Converter Motor Housing Seal Integration via Injection Molding
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Solution Overview
Problem
Conventional electrical devices, such as converter motors, face challenges in achieving a high degree of protection and precise assembly due to inadequate sealing between housing and cover parts.
Innovation Solution
The integration of a frame part with an injection-molded seal between the housing and cover parts, utilizing a metal frame and plastic/rubber seals, along with precise positioning mechanisms like pins and lug regions, ensures tight sealing and robust assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal is integrated into the frame part (injection-molded), then sealing reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The seal is integrated into the frame part through injection molding, merging two previously separate components (frame and seal) into a single integral structure. This eliminates the need for separate seal installation while maintaining reliable sealing between the housing part and cover part.
Solution Approach 2:
The solution combines different materials (metal frame and elastomeric seal material) into a composite structure through injection molding. The frame part serves as both structural support and seal carrier, utilizing the properties of both materials in a unified component.
2Manufacturing precision
If the seal is retained by the frame part in an integral fashion, then positioning precision is improved, but assembly complexity increases
Solution Approach 1:
The seal and frame part are merged into a single integral component, eliminating separate positioning steps for the seal. The seal's position is predetermined by the injection molding process, ensuring precise positioning during assembly without requiring additional adjustment.
Solution Approach 2:
The seal is pre-positioned and integrated into the frame part during manufacturing. This preliminary action ensures that the seal is already in the correct position before assembly, eliminating the need for separate positioning operations during final assembly.
3Reliability
If the seal extends from one side of the frame part to the other side, then sealing continuity is improved, but material consumption increases
Solution Approach 1:
The seal is designed with varying thickness and material distribution along its length. The seal extends from one side of the frame part to the other with optimized local properties, providing continuous sealing where needed while minimizing material consumption in less critical areas.
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
This configuration provides uninterrupted sealing, optimal space utilization, and cost-effective production while maintaining high protection against corrosion and environmental factors.
Implementation Method 1
the seal is made from a plastic material and/or rubber... the frame part has a robust configuration and the seals are elastically deformable
Data Source
AI summary
An electrical device, e.g., a converter motor, includes a housing part and a cover part. A frame part is positioned between the housing part and the cover part, and an electronic circuit is situated in the interior space surrounded by the housing that includes the housing part and the cover part, e.g., and the frame part. A seal is situated, e.g., injection-molded, on the frame part. For example, the seal touches both a connection surface, e.g., a planar connection surface arranged on the cover part, and it covers a connection surface, e.g., a planar connection surface arranged on the housing part. A region of the connection surface of the cover part touches the frame part, and a region of the connection surface of the housing part touches the frame part.