Cast Electronic Module Terminal Sealing
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Solution Overview
Problem
Existing cast modules face challenges in establishing a reliable electric connection and sealing of contact legs due to the escape of casting material during manufacturing, limiting the placement of housing openings and complicating the casting process, especially when connecting to external electric devices.
Innovation Solution
Incorporating at least one terminal accessible from outside the housing that extends into the housing, allowing for an electric connection to be cast jointly with the module, ensuring secure sealing and insulation by embedding the terminal and housing parts within the casting material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If contact legs protrude from the module to establish electric connection, then electric connection is enabled, but reliable sealing of contact legs against environment becomes difficult
Solution Approach 1:
A sealing element (sleeve) is introduced as an intermediary component between the contact leg and the casting material. This sealing element extends through the opening in the housing and creates a sealed pathway for the contact leg, allowing electrical connection while preventing environmental ingress. The sealing element acts as a mediator that reconciles the need for both electrical access and environmental protection.
2Ease of operation
If housing openings are formed for contact legs, then electric connection is possible, but casting material escapes when liquid state
Solution Approach 1:
The sealing element is installed in the housing opening before the casting process begins. This preliminary action prepares the opening to receive and seal around the contact leg, preventing casting material escape during the subsequent liquid casting phase. By preparing the sealing structure in advance, the casting process can proceed without material leakage.
3Adaptability or versatility
If multiple openings are formed on housing sides, then electric connections are enabled, but all openings must point upward during casting
Solution Approach 1:
Each housing opening is equipped with its own sealing element that can accommodate contact legs regardless of opening orientation. The sealing element is locally adapted to the specific opening geometry and position, allowing openings to be distributed throughout the housing without requiring uniform upward orientation during casting. This local sealing capability enables versatile electrical connections while simplifying casting orientation requirements.
4Ease of operation
If contact legs are held in position during casting, then electric connection is established, but casting operation becomes much more difficult
Solution Approach 1:
The contact leg positioning function is extracted from the casting operation itself and transferred to the sealing element structure. The sealing element is pre-configured with features that automatically guide and position contact legs during insertion, eliminating the need for complex external positioning fixtures or manual positioning during casting. This extraction of the positioning function simplifies the casting operation while maintaining reliable electrical connection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates simple and reliable casting with secure electrical connections and enhanced insulation, allowing for flexible placement of housing openings and preventing material escape, while ensuring reliable sealing and insulation against environmental influences.
Implementation Method 1
Another positive effect of the casting is the passive cooling effect of the casting material achieved as a result of its favorable thermal conductivity.
Implementation Method 2
This insulation has a positive effect within the module. That is, the electric and/or electronic components contained therein can be arranged in closer proximity to one another without causing contact between the components due to vibration or other influences.
Data Source
AI summary
A module of electric and/or electronic components, wherein the module is cast with a curable electrically insulating casting material in a housing, characterized in that at least one terminal extending at least slightly into the housing and remaining accessible from outside the housing is provided on the housing, is electrically connected to the module, and is cast together with the module from the inside.