Enclosure of an electrical device
Patent Information
- Application Number
- GB2023012228
- Authority / Receiving Office
- GB · GB
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-08-10
- Publication Date
- 2025-02-12
Smart Images

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Abstract
Description
Field The present disclosure particularly relates to an enclosure, to an electrical device, to a power system, to an aircraft and to a method for manufacturing a housing. Background Aircrafts are powered in many different ways. Internal combustion engines, e.g., piston engines or gas turbine engines, enable long ranges and high speeds. Propulsion systems with one or more electric motor(s) enable the use of sustainably generated energy and are often particularly quiet and only require little maintenance compared to, e.g., combustion engines. An important aspect is the distribution of electrical power. In the case of electrically driven aircrafts, a reliable power distribution from an energy source to electric motors is important. In this and other applications a robust enclosure that can be securely fixed to a structure and can safely protect the electrical components therein is needed. Enclosures for electrical devices can be, e.g., made of machined parts, of composite parts or of sheet metal. Sheet-metal housings can be manufactured in a simple and reliable manner and can be made light-weight and robust. A sealing between housings and lids of the various enclosures is commonly made using O-rings. Furthermore, in the case of enclosures for electrical devices, it is often desired to seal an opening of the housing closed by the lid against electromagnetic interference (EMI). Typically, the sealing of an enclosure is a tradeoff between the simplicity of the design and the properties of the sealing. There is a need to provide an improved enclosure for electrical components or at least provide a useful alternative to known enclosure for electrical components. Summary According to an aspect, an enclosure for electrical components is provided. The enclosure comprises a housing defining an inner space and an opening to the inner space, a lid for closing the opening in a closed state of the enclosure, a first sealing arranged to contact the housing and the lid when the lid closes the opening, for sealing the inner space, and a second sealing arranged to contact the housing and the lid when the lid closes the opening, the second sealing comprising an electrically conductive material. This arrangement allows to provide a high level of protection against EMI, water, dust and even air. Therefore, sensible electrical components can be safely operated in the enclosure even under harsh conditions. Here, two sealings for the two purposes of sealing against water and other ingress and sealing against EMI are provided. The first sealing may comprise (or consist of) a closed-cell material. This allows a particularly secure sealing against ingress of water, dust and air. The first sealing may comprise (or consist of) a flexible polymer. This allows to adopt a given form of the housing and the lid to ensure a tight sealing. The first sealing may have a rectangular cross section. By this, a tight sealing particular of sheet-metal housings can be provided. Further, the second sealing may comprise a core member covered by the electrically conductive material. In this manner, it can be ensured that the electrically conductive material covers a gap between the housing and the lid for a high level of an EMI protection. For example, the electrically conductive material comprises (or consists of) a metal mesh. This allows a particularly good level of EMI protection. The electrically conductive material may comprise or consist of copper and / or nickel. Further, the core member may comprise (or consist of) a flexible polymer. By this, the electrically conductive material can be urged against the lid and housing. As an example, the core member can comprise (or consist of) a polyurethane foam. This allows a light-weight, robust and flexible design. The core member may comprise or consist of an open-cell material. The second sealing may have a V-shaped cross section. This allows a particularly good adaption to the shape of the housing and lid. The first sealing may form a closed loop. Alternatively or in addition, the second sealing may form a closed loop. The first sealing may be surrounded by the second sealing. The first sealing may be in contact with the second sealing, particularly along the entire loop of the first sealing. The opening may be surrounded by an edge of the housing, wherein the first sealing is arranged to rest on the edge. Alternatively or in addition, the second sealing may be arranged to surround the edge and to circumferentially surround the housing along the edge. In this manner, a mechanically stable and robust sealing may be provided. For example, the first sealing and / or the second sealing is / are fixed to the lid, e.g., at a folded rim section of the lid. The first sealing and / or the second sealing may be fixed to the lid (or to the housing) by means of adhesive. This allows a further improvement of the sealing and, in addition, a simple assembly of the enclosure. The housing and / or the lid may be made of an electrically conductive material, in particular of a metal, particularly of sheet metal, e.g., steel or aluminum. This allows a very simple manufacturing and a high stability at a low weight. The housing may comprise opposing sidewalls arranged at an angle with respect to one another. This allows an arrangement of correspondingly shaped components in the housing and an adaption of the enclosure to the shape of a mounting location thereof. The first sealing may be configured for gas-tight sealing of the opening against the lid. Alternatively or in addition, the housing may comprise at least one vent allowing gas (or a gas mixture such as air) to enter or exit the inner space. This allows a controlled air flow between the inner space and an outside of the enclosure, e.g., with a maximum rate or using a filter. According to an aspect, an electrical device is provided. The electrical device comprises the enclosure of any embodiment described herein, and electrical components mounted in the inner space of the housing of the enclosure. Regarding the advantages of the electrical device, reference is made to the description of the enclosure above. The electrical device may be a (e.g., high-voltage) power distribution unit. The electrical device may comprise at least one input adapted to receive electrical power from at least one energy source. The electrical device may comprise at least one output configured to provide electrical power from the at least one input to at least one electrical load. Power distribution units often contain heavy components which can be safely housed and mounted using the described housing. According to an aspect, a power system, e.g., for an aircraft, is provided. The power system comprises the electrical device of any embodiment described herein. The power system further comprises the at least one energy source (being in electrical connection with the at least one input) and the at least one electrical load (being in electrical connection with the at least one output). Regarding the advantages, reference is made to the description of the enclosure above. The at least one energy source may comprise a rechargeable electrical battery. Alternatively, or in addition, the at least one electrical load comprises at least a part of an electric motor. According to an aspect, an aircraft comprising the enclosure and / or the electrical device and / or the power system of any embodiment described herein is provided. Regarding the advantages, again, reference is made to the description of the enclosure above. According to another aspect, a method of manufacturing an enclosure is provided, e.g., the enclosure of any embodiment described herein. The method comprises providing (e.g., manufacturing) a housing defining an inner space and an opening to the inner space and, at the same time, before or after, providing (e.g., manufacturing) a lid for closing the opening; and arranging a first sealing (e.g., on the lid) so as to make contact with the housing and with the lid in a closed state of the lid closing the opening, for sealing the inner space, and arranging a second sealing (e.g., on the lid and / or besides the first sealing) so as to make contact with the housing and with the lid (in the closed state of the lid), the second sealing comprising an electrically conductive material. Regarding the advantages, again, reference is made to the description of the housing above. Manufacturing of the first and / or second housing parts may comprise cutting and / or bending sheet metal. Brief description of the drawings Exemplary embodiments are now described with reference to the figures, wherein: Figure 1 shows an aircraft in the form of an airplane with a rotor unit; Figure 2 shows a power system for the aircraft of Figure 1, the power system comprising an electrical device in the form of a power distribution unit; Figure 3 shows two parts of a housing of the electrical device according to Figure 2; Figure 4 shows the two parts of Figure 3 mounted to one another; Figure 5 shows the electrical device of Figure 2 with the housing of Figure 4; Figure 6 shows the electrical device of Figure 5, wherein the housing is closed by a lid, thereby forming an enclosure; Figure 7 shows a cross-sectional view of an edge of the enclosure of Figure 6; Figure 8 shows an enclosure of an electrical device having a housing and a lid having a first sealing and a second sealing; Figure 9 shows a portion of the second sealing of Figure 8; and Figure 10 shows a method of manufacturing an enclosure. The following table lists the reference numerals used in the drawings with the features to which they refer: Ref no. Feature Figure 1 Housing 2456 1’ Housing 8 2 Electrical device 256 3 Power system 2 4 Aircraft 1 5 Enclosure 26 5’ Enclosure 8 10 First housing part 3 4 5 6 7 11 Second housing part 3456 12 Inner space 4 13 Outside 4 14 Projection 34 15 Sealant 3 16 Edge 7 17 Screw 6 20 Electrical component 2 5 21 Input 5 22 Output 5 40 Energy source 1 2 41 Electrical load 2 42 Fuselage 1 43 Wing 1 44 Rotor unit 1 45 Structure 6 50 Lid 7 51 Vent 8 100 Bottom wall 34 101 Sidewall 34 101’ Sidewall 8 102 Sidewall 34 102’ Sidewall 8 104A Section 3 104B Section 3 105 Bending 3 106A Mounting opening 3 106B Mounting opening 3 106C Mounting opening 3 8 107 Hole 3 110 Bottom wall 3 111 Sidewall 34 111’ Sidewall 8 112 Sidewall 34 113A Mounting opening 3 Ref no. Feature Figure 113B Mounting opening 3 113C Mounting opening 3 114 Bending 3 115 Hole 3 116 Flap 34 117 Mounting element 5 140 Mounting hole 34 400 Battery 2 410 Electric motor 1 411 Inverter 2 412 Electrical lane 2 440 Rotor blade 1 500 Cover section 78 501 Rim section 78 502 First sealing 78 503 Second sealing 789 504 First portion 79 505 Second portion 79 506 Core member 9 507 Metal mesh 9 508 Adhesive 7 O Opening 78 S1 Step 10 S2 Step 10 S3 Step 10 S4 Step 10 Detailed description Aspects and embodiments of the present disclosure will now be discussed with reference to 5 the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. Figure 1 shows an aircraft 4 in the form of an airplane having a fuselage 42, wings 43 and a rotor unit 44. The aircraft 4 comprises an electric motor 410 for driving the rotor unit 44. The rotor unit 44 10 comprises a plurality of rotor blades 440, in this example two rotor blades 440. In the example shown, the rotor blades 440 are mounted on a hub to form a propeller. In alternative embodiments, the aircraft 4 comprises, for example, a fan instead of a propeller and / or a plurality of propellers, fans or the like. The aircraft 4 further comprises one or more energy sources 40. In the present example, the one or more energy sources 40 comprise electric batteries. Alternatively, or in addition, the aircraft 4 may comprise an electric generator and / or a fuel cell as energy source(s). Figure 2 shows a power system 3 of the aircraft 4 of Figure 1. The power system 3 comprises an electrical device 2, at least one, here more than one, namely, two energy sources 40, and at least one, here more than one, namely, two electrical loads 41. The energy sources 40 of the present example each comprise a plurality of electrical batteries 400. The energy sources 40 provide electrical energy to the electrical device 2. Here, the energy sources provide high-voltage electrical power. In the present example, the electrical device 2 is a power distribution unit, more specifically, a high-voltage power distribution unit. The electrical device 2 comprises electrical components 20 such as switches, cables, forks or the like. The electrical device 2 provides electrical power (from the energy sources 40) to the electrical loads 41. Here, each of the electrical loads 41 comprises an inverter 411 and an electrical lane 412. The lanes 412 comprise electrical windings of the electric motor 410. By providing power to the electrical loads 41, the electric motor 410 drives the rotor unit 44. When the aircraft 4 comprises more than one rotor unit 44, each rotor unit 44 may be driven by a separate electric motor 410 powered by the electrical device 2. The electrical device 2 comprises an enclosure 5 with a housing 1 which encloses the electrical components 20 of the electrical device 2. Figure 3 shows two housing parts of the housing 1 of the electrical device 2: a first housing part 10 and a second housing part 11. Each of the first and second housing parts 10, 11 has a U-shaped form. As such, the first housing part 10 comprises a bottom wall 100 and two sidewalls 101, 102. The bottom wall 100 is larger than each of the sidewalls 101, 102. The bottom wall 100 is planar. The sidewalls 101, 102 of this example are planar, too. The sidewalls 101, 102 are arranged on opposing sides of the bottom wall 100. Each sidewall 101, 102 is connected with the bottom wall 100 via a bending 105. The bending 105 is a perpendicular bending. The sidewalls 101, 102 are arranged parallel to one another. The sidewalls 101, 102 of the present example are arranged perpendicular to the bottom wall 100. However, for a better accessibility of the inner space 12 during assembly an angle between the sidewalls 101, 102, 111, 112 and the respective bottom wall 100, 110 of more than 90° can be beneficial (as shown in Figure 8 described in more detail below). The bottom wall 100 is rectangular and has two opposing longer edges and two opposing shorter edges. The sidewalls 101, 102 are connected with the bottom wall 100 via the longer edges of the bottom wall 100. The sidewalls 101, 102 are substantially rectangular and elongate. Each of the sidewalls 101, 102 comprises two opposing longer edges and two opposing shorter sides. The sidewalls 101, 102 are connected with the bottom wall 100 via a respective one of their longer edges. The first housing part 10 further comprises a plurality of mounting holes 140. Here, the first housing part 10 comprises four mounting holes 140. The first housing part 10 comprises four corners on which the sidewalls 101, 102 are connected with the bottom wall 100. Each one of the mounting holes 140 is arranged on one of the corners. Specifically, each of the mounting holes 140 is arranged on a respective projection 14 of the first housing part 10 formed by a section 104A of the bottom wall 110 and a section 104B of one of the sidewalls 101, 102. The sections 104A, 104B are connected with one another via the bending 105. The projections 14 have an L-shaped cross-section. Therefore, the projections 14 are particularly stiff and robust. The projections 14 are located on four corners of the first housing part 10. Thus, the mounting holes 140 are arranged an each of the four corners of the housing 1. The projections 14 project from the respective edges of the bottom wall 100 and side walls 101, 102. The second housing part 11 comprises a bottom wall 110 and two sidewalls 111, 112. The bottom wall 110 is larger than each of the sidewalls 111, 112. The bottom wall 110 is planar. The sidewalls 111, 112 comprise flaps 116. Besides the flaps 116, the sidewalls 111, 112 are planar, too (in this example). The sidewalls 111, 112 are arranged on opposing sides of the bottom wall 110. Each sidewall 111, 112 is connected with the bottom wall 110 via a (perpendicular) bending 114. The sidewalls 111, 112 are arranged parallel to one another. The sidewalls 111, 112 are arranged perpendicular to the bottom wall 110. The bottom wall 110 of the second housing part 11 is rectangular and has two opposing longer edges and two opposing shorter edges. The sidewalls 111, 112 are connected with the bottom wall 110 via the shorter edges of the bottom wall 110. The sidewalls 111, 112 of the second housing part 11 are rectangular. Each of the sidewalls 111, 112 comprises two opposing longer edges and two opposing shorter edges. The sidewalls 111, 112 are connected with the bottom wall 110 via a respective one of their longer edges. Each of the first and second housing parts 10, 11 comprises a plurality of mounting openings 106A-106C, 113A-113C) in the sidewalls 101, 102, 111, 112. Each of the mounting openings 106A-106C, 113A-113C is formed in (only) one of the sidewalls 101, 102, 111, 112. The bottom wall 100 of the first housing part 10 is at least as large as the bottom wall 110 of the second housing part 11. Each of the first and second housing parts 10, 11 is made of sheet metal, e.g., steel. Each of the first and second housing parts 10, 11 is made in one piece. In the present example, each of the first and second housing parts 10, 11 is made my cutting (e.g., stamping) and bending a piece of sheet metal. For manufacturing the housing 1, the first and second housing parts 10, 11 are fixed to one another. In this regard, the housing parts 10, 11 are arranged as shown in Figure 3, i.e., the sidewalls 101, 102 of the first housing part 10 are arranged perpendicular to the sidewalls 111, 112 of the second housing part 11, and the bottom walls 100, 110 are arranged parallel to one another. All sidewalls 101, 102, 111, 112 extend from the bottom walls 100, 110 in the direction. Then, the bottom walls 100, 110 are laid on top of one another. Optionally, the bottom walls 100, 110 are brought in physical contact with one another. In the present example, the bottom walls 100, 110 of the first and second housing parts 10, 11 have the same size. Optionally, as shown in Figure 3, a sealant 15 is disposed on a side of the bottom wall 100 of the first housing part 10 facing the bottom wall 110 of the second housing part 11 (and / or on a side of the bottom wall 110 of the second housing part 11 facing the bottom wall 100 of the first housing part 10). Thus, when mounting the two housing parts 10, 11, the sealant 15 is arranged between the bottom walls 100, 110. In the present example, the sealant is silicone-based. Thus, the housing 1 has a double-layer bottom. Figure 4 shows the housing 1 after connecting the two housing parts 10, 11 to one another. Each of the bottom walls 100, 110 has holes 107, 115 (in this example screw holes) aligned to one another in the assembled state as shown in Figure 4. Further, the sidewalls 101, 102, 111, 112 also have holes 107, 115 (in this example screw holes) aligned to one another in the assembled state as shown in Figure 4. In the case of the second housing part 11, the holes 115 are located on the flaps 116 of the sidewalls 111, 112. The mounted housing 1 has the shape of a rectangular cuboid. The projections 14 project from the rectangular cuboid. Thus, as shown in Figure 4, the housing 1 (which is configured to receive electrical components) comprises the first housing part 10 having the bottom wall 100 and the sidewalls 101, 102, and the second housing part 11 having the bottom wall 110 and the sidewalls 111, 112, wherein the first and second housing parts 10, 11 are fixed to one another defining an inner space 12 and an outside 13 of the housing 1, wherein the bottom walls 100, 110 overlap with each other and wherein at least one of the first and second housing parts 10, 11 (here, the first housing part 10) forms the mounting holes 140, the mounting holes 140 being located on the outside 13 of the housing 1 (i.e., not in the inner space 13 of the housing 1), the mounting holes 140 being configured for mounting the housing 1 to another structure. As becomes apparent from Figures 3 and 4, the bottom wall 100 of the first housing part 10 faces the outside 13 and the bottom wall 110 of the second housing part 11 faces the inner space 12 of the housing 1. Therefore, the first housing part 10 can also be referred to as the outer housing part, and the second housing part 11 can also be referred to as the inner housing part As shown in Figure 4, the housing 1 defines an opening O through which the inner space 12 is accessible. Specifically, the opening O is defined by more than one sidewall 101, 102, 111, 112 of the housing 1. In the present example, the opening O is defined by the four sidewalls 101, 102, 111, 112. This opening O can also be referred to as access opening O. The opening O is rectangular. As in the example of Figure 4, the opening O can have the same with as the inner space 12 (e.g., adjacent the opening O). As in the example of Figure 4, the opening O can also have the same length as the inner space 12 (e.g., adjacent the opening O). Figure 5 shows the housing 1 with various electrical components 20 mounted therein. For mounting the electrical components 20, the electrical components 20 are entered into the inner space 12 via the (access) opening O. Further, inputs 21 and outputs 22 are mounted on the openings 106A-106C, 113A-113C, such as sockets for plugs. The inputs 21 and outputs 22 are electrically connected to the electrical components 20. Using mounting elements 117, such as screws and / or rivets or the like, the sidewalls 101, 102, 111, 112 are fixed to one another at the holes 107, 115. Similar, using mounting elements 117, such as screws and / or rivets or the like, the bottom walls 100, 110 are fixed to one another at the holes 107, 115. As shown in Figure 6, the housing 1 of the present example can be closed by a lid 50 to form the enclosure 5 of the aircraft 4. The lid 50 is mounted on the four sidewalls 101, 102, 111, 112. The lid 50 closes the inner space 12 of the housing 1. Further, Figure 6 shows the housing 1 mounted to the structure 45. For this purpose, screws 17 extend through the mounting holes 140 of the housing 1 and are fixed to the structure 45. In the present example, the structure 45 is a part of the aircraft 4 of Figure 1. As can be seen from Figures 3, 4 and 6, the inner space 12 of the housing 1 is located between the bottom walls 100, 110 of the first and second housing parts 10, 11 and the lid 50. In the inner space 12 of the housing 1, the electrical components 20 may be mounted. For sealing the lid 50 against the housing 1 the enclosure 5 comprises a first sealing 502 and a second sealing 503 as illustrated in Figure 7. As shown in Figure 7, the (access) opening O of the housing 1 is defined by an edge 16 of the housing 1. The edge 16 extends along the four sidewalls 101, 102, 111, 112 of the housing 1. Further, the lid 50 comprises a cover portion 500 and a rim portion 501. The rim portion 501 forms (four) sidewalls of the lid 50. Each sidewall of the rim portion 501 extends perpendicular to the cover portion 500. The cover portion 500 is planar. Here, the cover portion 500 is rectangular. The rim portion 501 is formed in one piece with the cover portion 500. The lid 50 is made of sheet metal, wherein the rim portion 501 is formed by bending the sheet metal. The first and second sealings 502, 503 are arranged in the corner between the cover portion 500 and the rim portion 501. In the present example, each of the first and second sealings 502, 503 is fixed to the lid 50 by means of adhesive 508. Here, the first sealing 502 is adhered to the cover portion 500, and the second sealing 503 is adhered to the rim portion 501. The first sealing 502 is arranged to contact both the housing 1 and the lid 50 when the lid 50 is mounted on the housing 1 to close the opening O. Thereby, the first sealing 502 seals the inner space 12 from the outside 13. The first sealing 502 consists of a flexible, closed-cell polymer such as a PVC, PU or PE. This material allows to adapt to the exact shape of the edge 16 and allows a liquid-tight, dust-tight, and even air-tight sealing. As shown in Figure 7, the first sealing 502 has a rectangular cross section. The first sealing 502 is a sheet sealing. One face of the first sealing 502 is in contact with the lid 50 (more specifically, the cover portion 500), while the opposite face of the first sealing 502 is in contact with the edge 16 of the opening O of the housing 1. The first sealing 502 forms a closed loop. It follows the rectangular shape of the opening O. In the cross section, the respective sidewall 101, 102, 111, 112 and the first sealing 502 are arranged so as to form a T. The second sealing 503 is arranged to contact the housing 1 and the lid 50 when the lid 50 is mounted on the housing 1 to close the opening O. The second sealing 503 comprises an electrically conductive material. The second sealing 503 is an EMI shield. Thus, the second sealing 503 protects electrical devices outside of the enclosure 5 from electromagnetic interference due to the operation of the electrical components 20 inside the enclosure 5 and vice versa. In the example of Figure 7, the second sealing 503 has a V-shaped (alternatively: U-shaped) cross section. Here, the V shape is formed by a first portion 504 and a second portion 505. In the cross section, the first portion 504 is elongate. Also, the second portion 505 is elongate in the cross section. The first and second portions 504, 505 form the two legs of the V. That is, the second sealing 503 is a V-shaped profile, the first and second portions 504, 505 are connected with one another at one of their respective ends. The two legs extend at an angle with respect to one another, i.e., the V is open. This allows to be elastically urged against the housing 1 and the lid 50. In the cross section, the first portion 504 is longer than the second portion 505. The first portion 504 (more specifically, a part thereof) is arranged between the rim section 501 and the first sealing 502 (and, optionally, in contact with the rim section 501 and the first sealing 502 on opposite sides of the first portion 504). The second portion 505 is arranged between (a part of) the first portion 504 and the housing 1 (more specifically, the sidewall 101, 102, 111, 112 at the respective location) adjacent the edge 16. The first portion 504 (more specifically, a part thereof) and the second portion are arranged between the housing 1 (i.e., the sidewall 101, 102, 111, 112 at the respective location) and the rim section 501. The first sealing 502 is surrounded by the second sealing 503. The edge 16 is surrounded by the second sealing 503 around the opening O. The second sealing 503 forms a closed loop. It follows the rectangular shape of the opening O. The first sealing 502 is arranged on top of the edge 16, while the second sealing 503 is arranged besides the edge 16. The first sealing 502 is squeezed when urging the lid 50 against the housing 1 without destroying the second sealing 503. Hence, the describes arrangement allows a particularly good sealing. Figure 8 shows an enclosure 5’ which is similar to the enclosure of Figures 2. 6 and 7, so in the following only differences are explained. While the lid 50 is constructed as described above, the housing T of the enclosure 5’ of Figure 8 the comprises opposing sidewalls 10T, 102’ which are arranged at an angle with respect to one another. Therefore, the other two sidewalls (one sidewall 111’ of which being visible in the cross-sectional view of Figure 8) have a shape of a trapezoid (more specifically, of an isosceles trapezoid). The first and second sealings 502, 503 allow a liquid-tight and gas-tight closure of the opening O as well as a secure EMI protection also in the case of the tapered housing T of Figure 8. As an example, the bending may be 80° (the corresponding angle of the sidewalls 10T, 102’, 111’ to the respective bottom wall can be 100°, e.g., + / - 5°). That is, opposing sidewalls 10T, 102’, 111’ may be at an angle, for example of 20° (e.g., +1- 10°), relative to one another. Figure 8 further shows that (as the housing described further above) the housing T comprises one or more, here two vents 51 allowing gas (e.g., air) to enter and / or exit the inner space 12. Thereby, a controlled venting of the inner space 12 is possible. Figure 9 shows a part of the second sealing 503. As can be seen in Figure 9, the second sealing 503 comprises a core member 506 covered by the electrically conductive material, wherein the electrically conductive material is a metal mesh 507 (or other metal fabric). The core member 506 has the V shape and the electrically conductive material surrounds this V shape. That is, each leg of the V shape is surrounded by the electrically conductive material. The entire surface of the core member 506 is covered by the electrically conductive material layer. The metal mesh 507 is wrapped around the core member 506. In this example, the electrically conductive material comprises copper and, optionally, nickel. The core member 506 is made of a flexible polymer, in this example with open cells, specifically, of an open-cell PU foam. This design of the second sealing 503 allows a particularly reliable and effective EMI protection. Figure 10 shows a method of manufacturing an enclosure 5, 5’, e.g., the enclosure 5 or 5’ as described above, and of manufacturing an electrical device. The method comprises the following steps. At step S1, a housing 1,1’, e.g., the housing 1, T as described above, is provided, for example manufactured. The housing 1,1’ defining an inner space 12 and an opening O to the inner space 12. Manufacturing the housing 1,1’ may comprise manufacturing a first housing part 10 with a bottom wall 100 and sidewalls 101, 10T, 102, 102’, e.g., by cutting and bending a piece of sheet metal, manufacturing a second housing part 11 with a bottom wall 110 and sidewalls 111, 11T, 112, e.g., by cutting and bending a piece of sheet metal, and fixing the first and second housing parts 10, 11 to one another to define the inner space 12 and an outside 13 of the housing 1, T, wherein the bottom walls 100, 110 may be arranged so as to overlap with each other and wherein at least one of the first and second housing parts 10, 11 may form mounting holes 140 on the outside 13 of the housing 1, 1’ for mounting the housing 1,1’ to another structure 45. At step S2, a lid 50 configured for closing the opening O is provided, e.g., manufactured. Manufacturing the lid 50 may comprise cutting and bending a piece of sheet metal (e.g., of the same type as for the housing 1, T). Step S2 may be performed before, after or at the same time as step S1. Step S3: arranging a first sealing 502 so as to make contact with the housing 1,1’ and with the lid 50, for sealing the inner space 12, and a second sealing 503 so as to make contact with the housing 1,1’ and with the lid 50, the second sealing 503 comprising an electrically conductive material, e.g., as shown in Figures 7-9. Step S4: Mounting electrical components 20 in the inner space 12 of the housing 1, 1’ to 5 produce an electrical device 2.
Claims
1. An enclosure (5, 5’) for electrical components (20), comprising:a housing (1, 1’) defining an inner space (12) and an opening (0) to the inner space;a lid (50) for closing the opening (O);a first sealing (502) arranged to contact the housing (1, 1’) and the lid (50) when the lid (50) closes the opening (O), for sealing the inner space (12); anda second sealing (503) arranged to contact the housing (1, 1’) and the lid (50) when the lid (50) closes the opening (O), the second sealing (503) comprising an electrically conductive material.
2. The enclosure (5, 5’) of claim 1, wherein the first sealing (502) comprises or consists of a closed-cell material.
3. The enclosure (5, 5’) of claim 1 or 2, wherein the first sealing (502) comprises or consists of a flexible polymer.
4. The enclosure (5, 5’) of any preceding claim, wherein the first sealing (502) has a rectangular cross section.
5. The enclosure (5, 5’) of any preceding claim, wherein the second sealing (503) comprises a core member (506) covered by the electrically conductive material.
6. The enclosure (5, 5’) of claim 5, wherein the electrically conductive material comprises or consists of a metal mesh (507).
7. The enclosure (5, 5’) of claim 5 or 6, wherein the core member (506) comprises or consists of a flexible polymer.
8. The enclosure (5, 5’) of any one of claims 5 to 7, wherein the core member (506) comprises or consists of a polyurethane foam.
9. The enclosure (5, 5’) of any preceding claim, wherein the second sealing (503) has a V-shaped cross section.
10. The enclosure (5, 5’) of any preceding claim, wherein the first sealing (502) forms a closed loop, and the second sealing (503) forms a closed loop and wherein the first sealing (502) is surrounded by the second sealing (503) and in contact with the second sealing (503).
11. The enclosure (5, 5’) of any preceding claim, wherein the opening (0) is surrounded by an edge (16) of the housing (1, T), wherein the first sealing (502) is arranged to rest onthe edge (16) and the second sealing (503) is arranged to surround the edge (16).
12. The enclosure (5, 5’) of any preceding claim, wherein the first sealing (502) and the second sealing (503) are fixed to the lid (50) at a folded rim section (501) of the lid (50) by means of adhesive (508).
13. The enclosure (5, 5’) of any preceding claim, wherein the housing (1, T) is made of sheet metal and the lid (50) is made of sheet metal.
14. The enclosure (5’) of any preceding claim, wherein the housing (T) comprises opposing sidewalls (10T, 102’) arranged at an angle with respect to one another.
15. The enclosure (5, 5’) of any preceding claim, wherein the first sealing (502) is configured for gas-tight sealing of the opening (0) against the lid (50), wherein the housing (1, T) comprises at least one vent (51) allowing gas to enter or exit the inner space (12).
16. An electrical device (2) comprising the enclosure (5, 5’) of any preceding claim and electrical components (20) mounted in the inner space (12) of the housing (1, T).
17. The electrical device (2) of claim 16, the electrical device (2) being a high-voltage power distribution unit and comprising at least one input (21) adapted to receive electrical power from at least one energy source (40) and at least one output (22) configured to provide electrical power from the at least one input (21) to at least one electrical load (41).
18. A power system (3) for an aircraft (4), the power system comprising an electrical device (2) of claim 17, the at least one energy source (40) in electrical connection with the at least one input (21) and the at least one electrical load (41) in electrical connection with the at least one output (22), wherein the at least one energy source (40) comprises an electrical battery (400) and the at least one electrical load (41) comprises at least a part of an electric motor (410).
19. An aircraft (4) including a power system (3) of claim 18.
20. A method of manufacturing an enclosure (5, 5’), the method comprising the steps of:providing (S1) a housing (1, T) defining an inner space (12) and an opening (0) to the inner space (12) and providing (S2) a lid (50) for closing the opening (O); andarranging (S3) a first sealing (502) so as to make contact with the housing (1, T) and with the lid (50), for sealing the inner space (12), and a second sealing (503) so as to make contact with the housing (1, T) and with the lid (50), the second sealing (503) comprising an electrically conductive material.17
Citation Information
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