chamber 205, 206, 207 and the housing chamber 235 is terminated after filling a predefined amount of the first precursor and / or the mixture of the first precursor and the second precursor and / or the liquid potting compound 280. The predefined amount of the first precursor and / or the mixture of the first precursor and the second precursor and the liquid potting compound 280 that is filled into the chamber 205, 206, 207 and / or the housing chamber 235 depends on the expansion behavior during curing to form the potting compound 280.

[0078] In a fifth process step following the fourth process step, the first precursor and / or the mixture of the first precursor and the second

[0079] The precursor and / or the liquid potting compound 280 are cured to form the solid potting compound 280. Curing is understood to mean that the first precursor and / or the mixture of the first precursor and the second precursor and / or the liquid potting compound 280 transitions from a liquid phase state to a solid phase state. During curing, the first precursor can crosslink with the second precursor and form the solid potting compound 280. For example, the mixture can foam and form a closed-cell foam.

[0080] The filled quantity of the first precursor and / or the mixture of the first precursor and the second precursor and / or the liquid potting compound 280 is selected such that after curing, the cured potting compound 280 is substantially flush with the first upper side 140.

[0081] Should the potting compound 280 protrude beyond the first upper side 140 and / or the second upper side 285 during curing, for example if the potting compound 280 foams, in an optional sixth method step after the potting compound 280 has cured, the potting compound 280 protruding beyond the first upper side 140 and / or the second upper side 285 can be separated, for example by means of a scraper.

[0082] The manufacture of such an electrical device 10 has the advantage that additional contact devices for connecting the power transmission components 60, 100, 110, 120 from the housing interior 30 to the surrounding area 35 are not required during assembly. This makes the manufacture of the electrical device 10 particularly simple and cost-effective using the method described above.

[0083] Furthermore, complex tools are no longer required, for example for producing the respective contact devices. Furthermore, the second power transmission component 100 can be directly connected to the second power transmission component 100 by means of a further contact device 325 (dashed in Figure 8 shown). The overall number of tools required to manufacture the electrical device 10 is also reduced.

[0084] The insert 50, 95, 105, 115 can be flexibly adapted to the respective power transmission component 60, 100, 110, 120 to be implemented, so that overall the geometry of the housing 25 and the first housing wall 55 does not have to be adapted, even if the power transmission component 60, 100, 110, 120 is different from the one shown in the Figures 1 to 8 shown design of the power transmission component 60, 100, 110, 120 is different.

[0085] Figure 9shows a perspective view of an electrical device 10 according to a second embodiment.

[0086] The electrical device 10 is essentially identical to that shown in the Figures 1 and 8 shown electrical device 10. In the following, only the differences of the Figure 9 electrical device 10 shown compared to the one shown in the Figures 1 to 8 The electrical device 10 shown is also discussed in detail. The first insert 50 is also explained in detail as an example. The explanations below for the first insert 50 also essentially apply to the second to fourth inserts 95, 105, 115.

[0087] Compared to the Figures 1 to 8In the embodiment of the electrical device 10 shown, the first outer contour 135 and the receptacle 255, 265, 270, 275 are modified. Although the insert 50, 95, 105, 115 and the respectively associated receptacle 255, 265, 270, 275 have a substantially trapezoidal basic shape, the first through-opening 150 is formed as a first indentation on the first underside 145 of the first wall 130. The first through-opening 150 is formed corresponding to an upper first partial section 300 of the first power transmission component 60. The first through-opening 150 is formed, for example, substantially in a central position relative to a third maximum extension c in the y-direction of the first insert 50 on the first upper side 140.

[0088] In Figure 9The second through-opening 215 is also concealed in the second wall 200 on the first underside 145. The second through-opening 215 is also formed corresponding to the first upper section 300 of the first power transmission component 60.

[0089] The second and third inserts 95, 105 are also designed analogously to the first insert 50, with the first and second through-openings 150, 215 each being arranged on the first underside 145 of the second and / or third inserts 95, 105 and being designed at least complementarily to the first subsection 300 of the second or third power transmission components 100, 110 to be sealed. The fourth insert 115 is designed identically to the first insert 50.

[0090] Figure 10 shows a perspective view of the first insert 50.

[0091] It is particularly advantageous if the first through-opening 150 is arranged completely between and spaced from the first connecting web 155 and the second connecting web 160.

[0092] The first through-opening 150 and the second through-opening 215 have a partially circular configuration corresponding to the first outer peripheral side 90 of the first power transmission component 60. The first underside 145 is formed, for example, laterally adjacent to the through-opening 150, 215 in the transverse direction, essentially extending in an xy plane.

[0093] Figure 11 shows a perspective view of the second insert 95.

[0094] The second insert 95 is essentially identical to that shown in Figure 10 shown first insert 50, wherein only the differences between the second insert 95 and the first insert 50 will be discussed below.

[0095] The first and / or second through-opening 150, 215 has a substantially rectangular configuration and essentially forms the first upper partial section 300 of an outer contour of the second power transmission component 100. The first and / or second through-opening 150, 215 extends transversely substantially over the entire first underside 145 of the second insert 95.

[0096] The contour of the first and / or second through-opening 150, 215 can, for example, be simplified compared to the outer contour of the second power transmission component 100 such that the first and second through-opening 150, 215 cannot abut the second power transmission component 100 in a fluid-tight manner.

[0097] Figure 12 shows a perspective view of the Figure 10 shown third insert 105.

[0098] The third insert 105 is essentially identical to that shown in Figure 11shown second insert 95. In the following, only the differences of the Figure 12 shown third insert 105 compared to the one in Figure 11 shown second insert 95.

[0099] The through opening 150, 215 is shorter in the transverse direction than in Figure 11 and extends, for example, over approximately half the width in the transverse direction of the first underside 145. The first and / or second through-opening 150, 215 is shaped to correspond to the upper first partial section 300 of the third current transmission component 110. For example, the first and / or second through-opening 150, 215 has a rectangular configuration.

[0100] Figure 13 shows a perspective view of the housing 25 and the first housing wall 55.

[0101] The first housing wall 55 is essentially identical to that shown in Figure 5shown first housing wall 55. In the following, only the differences between the Figure 13 shown first housing wall 55 opposite the one in Figure 5 shown first housing wall 55.

[0102] The third through-opening 245 is formed in some areas to correspond to a lower second sub-section 295 of the first power transmission component 60 and, for example, has a partially circular configuration. The fourth through-opening 250 is formed, for example, to correspond to the second lower sub-section 295 of the first power transmission component 60. The geometric configuration is selected to be essentially identical to the third through-opening 245, with the third and fourth through-openings 245, 250 being formed to overlap in the x-direction. An overlap in the x-direction is understood to mean that when two components, for example the third and fourth through-openings 245, 250, are projected into a projection plane in the x-direction that runs perpendicular to the x-axis and is formed, for example, as a yz-plane, the two components overlap in the projection plane when projected in the x-direction.

[0103] The second and third receptacles 265, 270 are designed analogously to the first receptacle 255. The fourth receptacle 275 is designed identically to the first receptacle 255 due to the identical configuration of the first power transmission component 60 and the fourth power transmission component 120. The third and fourth through-openings 245, 250 of the second and third receptacles 265, 270 are partially rectangular, preferably mirror-symmetrical, to the first through-opening 150 and the second through-opening 215 of the second insert 95 and the third insert 105, respectively.

[0104] The production of the Figure 9 The electrical device 10 shown is essentially identical to that shown in the Figures 1 to 8described electrical device 10. Deviating from this, instead of inserting the power transmission component 60, 100, 110, 120 through the first and second through-openings 150, 215 in the third method step, the power transmission component 60, 100, 110, 120 is inserted into the respectively associated third and fourth through-openings 245, 250 with the second lower subsection 295.

[0105] In the fourth method step, the insert 50, 95, 105, 115 is inserted into the respectively assigned receptacle 255, 265, 270, 275, wherein the insert 50, 95, 105, 115 nestles on the top side with the first and second through-openings 150, 215 against the first section 300 of the respectively assigned power transmission component 60, 100, 110, 120.

[0106] The filling in the fifth process step using the casting compound 280 is carried out in the same way as in the Figures 1 to 8described, however, the housing chamber 235 is designed such that the housing chamber 235 is formed circumferentially extending completely around the receptacle 255, 265, 270, 275. This ensures that the power transmission component 60, 100, 110, 120 is completely enclosed and embedded by the potting compound 280, so that fluid tightness is ensured at the power transmission component 60, 100, 110, 120.

[0107] The Figures 9 to 13 The configuration shown has the advantage that the insertion of the power transmission component 60, 100, 110, 120 through the respective associated insert 50, 95, 105, 115 is not required compared to the Figures 1 to 8 shown embodiment can be dispensed with, so that the manufacturing process for producing the electrical device 10 is particularly simple and cost-effective. Furthermore, the Figures 9 to 13 The design shown is particularly suitable for automated production.

[0108] Figure 14 shows a perspective view of an electrical device 10 according to a third embodiment.

[0109] The electrical device 10 is essentially identical to the one shown in the Figures 9 to 13 shown embodiment of the electrical device 10. In the following, only the differences of the Figure 14 electrical device 10 shown compared to the one shown in the Figures 9 to 13 shown electrical device 10.

[0110] In the embodiment, the electrical device 10 has only one collecting insert 305, wherein the collecting insert 305 contains the Figures 9 to 13shown first to fourth inserts 50, 95, 105, 115. The collective insert 305 thus has the first to fourth inserts 50, 95, 105, 115, wherein the inserts 50, 95, 105, 115 are each connected to one another via a coupling section 310. The coupling section 310 is arranged between two inserts 50, 95, 105, 115 arranged next to one another in the transverse direction and connects the inserts 50, 95, 105, 115 arranged closest to one another in the y-direction.

[0111] The first housing wall 55 is also designed to correspond to the configuration of the collective insert 305. The receptacles 255, 265, 270, 275 are designed to correspond to the collective insert 305. The first housing wall 55 is flattened between the first receptacle 255 and the second receptacle 265, as well as between the second receptacle 265 and the third receptacle 270, and between the third receptacle 270 and the fourth receptacle 275 to form a collective receptacle 290. The flattened area between the receptacles 255, 265, 270, 275 serves to accommodate the coupling section 310.

[0112] During the manufacture of the electrical device 10, in the fourth process step, instead of four inserts 50, 95, 105, 115, the collective insert 305 is inserted into the housing wall 55 in only one assembly step, thus reducing the number of assembly steps.

[0113] Figure 15shows a perspective view of an electrical device 10 according to a fourth embodiment.

[0114] The electrical device 10 is essentially a further development of the Figure 14 electrical device shown 10.

[0115] The collecting insert 305 is wider in the transverse direction and on the first underside 145 in the longitudinal direction than in Figure 14 shown, so that in an edge section 315 (dashed in Figure 15 marked) the collecting insert 305 and the first housing wall 55 preferably overlap in the x-direction on both the inner wall 225 and the outer wall 230.

[0116] The first housing wall 55 engages between the first wall 130 and the second wall 200 at least with the third connecting web 240. This configuration has the advantage that an exact positioning of the collecting insert 305, which is particularly wide in the y-direction, is ensured in the x-direction. As a result, an assembly force for mounting the collecting insert 305 in the z-direction is lower than Figure 14 reduced.

[0117] Figure 16 shows a perspective view of an electrical device 10 according to a fifth embodiment.

[0118] In this embodiment, only the second insert 95 is arranged on the first housing wall 55. The additional inserts 50, 105, 115 and power transmission components 60, 110, 120 are omitted.

[0119] For example, the second insert 95 additionally has a plug-in slot 320, which is arranged on the end face on a side facing away from the housing interior 30. The plug-in slot 320 can, for example, be designed as a circumferential edge surrounding the first through-opening 150, which is spaced apart from the second power transmission component 100, for example in Figure 16 two pins 125 of the second power transmission component 100 arranged at a distance in the transverse direction. The plug-in link 320 is formed at a distance in the vertical direction from both the first bottom side 145 and the first top side 140. The plug-in link 320 is formed during the first method step for producing the second insert 95 as part of the injection molding process of the second insert 95.

[0120] The Figure 16 The embodiment shown has the advantage that the further contact device 325 (in Figure 16 (shown in dashed lines) can be plugged onto the second power transmission component 100. In particular, the plug-in link 320 ensures correct alignment of the further contact device 325 with the second power transmission component 100. Furthermore, a contact housing of the further contact device 325 can be fastened, for example, by frictional engagement, using the plug-in link 320. List of reference symbols

[0121] 10 Electrical device 15 Control unit 20 Cable entry 25 Housing 30 Housing interior 35 Surroundings 40 Housing part 45 Housing cover 50 First insert 55 First housing wall 60 First power transmission component 65 Housing base 70 Second housing wall 75 Third housing wall 80 Sheathing 85 Electrical conductor 90 First outer peripheral side (of the sheathing) 95 Second insert 100 Second power transmission component 105 Third insert 110 Third power transmission component 115 Fourth insert 120 Fourth power transmission component 125 Pin 130 First wall 135 First outer contour 140 First top side 145 First bottom side 150 First through-opening 155 First connecting web 160 Second connecting web 165first side 170second side 175first transition 180second transition 185third transition 190plane of symmetry 195fourth transition 200second wall 205first chamber 206second chamber 207third chamber 210second outer contour 215second through-opening 220second underside 225inner wall 230outer wall 235housing chamber 240thirdConnecting bridge 245 third through-hole 250 fourth through-hole 255 first receptacle 265 second receptacle 270 third receptacle 275 fourth receptacle 280 potting compound 285 second top side 290 collective receptacle 295 second section 300 first section 305 collective insert 310 coupling section 315 edge section 320 plug-in gate 325 further contact device aminimal distance burst maximum extension lsecond maximum extension cthird maximum extension

Claims

1. Electrical device (10), in particular a control device, - having an insert (50, 95, 105, 115), a current-transfer component (60, 100, 110, 120) and a housing (25) with a housing wall (55) with an inner wall (225) and with an outer wall (230), which is arranged spaced apart from the inner wall (225) in relation to the axis (x), - wherein the insert (50, 95, 105, 115) has a first wall (130), a second wall (200), which is arranged offset in a manner spaced apart from the first wall (130) along an axis (x), and a first chamber (205), - wherein the first wall (130) has a first passage opening (150) and the second wall (200) has a second passage opening (215), - wherein the first passage opening (150) and the second passage opening (215) are configured to be aligned in relation to the axis (x), - wherein the first wall (130) is configured to abut against a current-transfer component (60, 100, 110, 120) of the electrical device (10) at the first passage opening (150), and the second wall (200) is configured to abut against said current-transfer component at the second passage opening (215), - wherein the first chamber (205) is arranged between the first wall (130) and the second wall (200), - wherein the first passage opening (150) and the second passage opening (215) open out into the first chamber (205), - wherein the outer wall (230) has a third passage opening (245), and the inner wall (225) has a fourth passage opening (250), into which the insert (50, 95, 105, 115) engages, - wherein the inner wall (225) and outer wall (230) delimit a housing chamber (235), - wherein the current-transfer component (60, 100, 110, 120) passes through at least the first and second passage openings (150, 215) and is embedded in the potting compound (280) between the first wall (130) and the second wall (200), characterized in that, - the housing chamber (235) and the first chamber (205) open out into one another, - wherein the first chamber (205) and the housing chamber (235) are filled with a potting compound (280).

2. Electrical device (10) according to Claim 1, - wherein the insert (95) has on a side facing away from the first chamber (205) a plug-in slotted guide (320) for a contact means (325), - wherein the plug-in slotted guide (320) is configured to extend peripherally around the current-transfer component (60, 100, 110, 120).

3. Electrical device (10) according to either of the preceding claims, - having a further insert (95, 105, 115), wherein the insert (50) is connected to the further insert (95, 105, 115) to form a collective insert (305), wherein the housing wall (55) engages between the insert (50) and the further insert (95, 105, 115), wherein the collective insert (305) is fastened in a form-fitting manner to the housing wall (55).

4. Electrical device (10) according to one of the preceding claims, - wherein the housing wall (55) and / or the insert (50, 95, 105, 115) comprises at least one of the following first materials: - plastic, - thermoplastic, - polyethylene, - silicone, - polyurethane, - foam, - closed-pore foam, - wherein the potting compound (280) comprises at least one of the following second materials: - plastic, - thermoplastic, - polyethylene, - silicone, - polyurethane, - and / or - wherein the first material and the second material are identical.

5. Electrical device (10) according to one of the preceding claims, - wherein the potting compound (280) connects the insert (50, 95, 105, 115) to the housing wall (55) and to the current-transfer component (60, 100, 110, 120) in a materially bonded manner.

6. Electrical device (10) according to one of the preceding claims, - wherein the insert (50, 95, 105, 115) has a second chamber (206) which is arranged between the first wall (130) and the second wall (200), wherein the second chamber (206) is formed in a groove-shaped manner at the insert (50, 95, 105, 115).

7. Electrical device (10) according to one of the preceding claims, - having at least one connecting web (155, 160), - wherein the connecting web (155, 160) extends between the first wall (130) and the second wall (200) and mechanically connects the first wall (130) to the second wall (200).

8. Method for producing an electrical device (10) according to one of the preceding claims, - wherein the insert (50, 95, 105, 115), at least one current-transfer component (60, 100, 110, 120) and the housing (25) are provided, - wherein the current-transfer component (60, 100, 110, 120) is led through the first and second passage openings (150, 215), - wherein the insert (50, 95, 105, 115) is plugged into the housing wall (55) in such a way that the first chamber (205) of the insert (50, 95, 105, 115) and the housing chamber (235) of the housing wall (55) are connected fluidically to one another, - wherein a precursor of a potting compound (280) or a liquid potting compound (280) is introduced into the first chamber (205) of the insert (50, 95, 105, 115) and the housing chamber (235) of the housing wall (55), - wherein the precursor is cured to form the potting compound (280) or the liquid potting compound (280) is cured.

9. Method according to Claim 8, - wherein the precursor of the potting compound (280) flows around the current-transfer component (60, 100, 110, 120) in the first chamber (205).

10. Method according to Claim 8 or 9, - wherein the precursor of the potting compound (280) foams when it is cured.

11. Method according to one of Claims 8 to 10, - wherein the housing wall (55) and the first wall (130) and / or second wall (200) are arranged in an overlapping manner.